14 - 20res Kohler Home Generator

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

Table of Contents, continued
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 TP-6735 9/10

Table of Contents, continued
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 Table of Contents

6 TP-6735 9/10
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
DANGER can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Accidental starting can cause goggles, rubber gloves, and boots
Danger indicates the presence of a severe injury or death. Before when servicing the battery. Do not
hazard that will cause severe working on the generator set or open a sealed battery or mutilate the
personal injury, death, or connected equipment, disable the battery case. If battery acid splashes in
substantial property damage. generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
position. (2) Disconnect the power to with large quantities of clean water.
WARNING the battery charger. (3) Remove the Seek immediate medical aid in the case
battery cables, negative (--) lead first. of eye contact. Never add acid to a
Reconnect the negative (--) lead last battery after placing the battery in
Warning indicates the presence of a when reconnecting the battery. Follow service, as this may result in hazardous
hazard that can cause severe these precautions to prevent starting of spattering of battery acid.
personal injury, death, or the generator set by an automatic
substantial property damage. transfer switch, remote start/stop Battery acid cleanup. Battery acid
switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
CAUTION bicarbonate of soda (baking soda) to a
Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
Caution indicates the presence of a neutralizing solution on the spilled
hazard that will or can cause minor battery acid and continue to add the
personal injury or property damage. WARNING neutralizing solution to the spilled
battery acid until all evidence of a
NOTICE chemical reaction (foaming) has
Notice communicates installation, ceased. Flush the resulting liquid with
operation, or maintenance information water and dry the area.
that is safety related but not hazard
related. Battery gases. Explosion can cause
Sulfuric acid in batteries. severe injury or death. Battery gases
Safety decals affixed to the equipment Can cause severe injury or death. can cause an explosion. Do not smoke
in prominent places alert the operator or permit flames or sparks to occur near
Wear protective goggles and a battery at any time, particularly when
or service technician to potential
clothing. Battery acid may cause it is charging. Do not dispose of a
hazards and explain how to act safely.
blindness and burn skin. battery in a fire. To prevent burns and
The decals are shown throughout this
publication to improve operator sparks that could cause an explosion,
recognition. Replace missing or avoid touching the battery terminals
damaged decals. with tools or other metal objects.
TP-6735 9/10 Safety Precautions and Instructions 7

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

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

Welding on the generator set. Can Testing live electrical circuits. Servicing the alternator. Hot parts
cause severe electrical equipment Hazardous voltage or current can can cause severe injury or death.
damage. Before welding on the cause severe injury or death. Have Avoid touching the alternator field or
generator set perform the following trained and qualified personnel take exciter armature. When shorted, the
steps: (1) Remove the battery cables, diagnostic measurements of live alternator field and exciter armature
negative (--) lead first. (2) Disconnect circuits. Use adequately rated test become hot enough to cause severe
all engine electronic control module equipment with electrically insulated burns.
(ECM) connectors. (3) Disconnect all probes and follow the instructions of the
generator set controller and voltage test equipment manufacturer when Servicing the exhaust system. Hot
regulator circuit board connectors. performing voltage tests. Observe the parts can cause severe injury or
(4) Disconnect the engine battery- following precautions when performing death. Do not touch hot engine parts.
charging alternator connections. voltage tests: (1) Remove all jewelry. The engine and exhaust system
(5) Attach the weld ground connection (2) Stand on a dry, approved electrically components become extremely hot
close to the weld location. insulated mat. (3) Do not touch the during operation.
enclosure or components inside the Servicing the engine heater. Hot
High voltage test. Hazardous enclosure. (4) Be prepared for the
voltage can cause severe injury or parts can cause minor personal
system to operate automatically. injury or property damage. Install the
death. Follow the instructions of the (600 volts and under)
test equipment manufacturer when heater before connecting it to power.
performing high-voltage tests on the Operating the heater before installation
rotor or stator. An improper test can cause burns and component
procedure can damage equipment or
Heavy Equipment damage. Disconnect power to the
lead to generator set failure. heater and allow it to cool before
WARNING servicing the heater or nearby parts.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death. Notice
Reconnect the battery correctly,
positive to positive and negative to NOTICE
negative, to avoid electrical shock and Canadian installations only. For
damage to the battery charger and standby service connect the output of
battery(ies). Have a qualified Unbalanced weight.
Improper lifting can cause severe the generator set to a suitably rated
electrician install the battery(ies). transfer switch in accordance with
injury or death and equipment
Short circuits. Hazardous damage. Canadian Electrical Code, Part 1.
voltage/current can cause severe
injury or death. Short circuits can Do not use lifting eyes. NOTICE
cause bodily injury and/or equipment Lift the generator set using lifting bars Electrostatic discharge damage.
damage. Do not contact electrical inserted through the lifting holes on Electrostatic discharge (ESD)
connections with tools or jewelry while the skid. damages electronic circuit boards.
making adjustments or repairs. Prevent electrostatic discharge
Remove all jewelry before servicing the damage by wearing an approved
equipment. grounding wrist strap when handling
Hot Parts electronic circuit boards or integrated
Electrical backfeed to the utility. circuits. An approved grounding wrist
Hazardous backfeed voltage can strap provides a high resistance (about
cause severe injury or death. Install
WARNING
1 megohm), not a direct short, to
a transfer switch in standby power ground.
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe Hot engine and exhaust system.
injury or death to utility personnel Can cause severe injury or death.
working on power lines.
Do not work on the generator set until
it cools.
10 Safety Precautions and Instructions TP-6735 9/10

Introduction
This manual provides troubleshooting and repair List of Related Materials

instructions for the generator set models listed on the
front cover. This manual may also be supplied for similar Separate manuals contain operation, installation, and
models not listed on the front cover. parts information not provided in this manual. Separate
engine operation and service manuals are also
Information in this publication represents data available available. The following table lists the available manual
at the time of print. Kohler Co. reserves the right to part numbers.
change this publication and the products represented
without notice and without any obligation or liability Document Description Part Number
whatsoever. Installation Manual TP-6733
Read this manual and carefully follow all procedures Operation Manual TP-6734
and safety precautions to ensure proper equipment Parts Catalog TP-6736
operation and to avoid bodily injury. Read and follow the Engine Service Manual, CH740 TP-2428
Safety Precautions and Instructions section at the Engine Service Manual, CH1000 TP-2580
beginning of this manual. Keep this manual with the SiteTecht Software Operation Manual TP-6701
equipment for future reference.
The equipment service requirements are very important

to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
skilled and suitably trained maintenance personnel
familiar with generator set operation and service.
For engine service procedures not covered in this

manual, refer to the Engine Service Manual.
6735
Figure 1 Model 20RES
TP-6735 9/10 Introduction 11

Service Assistance
For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 Phone: (863) 619-7568
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
12 Service Assistance TP-6735 9/10

Section 1 Specifications
1.1 Introduction 1.4 Engine Specifications

The specification sheets for each generator set provide 14RES/ 20RES/
specific generator and engine information. Refer to the Engine Specification RESL RESL
generator set specification sheet for ratings and other Manufacturer Kohler
data not supplied in this manual. Consult the generator Model CH740 CH1000
set installation manual, engine operation manual, and
Cycle 4 4
engine service manual for additional specifications.
Number of cylinders 2 2
Consult the generator set nameplate for specific Compression ratio 9:1 8.8:1
generator set ratings. Displacement, cc (cu. in.) 725 (44) 999 (61)
Rated power, propane fuel,
17.6 (23.6) 23.0 (30.9)
kW (HP)
1.2 Controller Specifications Rated power, natural gas,
15.3 (20.5) 20.2 (27.1)
kW (HP)
Model 14RES and 20RES generator sets are equipped
with the Residential Digital Control (RDC). Model Rpm, 60 Hz 3600
14RESL and 20 RESL generator sets are equipped with Rpm, 50 Hz 3000
the Digital Control (DC). For a specific description of the 83 x 67 90 x 78.5
Bore x stroke, mm (in.)
controller, see Section 2, Operation, in the operation (3.27 x 2.64) (3.54 x 3.1)
manual. Valve material Steel/Stelliter
Cylinder block material Aluminum w/cast iron liners
Environmental Specification All Models Cylinder head material Aluminum
Operating temperature --30_ to 70_C Piston rings 2 compression/ 1 oil
Storage temperature --40_ to 85_C Crankshaft material Heat-treated ductile iron
Humidity 0--95% condensing Main bearings: number, type 2, parent material
Power requirements: Lubrication system Full pressure
Voltage 12 VDC Oil capacity (w/filter), L (qt.) 1.9 (2.0) 2.8 (3.0)
Current (standby state) 250 mA @ 12 VDC Oil pressure, kPa (psi) 172--241 (25--35)
Fuel system LP gas or natural gas
Minimum fuel supply
LP and NG: 1.2-- 2.7 (5--11)
1.3 Engine Service pressure, kPa (in. H2O)
Battery voltage 12 VDC
Generator sets covered in this manual are equipped
Battery ground Negative
with four-cycle, twin cylinder, air-cooled Kohler engines.
Spark plug gap, mm (in.) 0.76 (0.030)
For engine service information and specifications not Ignition system Capacitor discharge
covered in this manual, see the engine service manual. Starter motor Electric, solenoid shift
See the List of Related Materials in the Introduction Cooling system Air-cooled
section.
TP-6735 9/10 Section 1 Specifications 13

1.5 Alternator Specifications
Alternator Specification 14RES/RESL 20RES/RESL
Frequency Hz 50/60 50/60
Phase Single-Phase Single-Phase
Number of leads 4 4
Excitation method Static Excited Static Excited
Voltage regulator type Digital Digital
Coupling type Direct Direct
Insulation (rotor and stator) Epoxy varnish, vacuum impregnated
Class 180 (H)
Winding material Copper Copper
Bearing, number and type 1, Sealed Ball 1, Sealed Ball
Circuit protection
Battery charger inline fuse F1 10 amps 10 amps
Fuel solenoid/starter relay/throttle control fuse F2 7.5 amps 7.5 amps
Controller power, fuse F3 3 amps 3 amps
Aux. winding mini-breaker 20 amps 20 amps
Generator AC output line circuit breaker 70 amps 100 or 125 amps
Rotor resistance, ohms, cold 5.2 5.6
Stator resistance, ohms,* cold
Single-Phase Leads 1-2, 3-4 0.06 0.02
11-44 0.13 0.04
55-66 0.60 0.44
Stator output voltage with separately excited rotor using 12-volt
battery, minimum
Leads: 1-2, 3-4 105 V 88 V
11-44 210 V 176 V
55-66 142 V 117 V
Rotor field voltage/current readings at rated output voltage, hot
No load 19 V/3.2 A 19 V/3.9 A
Full load 48 V/7.2 A 53 V/7.4 A
Brush length, new 19.05 mm (0.75 in.) 19.05 mm (0.75 in.)
* Most ohmmeters do not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance
reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with
a reading indicating a shorted winding.
1.6 Torque Specifications

Torque Specifications,
Nm (ft. lb.) 14/20RES/RESL
Alternator overbolts 15 (11)
Alternator thrubolt 85 (63)
Generator adapter screws 40 (28) *
Muffler flange bolts 24 (17.7)
3/4 to 1 turn after
Oil filter
gasket contact
Spark plug 24.4--29.8 (18--22)
* Not applicable to the 20RES/RESL.
14 Section 1 Specifications TP-6735 9/10

1.7 Service View
1
11
10
9 17
7, 8
6 2, 4 18, 19
5 3 20
CONTROLLER
17 TOP VIEW
24 16 18, 19
AIR INTAKE SIDE --PANEL 15
REMOVED TO SHOW DETAIL 14
13 20
12 21
AIR
INTAKE
SIDE
EXHAUST 22
SIDE
23
24
25 ADV-7876
26 TP-6735
23
1. Field-connection terminal block 14. Governor assembly

2. Digital spark advance ignition (DSAI) leads 15. Air cleaner
3. Fuel inlet 16. Oil filter
4. Fuel solenoid valve 17. RDC or DC controller
5. Engine starting battery location (battery purchased separately) 18. Fuses
6. Battery cables 19. USB connector (for firmware updates)
7. Battery charger location (charger not shown) 20. Line circuit breaker
8. 120 VAC receptacles for battery charger and optional carburetor 21. Oil fill
heater (not shown) 22. Spark plugs
9. Nameplate location 23. Lifting holes
10. Gas regulator assembly 24. Oil drain hose
11. Fuel block or LP orifice location (inside hose fitting) 25. Oil drain valve
12. Muffler (located below cover plate) 26. Alternator
13. Oil check dipstick
Figure 1-1 Generator Set Service View
TP-6735 9/10 Section 1 Specifications 15

Notes
16 Section 1 Specifications TP-6735 9/10

Section 2 Scheduled Maintenance
See the Safety Precautions and Instructions at the

WARNING beginning of this manual before attempting to service,
repair, or operate the generator set. Have an authorized
distributor/dealer perform generator set service.
Alternator Service. Under normal operating conditions

the generator set alternator does not require scheduled
Accidental starting.
service. Refer to the service schedule for items that
Can cause severe injury or death.
require maintenance.
Disconnect the battery cables before
working on the generator set. Engine Service. Perform generator set engine service
Remove the negative (--) lead first at the intervals specified by the engine service literature.
when disconnecting the battery. Contact an authorized Kohlerr service distributor/
Reconnect the negative (--) lead last dealer to obtain engine service literature.
when reconnecting the battery.
All generator sets have emission-certified engines. The
Disabling the generator set. Accidental starting can carburetors on emission-certified engines are not
cause severe injury or death. Before working on the adjustable.
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the Generator Set Service. See the Safety Precautions
OFF position. (2) Disconnect the power to the battery charger. and Instructions at the beginning of this manual before
(3) Remove the battery cables, negative (--) lead first. attempting to service, repair, or operate the generator
Reconnect the negative (--) lead last when reconnecting the
set. Have an authorized Kohlerr service distributor/
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote dealer perform all generator service.
start/stop switch, or engine start command from a remote
computer. Routine Maintenance. Refer to the following generator
set service schedule, the engine service schedule, and
the runtime hours displayed on the generator set
WARNING controller to determine when to schedule routine
maintenance. Service the generator set more
frequently if it is subject to extreme weather, long
operating hours, or dusty or dirty conditions.
Hot engine and exhaust system. Service Schedule. Perform maintenance on each item
Can cause severe injury or death. in the service schedule at the designated interval for the
Do not work on the generator set until life of the generator set.
it cools.
Tools. Tools and instruments used to perform some
Servicing the exhaust system. Hot parts can cause maintenance items are not generally available to the
severe injury or death. Do not touch hot engine parts. The generator set owner. Therefore, have service
engine and exhaust system components become extremely performed by an authorized distributor/dealer.
hot during operation.
WARNING 2.1 Service Schedule

Perform the items listed in the service schedule at the
designated intervals for the life of the generator set. For
example, an item serviced every 100 hours or 3 months
must also be serviced after 200 hours or 6 months,
Hazardous voltage. Moving parts.
Can cause severe injury or death. 300 hours or 9 months, etc.
Operate the generator set only when

all guards and electrical enclosures
are in place.
TP-6735 9/10 Section 2 Scheduled Maintenance 17

Procedure
See Visually
System Component or Procedure Section Inspect Check Change Clean Test
Fuel
Flexible lines and connections Q R
Main tank supply level (LP) W
Fuel piping Y
Lubrication 2.2
Oil level 2.2.2 8 or E
Change oil 2.2.4 Y or 150
Replace filter 2.2.4 Y or 150
Crankcase breather hose Y or 500
Oil cooler 2.2.6 Y Y or 100
Cooling 2.5
Air ducts, louvers Y Y
Exhaust System 2.7
Leakage W W
Insulation, fire hazards Y
Obstructions or combustible materials near exhaust outlet W
DC Electrical System
Battery charger operation, charge rate M
Remove corrosion, clean and dry battery and rack 2.8 Y Y
Clean and tighten battery terminals and inspect boots Y Y
Tighten DC electrical connections Y
AC Electrical System
Tighten control and power wiring connections Y
Remote control system, if equipped M
Visible wear or damage Q
Wire abrasions where subject to motion 6 months 6 months
Wire-cable insulation condition 3Y or 500
Engine and Mounting
Visible wear or damage W
Air cleaner service * 2.4 150 300
Spark plugs 2.3 150 300
Replace stepper motor coupling and bushing 2.6 500 (D)
Generator
Visible wear or damage Q
Exercise generator set W
Brushes and collector ring 5.5, 5.6 Y (D) Y (D)
Measure and record resistance readings of windings with
insulation tester (Meggerr, with controller or rectifier and 3Y (D)
load leads disconnected)
General Condition of Equipment
Evidence of vibration, leakage, deterioration, unusual or
excessive noise or temperature W W W
Interior of sound enclosure Q Q
* Service more frequently under extremely dusty/dirty conditions. E Each use Number = hours of operation
Meggerr is a registered trademark of Biddle Instruments. W Weekly D Authorized distributor/dealer only
M Monthly R Replace as necessary
Q Quarterly S/M Service Manual
Y Yearly
Figure 2-1 Service Schedule
18 Section 2 Scheduled Maintenance TP-6735 9/10

2.2 Lubrication System 2.2.3 Engine Oil Recommendation
See Section 2.1, Service Schedule, for oil change and Use 5W-30 API (American Petroleum Institute) Service
oil filter replacement intervals. See Section 1.7, Service Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes
View, for the oil drain, oil check, oil fill, and oil filter and thickens less than other oils and leaves the engine
locations. intake valves and pistons cleaner.
Model Oil Capacity, L (qt.)

2.2.1 Low Oil Pressure Shutdown
14RES/RESL 1.9 (2.0)
The low oil pressure (LOP) shutdown feature protects 20RES/RESL 2.8 (3.0)
the engine against internal damage if the oil pressure
Figure 2-3 Oil Capacity (approximate)
drops below a minimum pressure because of oil pump
failure or other malfunction.
2.2.4 Oil Change Procedure
Note: The LOP shutdown feature does not protect
against damage caused by operating when the Note: Dispose of all waste materials (engine oil, fuel,
oil level is low; it is not a low oil level shutdown. filter, etc.) in an environmentally safe manner.
Check the oil level regularly, and add oil as
needed. Drain the oil while it is still warm.
1. Drain the oil.

2.2.2 Oil Check
a. Press the OFF button on the controller.
The generator set is shipped with oil. Before operating
the generator set, check the engine oil in the crankcase. b. Disconnect the power to the battery charger.
See Figure 2-2 for the dipstick location.
c. Disconnect the generator set engine starting
Maintain the oil level at or near, not over, the full mark on battery, negative (--) lead first.
the dipstick. Add 5W-30 synthetic oil when the oil level is
low. See Section 2.2.3, Engine Oil Recommendation. d. Remove the housing intake panel.
Check the oil level before each use. For extended e. Clean the area around the dipstick and oil fill
operation, check the oil level every 8 hours. Do not cap.
check the oil level when the generator set is running.
Shut down the generator set and wait several minutes f. Remove the cap from the oil drain hose and
before checking the oil. lower the hose into an oil collection container.
g. Open the oil drain valve on the engine.
h. Remove the dipstick and oil fill cap. Allow time

for the engine oil to drain completely.
i. Close the oil drain valve. Replace the cap on

the oil drain hose. Replace the oil drain hose in
its retaining clip.
j. Replace the dipstick.
2. Replace the oil filter.
a. Clean the area around the oil filter. Remove the

oil filter by rotating it counterclockwise with an
oil filter wrench.
6515
b. Clean the gasket sealing surface of the oil filter
Figure 2-2 Oil Check adapter.
c. Apply a light coat of clean oil to the rubber seal

of the new oil filter.

d. Install the new oil filter following the instructions
provided with the filter.
3. Fill with oil.
a. Fill the engine to the F mark on the dipstick.

Section 2.2.3, Engine Oil Recommendation,
for oil selection. See Figure 2-3 for the engine
oil capacity.
b. Reinstall the dipstick and the oil fill cap.

1
c. Check that the generator set is off (the OFF
LED is on). 2
1. Oil filter 24 590 01--A
d. Reconnect the generator set engine starting 2. Oil cooler
battery, negative (--) lead last.
Figure 2-4 Oil Cooler Location, 14RES/RESL
e. Reconnect the power to the battery charger.
f. Start and run the generator set for a minute to

allow the oil pressure to reach operating range.
g. Stop the generator set, wait 1 minute, and then

recheck the oil level. Add oil to bring the level
up to the F mark on the dipstick.
4. Check for leaks.
a. Check for oil leaks.
b. Fix leaks and recheck the oil level.
c. Reinstall the housing side panel.
2.2.5 Oil Cooler, 14RES/RESL

Inspect and clean the oil cooler at the intervals shown in
the Service Schedule. The oil cooler must be kept free
24 590 01--A
of debris.
Figure 2-5 Cleaning the Oil Cooler
Remove the front enclosure panel to access the oil
cooler. See Section 6.2 for instructions to remove the
front panel.
See Figure 2-4 for the oil cooler location. Clean the
outside of the oil cooler with a brush or compressed air.
If it is necessary to clean the back of the oil cooler,
remove the two screws holding the oil cooler unit to the
blower hosing. Tilt the cooler and clean with a brush or
compressed air as shown in Figure 2-5. After cleaning,
reinstall the oil cooler and secure with the mounting
screws.

2.2.6 Oil Cooler, 20RES/RESL 2.3 Spark Plugs
Inspect and clean the oil cooler at the intervals indicated Reset the spark plug gap or replace the plugs with new
in the service schedule. The oil cooler must be kept free plugs as necessary.
of debris.
1. Clean the area around the base of the spark plug to
Remove the front enclosure panel to access the oil keep dirt and debris out of the engine.
cooler. See Section 6.2 for instructions to remove the
front panel. 2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is
See Figure 2-6 for the oil cooler location. The oil cooler questionable.
is located under the No. 2 cylinder shroud. Remove the
top mounting screw and loosen the two side screws, 3. Check the spark plug gap using a wire feeler
then lift off the cylinder shroud. Clean the outside of the gauge. Adjust the gap to 0.76 mm (0.030 in.) by
oil cooler fins with a brush or with compressed air. carefully bending the ground electrode. See
Figure 2-7 and Figure 2-8.
4. Reinstall the spark plug into the cylinder head.

Torque the spark plug to 24.4--29.8 Nm
(18--22 ft. lb.)
1--514
1 Figure 2-7 Checking the Spark Plug Gap

1. Oil cooler 62 590 01
Figure 2-6 Oil Cooler Location, 20RES/RESL
1--511
Figure 2-8 Adjusting the Spark Plug Gap

2.4 Air Cleaner Service 2. Disconnect the power to the battery charger.
3. Disconnect the battery, negative (--) lead first.

2.4.1 Air Cleaner, 14RES/RESL Models
4. Loosen the cover retaining knob and remove the
The engine has a replaceable high-density paper air cover. Remove the precleaner from the paper
cleaner element with an oiled foam precleaner. See element. Wash the precleaner in warm water with
Figure 2-9. detergent. Rinse the precleaner thoroughly until all
traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
1
to air dry.
5. Saturate the precleaner with new engine oil.

2 Squeeze out all of the excess oil.
3 6. Reinstall the precleaner over the paper element.
7. Reinstall the air cleaner cover. Secure the cover

4
with the cover retaining knob.
8. Reconnect the power to the battery charger.

5
9. Reconnect the generator set engine starting
6
Paper Element Service
7 Use the following procedure to replace the paper
element at the intervals specified in the service
schedule. Replace the paper element more often under
586536 extremely dusty or dirty conditions.
1. Cover knob 1. Press the OFF button on the generator set

2. Air cleaner cover controller.
3. Element cover nut
4. Element cover 2. Disconnect the power to the battery charger.
5. Foam precleaner
6. Air cleaner element
7. Air cleaner base 3. Disconnect the generator set engine starting
battery, negative (--) lead first.
Figure 2-9 Air Cleaner Components, 14RES/RESL
4. Loosen the cover retaining knob and remove the
Check for a buildup of dirt and debris around the air cover.
cleaner system. Keep this area clean. Also check for
loose or damaged components. Replace all bent or 5. Remove the element cover nut, element cover, and
damaged air cleaner components. the paper element with precleaner.
Note: Operating the engine with loose or damaged air 6. Remove the precleaner from the paper element.
cleaner components could allow unfiltered air
into the engine causing premature wear and Note: Do not wash the paper element or clean it
failure. with pressurized air, as this will damage the
element.
Precleaner Service 7. Replace the element if it is dirty, bent, or damaged.
Use the following procedure to wash and reoil the 8. Check the air cleaner base. Make sure it is secure
precleaner as indicated in the service schedule. Wash and not bent or damaged. Also check the element
and reoil the precleaner more often under extremely cover for damage and fit. Replace all damaged air
dusty or dirty conditions. cleaner components. Remove any loose dirt or
debris from the air cleaner base. Wipe the base
1. Press the OFF button on the generator set
carefully so that no dirt drops into the intake throat.
controller.

Check the condition of the rubber seal on the air 1. Loosen the two cover retaining knobs and remove
cleaner stud and replace the seal if necessary. the cover.
9. Reinstall the paper element, precleaner, element 2. Remove the paper element.
cover, element cover nut, and the air cleaner cover.
Secure the cover with the cover retaining knob. 3. Do not wash the paper element or use pressurized
air, as this will damage the element. Replace a
10. Reconnect the power to the battery charger. dirty, bent, or damaged element. Handle new
elements carefully; do not use if the sealing
11. Reconnect the generator set engine starting surfaces are bent or damaged.
4. When servicing the air cleaner, check the air
cleaner base. Make sure it is secured and not bent
2.4.2 Air Cleaner, 20RES/RESL Models or damaged. Also, check the element cover for
The engine is equipped with a replaceable, high density damage or improper fit. Replace all damaged air
paper air cleaner element. See Figure 2-10. cleaner components.
Note: If any loose dirt or debris fell on the air cleaner

base when the element was removed, carefully
1 remove it and wipe the base clean. Be careful that
none of it drops into the intake throat.
2
5. Reinstall the paper element onto the air cleaner
base. Make sure the element is flat and properly
3
seated.
6. Install the air cleaner cover and secure with the two
retaining knobs.
4
2.5 Cooling System
The engine fan draws cooling air through the openings
in the sides and end near the battery. The alternator fan
tp6515
draws cooling air through openings on the side walls of
the enclosure. The cooling air mixes with the engine
1. Knobs (qty. 2)
exhaust and is discharged at the exhaust outlet. See
2. Cover
3. Paper element Figure 2-11. To prevent generator set damage caused
4. Base by overheating, keep the housing cooling inlets and
outlets clean and unobstructed at all times.
Figure 2-10 Air Cleaner Components, 20RES/RESL
Note: Do not block the generator set cooling air inlets or
Check the air cleaner daily or before starting the engine. mount other equipment above them.
Check for a buildup of dirt and debris around the air Overheating and severe generator damage may
cleaner system. Keep this area clean. Also check for occur.
loose or damaged components. Replace all bent or
damaged air cleaner components.
1
1 2
Note: Operating the engine with loose or damaged air
cleaner components could allow unfiltered air
into the engine causing premature wear and
failure.
Paper Element Service
Replace the paper element at the intervals indicated in tp6733

REAR VIEW
the service schedule. See Figure 2-1 for the service
1. Air intake
schedule. See Figure 2-10 for the air cleaner
2. Exhaust outlet
components. When element replacement is necessary,
order genuine Kohler parts. Figure 2-11 Cooling Air Intake and Exhaust

2.6 Stepper Motor Coupling 2.7 Exhaust System
Replace the stepper motor coupling and bushings at the Remove all combustible materials from the exhaust
intervals shown in the service schedule. See the Parts location. Combustible materials include building
Catalog for replacement part numbers. materials as well as natural surroundings. Keep dry field
grass, foliage, and combustible landscaping material a
Figure 2-12 shows the location of the coupling minimum of 1.5 m (5 ft.) from the exhaust outlet.
assembly under the air cleaner. Loosen the set screw to
remove the coupling from the motor shaft. Periodically inspect the exhaust system components for
cracks, leaks, and corrosion.
D Check for corroded or broken metal parts and replace

them as needed.
D Check that the exhaust outlet is clear.
2.8 Battery
WARNING
Sulfuric acid in batteries.

tp6519
1 Wear protective goggles and
1. Coupling and bushing clothing. Battery acid may cause
blindness and burn skin.
Figure 2-12 Stepper Motor Coupling
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
1 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
2 tp6518_9 acid.
1. Coupling Battery acid cleanup. Battery acid can cause severe
2. Bushing
injury or death. Battery acid is electrically conductive and
Figure 2-13 Stepper Motor Coupling and Bushing 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 1 2
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. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface EZ-273000-J
away from the battery. To avoid sparks, do not disturb the 1. To positive (+) terminal on starter solenoid.
battery charger connections while the battery is charging. 2. To ground (--) terminal on or near starter motor.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing Figure 2-14 12-Volt Engine Electrical System Single
batteries to prevent accumulation of explosive gases.
Starter Motor, Typical Battery Connection
Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or Clean the battery and cables and tighten battery
equipment damage. Disconnect the battery before generator terminals using the service schedule recommendations.
set installation or maintenance. Remove all jewelry before To prevent corrosion, maintain tight, dry electrical
servicing the equipment. Use tools with insulated handles. connections at the battery terminals. To remove
Remove the negative (--) lead first when disconnecting the
corrosion from battery terminals, disconnect the cables
battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
from the battery and scrub the terminals with a wire
battery cable to the positive (+) connection terminal of the brush. Clean the battery and cables with a solution of
starter solenoid. Do not test the battery condition by shorting baking soda and water. After cleaning, flush the battery
the terminals together. and cables with clean water and wipe them with a dry,
lint-free cloth.
This section contains general battery information and
maintenance instructions. Also consult the battery After reconnecting the battery cables, coat the battery
manufacturer’s instructions for battery maintenance. terminals with petroleum jelly, silicone grease, or other
nonconductive grease.
All generator set models use a negative ground with a
12-volt engine electrical system. Consult the generator
set nameplate for the engine electrical system voltage. 2.9 Battery Charger
Consult the generator spec sheet for battery capacity
The generator set is equipped with a battery charger to
recommendations for replacement purposes. Wiring
maintain the engine starting battery. See Section 1.7,
diagrams provide battery connection information. See
Service Views, for the battery charger location.
Figure 2-14 for typical battery connections.
The charger’s DC leads are factory-wired. Periodically
tighten all connections. See the generator set operation
manual for battery charger troubleshooting instructions.

2.10 Storage Procedure 2.10.3 Cylinder Lubrication
Perform the following storage procedure before 1. Remove the spark plugs.
removing the generator set from service for three
months or longer. Follow the engine manufacturer’s 2. Pour one tablespoon of engine oil into each spark
recommendations for storage, if available. plug hole. Install the spark plugs and ground the
spark plug leads. Do not connect the leads to the
Note: Run the generator set monthly whenever plugs.
possible.
3. Press RUN and then OFF to crank the engine two
or three revolutions to lubricate the cylinders.
2.10.1 Lubricating System
1. Operate the generator set until it reaches operating 2.10.4 Exterior Preparation
temperature, or about 15 minutes.
1. Clean the exterior surface of the generator set.
2. Stop the generator set.
2. Seal all openings in the engine with nonabsorbent
3. While the engine is still warm, drain the engine adhesive tape.
lubrication oil from the engine crankcase.
3. Mask all areas to be used for electrical contact.
4. Refill the engine crankcase with oil. See
Section 2.2.3 for oil recommendations. 4. Spread a light film of oil over unpainted metallic
surfaces to prevent rust and corrosion.
5. Run the generator set for a few minutes to
distribute the clean oil. 2.10.5 Battery
6. Stop the generator set. Perform battery storage last.

2.10.2 Fuel System
controller.
1. Start the generator set.
2. Disconnect the battery, negative (--) lead first.
2. With the generator set running, shut off the gas
supply. 3. Clean the battery.
3. Run the generator set until the engine stops. 4. Place the battery in a warm, dry location.
4. Press the OFF button on the controller. 5. Connect the battery to a float/equalize battery
charger, or charge the battery monthly using a
trickle charger. Follow the battery charger
manufacturer’s recommendations.

Section 3 Troubleshooting
3.1 Introduction 3.3 Controller Service Access

Corrective action and testing in many cases requires The controller fuses and alternator winding circuit
knowledge of electrical systems and electronic circuits. breaker are accessible from the front of the controller.
Have an authorized distributor/dealer or trained service Remove the service access door to reach the circuit
technician perform testing and service. breaker and fuses. See Figure 3-1.
Refer to the engine service manual for engine service Obtain replacement fuses from a Kohler authorized
information. See the List of Related Materials for the distributor/dealer.
document part number.
If the troubleshooting procedures in this section identify 1 2

a failed part, refer to the parts catalog for replacement
part numbers. See the List of Related Materials in the
Introduction for the parts catalog number.
3.2 Initial Checks

When troubleshooting, always check for simple
problems first. Check for the following common 4
problems before replacing parts: GM62860
3
D Loose connections or damaged wiring. 1. USB port (for computer connection for SiteTech software)
2. Alternator winding circuit breaker
3. Controller fuses F2 and F3
D Dead battery. 4. Run and crank LEDs
D Fault shutdown. Check for a fault code on the Figure 3-1 Controller Service Access (cover
controller display. Section 4.8 describes the warning removed)
and shutdown fault codes. If a fault code is displayed,
identify and correct the cause of the fault condition. 3.4 Troubleshooting Chart
Then reset the controller.
Use the following table as a reference in troubleshooting
D Blown fuses. Two controller fuses are located in the individual problems. Generator set faults are listed in
controller’s service access area. See Figure 3-1. A groups and include likely causes and remedies. The
battery charger fuse is located in the positive battery simplest and most likely causes of the problem are listed
lead. Always check for and replace any blown fuses first; follow the recommendations in the order shown.
before replacing other components. Identify and The reference column provides additional sources of
correct the cause of the blown fuse. See information in this and related manuals regarding the
Section 5.14.2 for fuse part numbers. problem and solution.
D Incorrect controller settings. Always check the
controller configuration settings before replacing the
controller. Section 4.11 contains the instructions for
checking and changing the controller configuration.
D Inadequate fuel supply. Check for damaged

primary or secondary fuel regulators, loose
connections to the fuel solenoid valve, a damaged or
closed fuel shutoff valve, an empty LP fuel tank, or
other problems with the fuel supply. Check the fuel
supply pressure to the generator set. See
Section 5.11, Fuel Systems.
TP-6735 9/10 Section 3 Troubleshooting 27

Problem Possible Cause Test Corrective Action Reference
Generator Battery connections Check for reversed or poor Correct and tighten battery —
set engine battery connections. connections.
does not Weak or dead Test the battery voltage. Recharge or replace battery. O/M
crank battery Test battery according to battery
manufacturer’s recommendations.
If battery is weak or dead, check O/M
the battery charger.
Check battery charger fuse and Tighten connections and replace
connections. charger fuse if blown.
Check 120VAC power supply to Connect 120VAC power to
the charger. charger.
Test charger operation. Replace charger if necessary.
Open circuit in Check for loose connections. Tighten connections. Section 5.13
engine/controller Check the wire harness Replace harness or harness Section 7
connections continuity. leads if damaged.
Blown controller Use a test lamp or meter to check Replace fuse; if fuse blows again, Section 5.14.2
fuse F3 fuse F3. check circuit and components. Section 7
Blown fuse F2 Use a test lamp or meter to check Replace fuse. Section 5.14.2.
fuse F2. If fuse blows again, disconnect Section 7
the following leads. Reconnect
one at a time and attempt to start
to identify the cause of the blown
fuse:
Lead 70A at the fuel valve
Lead IGN at the ignition module
Lead 71A at the starter relay
Leads FP and FN at the rotor
Repair or replace the component
causing the blown fuse.
Crank relay K3 on Check connections to the Tighten connections. Section 4.13
controller circuit controller. Replace wiring if damaged.
board Check for a good ground Tighten/repair ground connection. Section 7
connection.
Check the crank LED to verify If the Crank LED is not lit, check Section 7
12VDC to relay K3. for 12VDC to the board. Section 4.13
If the Crank LED is lit but relay K3
does not operate, replace the
controller circuit board.
W/D = Wiring Diagram(s) (Section 7) S/S = Generator Set Specification Sheet O/M = Generator Set Operation Manual
I/M = Generator Set Installation Manual Engine S/M = Engine Service Manual
* RDC controller settings can be checked and adjusted using the controller user interface or using a personal computer running SiteTech
software. DC controller settings can only be changed using SiteTech.
28 Section 3 Troubleshooting TP-6735 9/10

Generator Poor ground (--) Test ground connection. Clean and retighten. —
set engine connection
does not Starter relay Check connections to the starter Tighten connections. Section 1.7
crank, relay. Replace wiring if damaged.
continued
Check continuity of circuit. Section 5.13
Section 7
Check that the starter relay picks Replace starter relay. Section 7
up when 12VDC is applied at lead
71A connection.
Starter Check starter connections. Tighten connections. Section 1.7
Replace wiring if damaged. Section 7
Troubleshoot the starter. See the Rebuild or replace starter. Engine S/M
engine service manual for
instructions.
Controller Check the controller settings. Adjust controller settings. Section 4.11
Test the controller as described in See Section 3.5. Section 3.5
Section 3.5.
Cranks but No fuel Verify that manual fuel valve is Open (turn on) manual fuel valve. —
does not open.
start Check fuel supply tank (LP). Contact fuel supplier to add fuel
to fuel supply tank (LP).
Insufficient fuel Check fuel pressure to the Contact fuel supplier to replace Section 5.11.3
pressure generator set. Verify adequate fuel supply lines with larger pipe
fuel pressure and pipe size for the and replace gas meter if fuel
generator set plus all other gas pressure is insufficient.
appliances.
Fuel regulator/valve Check regulator/valve operation. Check regulator/valve operation. Section 5.11
Section 4
Spark plugs or Check spark plug wires and Tighten connections. Replace O/M
spark plug connections. spark plug wires if damaged.
connections Check spark plugs. Replace or clean and regap spark
plugs.
Loose connection Check for loose or open Tighten connections. Section 7
or open circuit connection at the fuel valve (lead Replace wiring if damaged.
70A) and at the engine spark
control module (leads IGN and
70A). Check controller/engine
wiring continuity.
Air cleaner clogged Check for a dirty air cleaner Replace air cleaner element. O/M
element. Check and replace air cleaner
element at the intervals shown in
the Service Schedule.
Magnetic pickup Check for 3.0 volts or higher from Tighten loose connections or Section 5.9.4
the magnetic pickup during replace wiring as necessary.
cranking. Test magnetic pickup Adjust magnetic pickup air gap if
and check gap according to the necessary. Replace mag pickup
procedure in Section 5.9.4. if necessary after testing.

Cranks but Incorrect controller Check for correct engine Enter the correct controller Section 4.11
does not configuration configuration parameter (EC). configuration parameters.
start, Ignition system Test according to instructions in Adjust or replace components as Engine S/M
continued spark control or the engine service manual. indicated in engine service
ignition coil manual.
Digital spark Check DSAI leads. Connect for natural gas. Section 5.11.2
advance (DSAI) Disconnect for LP.
leads incorrectly Check for loose connections. Tighten connections.
connected or Replace wiring if damaged.
disconnected
No engine rotation Check mag pickup. See See magnetic pickup, above. Section 5.9.4
sensed (check for magnetic pickup, above.
an overcrank fault
shutdown)
Starts hard Low battery voltage Check battery voltage during Charge battery. Replace battery O/M
cranking. if necessary.
Check battery charger Tighten loose connections.
connections, power supply, and
operation.
Air cleaner clogged Check for a dirty air cleaner Replace element. O/M
element.
Fuel mixture Use oxygen sensor to check fuel Adjust fuel mixture. Section 5.11
adjustment mixture.
incorrect
DSAI leads Check DSAI connection. Connect for natural gas. Section 5.11.2
incorrectly Disconnect for LP.
connected or
disconnected
Spark plug(s) Check spark plug condition and Replace or regap spark plug(s). O/M
gap.
Spark plug wire(s) Check spark plug wires and Tighten connections. Replace Engine S/M
connections. spark plug wires if damaged.
Ignition Test ignition components Replace ignition components if Engine S/M
components (spark according to instructions in the necessary.
control or ignition engine service manual.
module)
Insufficient fuel Check fuel pressure to the Contact fuel supplier to replace Section 5.11.3
pressure generator set. Verify adequate fuel supply lines with larger pipe
fuel pressure and pipe size for the and replace gas meter if fuel
generator set plus all other gas pressure is insufficient.
appliances.
Worn piston rings, Check compression. See the See engine service manual. Engine S/M
valves engine service manual.
Starts but Fault shutdown Check for a fault shutdown code Correct the fault and then press Section 5.10
shuts on the controller display. Identify the controller’s OFF button to
down the cause of the fault. reset the controller.

Stops Fault shutdown Check for a fault shutdown code Correct the fault and then press Section 4.8
suddenly on the controller display. Identify the controller’s OFF button to Section 5.10
the cause of the fault. reset the controller.
No fuel Check fuel valves and fuel supply. Open manual fuel valve. Contact —
fuel supplier to replenish fuel
supply.
Fuel line restriction Inspect fuel lines. Clear restriction. —
Fuel lines too long Check fuel line length and pipe Contact fuel supplier to replace Generator set
size. fuel lines with larger pipe. S/S, I/M
Air cleaner clogged Check for a dirty air cleaner Replace air cleaner element. O/M
element.
Blown fuse Check fuses F2 and F3 on the Replace fuse. If fuse blows again, Section 5.14.2
controller. test generator components.
Spark plug(s) Check spark plug(s). Replace or regap plug(s). O/M
Engine overheated Check air intake and generator Clear air intake and enclosure air O/M
(hot engine only) set enclosure air inlets and outlet. inlets and outlets.
Use oxygen sensor to check fuel Adjust fuel mixture. Section 5.11
mixture.
Check oil level. Add oil. Check and replace oil at O/M
the intervals shown in the Service
Schedule.
Low oil pressure Check oil pressure. See engine S/M. Engine S/M
(LOP) switch Attempt startup. If unit shuts Replace faulty LOP shutdown Section 5.10.2
down, remove lead from LOP switch.
switch and reset controller. A Note: Check engine oil pressure
successful restart attempt before performing test and/or
indicates a faulty LOP shutdown replacing LOP shutdown switch.
switch.
Note: Check engine oil pressure
before performing test and/or
replacing LOP shutdown switch.
Fuel valve/fuel Check fuel valve connections. Tighten fuel valve connections. Section 5.11
regulator Check regulator/valve operation. Replace damaged wires.
Check fuel pressure. Replace regulator or valve .
Engine overloaded Reduce electrical load and check Unplug some lights or appliances —
operation. connected to the generator set.
Magnetic pickup Check for loose connections to Tighten connections to the mag Section 5.9
connections the mag pickup. pickup. Replace damaged wiring.
Ignition module Test the ignition system according Service the ignition system Engine S/M
to the instructions in the engine according to the instructions in
service manual. the engine service manual.
Loss of generator Check connections at P2 plug. Tighten connections at P2 plug. Section 7
output voltage to Check continuity of AC sensing Replace wiring if damaged. Section 5.3
controller leads 11 and 44 (1 ph) or V7, V8,
and V9 (3 ph). Section 5
See Section 5 for alternator test Repair or replace components if
procedures. necessary, as indicated by tests
in Section 5.
Overheats Inadequate cooling Inspect engine and enclosure for Clear any air intake obstructions. O/M
air intake obstructions.
Fuel mixture Use an oxygen sensor to check Readjust fuel mixture. Section 5.11
adjustment the fuel mixture. Note: Adjusting the fuel mixture
incorrect
may void the emission
certification.

Noisy Exhaust system Check silencer and connections Replace gaskets and exhaust —
operation leaks for leaks. system components as
necessary.
Engine not running See “Erratic operation,” this table. See “Erratic operation,” this table. —
smoothly
Broken or damaged Inspect vibromounts. Replace as necessary. Section 6
vibromount(s)
Loose or vibrating Check for loose screws and Retighten screws, replace rivets.
sheet rivets. —
metal/housing
Exhaust piping or Inspect for loose parts. Secure loose parts as necessary. —
air inlets/outlets not
securely installed
Excessive Check rotor, crankshaft, bearing, Check, rotor, crankshaft, bearing, Section 6
engine/generator etc. (disassembly of engine etc. (disassembly of engine Engine S/M
vibration and/or alternator may be and/or alternator may be
required). required).
Erratic Air cleaner clogged Check air filter element. Replace element. O/M
operation Spark plug(s) Check spark plug condition and Replace or regap plugs. O/M
gap.
Spark plug wire(s) Check spark plug connections Tighten connections. Replace Engine S/M
and wires. damaged spark plug wires.
DSAM leads Check DSAM/DSAI lead Connect for natural gas. Section 5.11.2
incorrectly connection. Disconnect for LP.
connected or
disconnected
Fuel line restriction Check fuel lines. Clear restricted fuel lines. Section 5.11.3
Check fuel pipe size. Contact fuel supplier to install
larger diameter pipe.
Fuel mixture Use oxygen sensor to check fuel Adjust fuel mixture. Section 5.11
adjustment mixture.
incorrect
Magnetic pickup Check for loose connections to Tighten mag pickup connections. Section 5.9
connections the mag pickup. Replace damaged wiring.
Governor Check governor operation. Adjust governor. Section 5.9
adjustment Check controller engine speed Adjust controller engine speed. * Section 4.11 and
incorrect (frequency) adjustment. * Installation Man.
Ignition system Test ignition system according to Service ignition system according Engine S/M
instructions in engine service to instructions in engine service
manual. manual.
Inadequate cooling Check air inlet and outlet. Clear air inlet and outlet. —
(hot engine only)
Other engine See engine service manual. Service according to instructions Engine S/M
service required in engine service manual.
Light Voltage stability Check the voltage stability (gain) Adjust the voltage stability (gain) Section 4.11.5
flicker (gain) setting setting using the RDC controller. * setting using the RDC controller. *

High Incorrect controller Check the controller configuration Adjust the controller configuration Section 4.11.2
output configuration parameters. * parameters. *
voltage Incorrect controller Check the controller voltage Adjust the controller voltage Section 4.11.5
voltage settings settings. * settings. *
Loose voltage Check connections: Tighten connections. Section 7 W/D
sensing stator leads 11 and 44 and
connections P2 controller connection.
Section 3.5.
Lacks Air intake Inspect air intakes and exhaust Inspect air intakes and exhaust O/M
power restriction, for obstructions. for obstructions.
inadequate cooling Check air cleaner. Check air cleaner. O/M
Generator Reduce electrical load and check Unplug some lights or appliances —
overloaded operation. connected to the generator set.
Spark plug(s) Check spark plugs. Regap and/or replace plug(s). O/M
Spark plug wire(s) Check tightness and condition of Tighten or replace spark plug Engine S/M
spark plug wires. wires.
DSAI leads Check DSAI leads. Connect for Connect for natural gas. Section 5.11.2
incorrectly natural gas. Disconnect for LP. Disconnect for LP.
connected or
disconnected
Insufficient fuel Check fuel pressure at carburetor Contact fuel supplier to replace Section 5.11
pressure outlet. Check for adequate fuel pipe and/or meter as required to
pipe size and meter capacity for provide sufficient fuel supply
generator set and all gas-fired pressure for the generator set and
appliances. all gas-fired appliances.
Fuel line restriction Check fuel pipe size. Contact fuel supplier to provide Section 5.11
larger pipe.
Fuel regulator Check function of fuel regulator. Repair or replace fuel regulator. Section 5.11
Engine not running Check controller setting for Reset controller setting for engine Section 4.11
at rated rpm engine type (EC). * type (EC). *
Check engine speed. Adjust engine speed.
Engine power loss Refer to the engine service Refer to the engine service Engine S/M
manual for troubleshooting and manual for troubleshooting and
repair instructions. repair instructions.
Governor Test governor. Adjust governor. Section 5.9
malfunction or
misadjustment
Ignition system See the engine service manual See the engine service manual Engine S/M
for service procedures. for service procedures.

Low output Generator Reduce electrical load and check Unplug some lights or appliances —
or overloaded operation. connected to the generator set.
excessive Incorrect controller Check the controller configuration Adjust the controller configuration Section 4.11
drop in configuration parameters. * parameters. *
voltage
Incorrect controller Check the controller voltage Adjust the controller voltage Section 4.11.5
voltage settings settings. * settings. *
Alternator or control Perform separate excitation Troubleshoot the alternator or Section 5.2
system procedure to isolate problem to control system as indicated by
the alternator or the control test results.
system.
Section 3.5.
Rotor Test rotor for open, grounded, or Replace rotor if faulty windings Section 5.4
shorted windings. are found.
Stator Test stator for open, grounded, or Replace stator if faulty windings Section 5.3
shorted windings. are found.
Brush connection Check for loose brush Tighten loose brush connections. Section 5.6
connections.
Check for loose brush mounting. Tighten mounting screws.
Check the resistance through the Replace brushes if they show
brushes. Resistance through the uneven wear or are worn to
brushes should be low, 0.1--0.2 one-half their original length.
ohms without meter lead
resistance.
Low engine speed Check system voltage/frequency Change system voltage/frequency Section 4.11.2
causing voltage (Uu) and engine type (Ec) (Uu) and engine type (Ec)
roll-off parameters. * parameters if not correct. *
Check engine speed. Adjust engine speed. Section 4.11.5
Engine problem. Troubleshoot the engine. Engine S/M

No output AC output circuit Check for AC voltage on the Check for and correct short —
voltage breaker open generator side of circuit breaker. circuits or overloading on the load
If there is AC voltage on the side before resetting the circuit
generator side of the breaker, breaker.
then a problem in the load circuits
is causing the line circuit breaker
to trip.
Alternator or control Perform separate excitation Troubleshoot the alternator or Section 5.2
system procedure to isolate the problem control system components as
to the alternator or the control described below and elsewhere in
system. this table.
Blown fuse Check fuse F2. Replace fuse F2. Section 5.14.2
Section 3.5.
Open wiring, Check fuses and wiring. Replace fuses or wiring as Section 5.14.2
terminal, or pin in necessary. Section 7 W/D
buildup circuit
Brushes Inspect brushes. Replace brushes if worn. Section 5.6
Check for brushes sticking in Replace brush spring or brush Section 5.6
brush holder or broken brush assembly.
spring.
Check that brush holder is Tighten brush holder screws. Section 5.6
securely mounted.
Rotor slip rings dirty Check slip ring condition. Clean slip rings as described in Section 5.5
or corroded Section 5.5. Machine slip rings if
necessary.
Rotor (open, Check voltage and continuity as Repair or replace rotor if indicated Section 5.4
grounded, or described in Section 5.4. by the tests.
shorted windings)
Stator (open, Check voltage and continuity as Repair or replace the stator if Section 5.3
grounded, or described in Section 5.3. indicated by the test results.
shorted windings)
Aux. winding circuit Check the breaker in the service Reset breaker. Figure 3-1
breaker tripped access area of the controller. If breaker trips again, check Section 5.3
If breaker trips again, check stator.
stator.

3.5 Controller Troubleshooting The following RDC/DC controller functions require
connection to a Kohlerr Model RRT automatic transfer
Refer to the controller troubleshooting table in this switch.
section when troubleshooting procedures in Section 3.4
indicate a possible controller problem. Always check D Utility voltage display on the RDC or DC controller
the controller configuration settings before replacing the
controller. D Automatic exercise initiated using the RDC down
arrow button or the DC Exercise button, loaded or
The RDC controller settings can be checked and unloaded
adjusted through the controller user interface or using a
personal computer and Kohlerr SiteTecht software. D Ultra-quiet diagnostic test
The generator set installation manual contains the
D Loaded test initiated from the RDC or DC controller
instructions for checking and changing the controller
configuration. The DC controller settings can only be D Engine cooldown
changed using SiteTecht. See TP-6701, SiteTech
Software Operation Manual. Kohlerr SiteTecht D Load control
software is available to authorized distributors and
dealers. D Automatic generator set startup and load transfer
when utility power is lost (also available with other
Also check the controller display for fault codes and refer Kohler model transfer switches connected to engine
to Section 4.8, Faults. start leads 3 and 4)
Check the connection to the Model RRT transfer switch

when troubleshooting problems with the functions listed
above. See Section 4.10 for more information about
these operations. See Section 4.10.6 for connections.
Test Corrective Action Reference

Check controller settings. * Adjust controller settings as required. * Section 4.11
Check for power to the controller at lead P Check/replace fuse F3. If fuse blows again, check Section 5.14.2
(connection P1--1). the wiring harness for shorts to ground.
Check connections and wiring. Tighten connections Wiring
and repair/replace wiring as needed. diagrams,
Section 7
Check battery and battery charger. Installation
manual.
Check controller fuse F3. Replace controller fuse. If fuse blows again, check Section 5.14.2
the wiring harness for shorts to ground. Section 7
If fuse F3 blows repeatedly in RUN mode, check the Section 5.9.2
stepper motor.
Check controller fuse F2. Replace controller fuse. If fuse blows repeatedly, Section 4.13.2
check the components listed in Section 4.13.2.
Check controller wiring and connections. Tighten connections and/or replace wiring. Wiring
diagrams,
Section 7
Check RUN and CRANK LEDs and relays. See Section 4.13 for instructions. Section 4.13
software. DC controller settings can only be changed using SiteTech. See TP-6701, SiteTech Software Operation Manual.
Figure 3-2 Controller Troubleshooting

Section 4 Controller
4.1 Introduction 4.2 RDC and DC Generator Set/

This section covers operation, configuration, Transfer Switch Controllers
adjustment, and replacement of the RDC and DC The Residential Digital Control (RDC) and Digital
controllers. See Section 3 for troubleshooting Control (DC) control the power system generator set
procedures. and Model RRT automatic transfer switch (ATS) (if
equipped). The controller receives voltage sensing data
See the service view and Figure 4-1 for the controller
from the ATS and operates the generator set and
location.
transfer switch to provide standby power when utility
power is lost.
1 If the generator set is not connected to a Kohlerr Model

RRT ATS, the RDC/DC controller functions as a
generator set controller only. ATS communication and
functions do not operate with other ATS models. The
ultra-quiet diagnostic test/exercise is not available with
other ATS models.
4.3 Controller Power

The RDC and DC controllers are powered by the
generator set engine starting battery.
Note: The generator sets are equipped with factory-

installed battery chargers to prevent battery
discharge. The battery charger must be
connected to utility power.
1. Controller
Figure 4-1 Controller Location
TP-6735 9/10 Section 4 Controller 37

4.4 Controls and Indicators
Figure 4-2 illustrates the RDC and DC controller user
interfaces.
1 1
2
3
4 5
9 9
8 8
7 7
6 6
Residential Digital Controller (RDC) Digital Controller (DC)
1. LED display 6. Service access (see Section 3.3)

2. Up button (RDC only) 7. RUN button and LED
3. Select button (RDC only) 8. AUTO button and LED
4. Down/Exercise button (RDC) 9. OFF button and LED
5. Exercise button (DC)
Figure 4-2 RDC and DC Controls and Indicators
38 Section 4 Controller TP-6735 9/10

4.4.1 LED Display Display Description
When the system is in AUTO and the generator set is not Blank (dark) Controller is off.
running, the LED display shows the engine run time u#.# Controller software version number
hours. During cranking, the display shows the crank XXX.X Engine hours to 999.9
cycle information.
XXXX Engine hours, 1000 to 9999
When the generator is running, the display steps bXX.X Battery voltage
through the status messages shown in Figure 4-3, as tXXX Engine temperature
applicable. The generator set must be connected to a
UXXX Utility voltage
Model RRT transfer switch for the utility voltage display.
EXXX Generator voltage
When a fault or warning condition exists, the controller tnLd Test, no load
will show the respective message. The following table
t Ld Test, loaded
shows the various generator conditions and expected
display or messages. EnLd Exercise, no load
E Ld Exercise, loaded
Test or exercise mode, CC1, 2, or 3 Engine crank cycle 1, 2, or 3. Flashes
if applicable. during crank pause.
tnLd, t LD, EnLd, or E Ld Fault code Warning or fault. See Figure 4-7.
Figure 4-4 RDC Controller Display

Engine Runtime
XXX.X or XXXX hours
4.4.2 Controller Keypad
The Run, Off, Auto, and Down arrow or Exercise buttons
Battery Voltage control the generator set as described in Figure 4-5.
bXX.X VDC See Section 4.5 for operation instructions.
RDC controller (RES models) only: The Select, Up,

Engine Temperature and Down buttons on the controller keypad are used to
tXXX
adjust the controller parameters. The system
configuration and performance is factory-set and should
not require changes under normal operating conditions.
Utility Voltage
UXXX VAC To prevent inadvertent changes, a pass code is required
to access the controller parameter settings. See the
generator set Installation Manual for controller
Generator Voltage configuration instructions. See Section 5.8 of this
EXXX VAC manual for performance adjustment instructions.
tp6734 For the DC controller (RESL models), a personal

computer with Kohlerr SiteTecht software is required
D Generator set is running. for system configuration changes and performance
D Model RRT transfer switch is required for utility voltage adjustment.
display.
D Display steps through the parameters in sequence for
2 seconds each.
Figure 4-3 Data Displays, Generator Running

Button
Press Response in AUTO or OFF Mode Response during EXERCISE Response during TEST
OFF Stops the generator set and places Immediately ends the exercise and Immediately ends the test and
the controller in OFF mode. The shuts down the generator. The shuts down the generator. The
OFF LED turns ON and then engine cooldown time delay is engine cooldown time delay is
flashes every 2 seconds. ignored. The AUTO LED turns ignored. The RUN LED turns OFF.
Pressing OFF during the engine OFF. The OFF LED turns ON and The OFF LED turns ON and then
crank cycle will stop the crank then flashes every 2 seconds. flashes every 2 seconds.
cycle.
If a fault code is displayed,
pressing OFF resets the controller.
Press and hold the OFF button for
3 seconds to view the event history.
AUTO Places the controller in AUTO Shuts down the engine through Shuts down the engine through
mode. AUTO LED turns ON. normal timing sequences and goes normal timing sequences and goes
Generator set will respond to to the AUTO mode. AUTO LED to the AUTO mode. AUTO LED
remote start/stop signals. turns ON. RUN LED turns OFF. turns ON. RUN LED turns OFF.
RUN Starts the generator set in Ends the exercise time period but No effect when a test is already
unloaded test mode. The does not shut down the generator running.
generator set starts and the display set. Engine ramps up to normal
indicates an unloaded test, tnLd. operating speed of 3600 RPM.
RUN LED turns on. RUN LED turns on, and AUTO LED
turns off. Generator continues to
run in test mode until stopped by
the OFF or AUTO buttons.
DOWN From AUTO mode: Press once to Press during an unloaded exercise Press during an unloaded test to
arrow/ start an unloaded exercise. The to change to a loaded exercise. change to a loaded test, causing
EXERCISE engine starts and EnLd appears on Engine ramps up to normal the ATS to transfer to the
the display. operating speed and the ATS emergency source. The display
From OFF mode: No effect. transfers to the emergency source. indicates a loaded test, t Ld.
Display changes to indicate a
loaded exercise, E Ld. Future
exercise periods will be loaded and
will start at the time of the first
button press.
Pressing this button again during a
loaded exercise run has no effect.
Select and Used for RDC controller configuration and performance adjustment. See the generator set installation manual
UP Arrow and Section 5.8 of this manual.
Buttons
(RDC only)
Figure 4-5 Controller Pushbutton Operation
4.4.3 LED Indicators

LEDs above the RUN, OFF, and AUTO buttons indicate
the mode of operation as shown in Figure 4-6.
Mode LED Indication Description
RUN RUN LED is on The generator set was started by pressing the RUN button. Generator set is
running. Remote start and stop commands are ignored.
OFF OFF LED lights for 2 The OFF button was pressed. Generator set and controller are off. Remote
seconds, then flashes start/stop commands have no effect.
every 2 seconds.
AUTO AUTO LED is on Automatic mode. Generator set will respond to engine start and stop commands
from an ATS or from Kohlerr SiteTecht software. Time delays operate as described
in Section 4.5.
Figure 4-6 Operation Modes and LED Indicators

4.5 Generator Set Operation 3. After the Normal-to-Emergency time delay, the
ATS is signaled to transfer the load to the
emergency source.
4.5.1 Engine Start Crank Cycle
The controller attempts to start the generator set three Automatic Stop with Engine Cooldown
times (three crank cycles, 15 seconds crank and
1. When the utility source is restored, the
15 seconds off). See Figure 4-4 for display information
Emergency-to-Normal time delay starts.
during the crank cycle. If the generator set does not start
in three attempts, the system shuts down on an 2. When the Emergency-to-Normal time delay
overcrank fault. See Section 4.8. expires, the load is transferred to the utility.
Pressing the OFF button during the crank cycle stops 3. The controller runs the generator set for the
the cranking. No other buttons are acknowledged cooldown time and then stops the generator set.
during the crank cycle.
4.5.4 Automatic Operation with Model

4.5.2 Local Starting and Stopping
RDT or RSB Transfer Switches
Start If a Kohlerr Model RDT or RSB transfer switch is used,
the engine start contacts from the ATS must be
Press the RUN button to immediately start the generator
connected to engine start leads 3 and 4 on the generator
set. The engine start time delay will be ignored.
set.
The controller attempts to start the generator set three
The controller must be in AUTO mode to respond to
times. If the generator set does not start in three
remote start/stop signals from an ATS or remote switch.
attempts, the system shuts down on an overcrank fault.
Press the AUTO button to put the controller into
See Section 4.8.
automatic mode.
Stop
Automatic Start
1. Run the generator set with no load for at least
The engine start contacts on the ATS close to signal the
2 minutes to ensure adequate engine cooldown.
generator set to start, and remain closed while the
2. Press the OFF button. The engine stops. generator set is running.
Automatic Stop
4.5.3 Automatic Operation with Model
RRT Transfer Switch Open the contact across engine start leads 3 and 4 to
signal the generator set to stop.
The Model RRT transfer switch connects to the RDC/DC
controller through the ATS interface board on the
transfer switch. Also see Section 4.10, Model RRT
Transfer Switch Operation.
The controller must be in AUTO mode. Press the AUTO

button to put the controller into automatic mode.
Automatic Start
The RDC/DC controller receives utility source voltage
sensing data from the Model RRT transfer switch.
1. If the utility source voltage falls below an

acceptable level, the controller starts the engine
start time delay.
2. If the utility source is not restored before the time

delay expires, the generator set starts.

4.6 Exercise diagnostic test will occur at the same time every seven
days.
Note: A Kohlerr Model RRT transfer switch is required
for operation of the automatic exercise function
on the RDC and DC controllers.
4.6.2 Low-Speed Diagnostics
During the unloaded diagnostic test, the controller
A power system that includes a Model RES or RESL
monitors the following data. The controller display
generator set and a Model RRT transfer switch can be
indicates an unloaded exercise run (EnLd) during the
set to automatically run the generator set at the same diagnostics, unless a fault is detected as described
time and day each week. Exercising the generator set
below.
weekly is required in order to keep the engine and
alternator in good operating condition. D Battery voltage. If the controller detects low battery
voltage, a low battery warning is indicated and the
Follow the instructions in this section to start a 20-minute
exercise does not start.
exercise run and set the exerciser to run at the same
time every 7 days. Figure 4-5 summarizes the D Generator output frequency and voltage. The
operation of the controller buttons. controller verifies that the voltage and frequency are
within acceptable limits for the run speed.
Other transfer switches: If a transfer switch other than
the Model RRT is used with the generator set, refer to D ATS connection. The controller verifies that the ATS
the instructions provided with the transfer switch to set interface board, if connected, remains connected. An
the exerciser. ATS Communication Lost fault will be displayed if the
connection is lost.
4.6.1 Unloaded Exercise with
D Oil pressure. The controller verifies the engine oil
Diagnostic Test pressure during low speed operation.
An unloaded exercise runs the generator set without
signaling the transfer switch to transfer the electrical 4.6.3 Loaded Exercise
load from the utility source to the generator set. To start
an unloaded, ultra-quiet diagnostic test, the control must A loaded test or exercise starts the generator set and
be in the AUTO mode with the AUTO LED ON and the then transfers the electrical load from the utility source to
Utility power available. the generator set. The load is transferred back to the
utility source before the generator set shuts down.
1. Press the down arrow button (RDC) or exercise
button (DC) to initiate the engine start signal. To start a loaded full-speed exercise, the control must be
in the AUTO mode with the AUTO LED on and utility
2. The generator begins its crank cycles. During the power must be available.
crank cycles CCn appears on the display. No
button presses are acknowledged during the crank 1. Press the down arrow button (RDC) or the exercise
cycles. button (DC) to initiate the engine start signal.
3. EnLd appears on the display once the generator is 2. The generator begins its crank cycles. During the
running. The generator runs at low speed. The crank cycles CCn appears on the display. No
AUTO LED will be illuminated. The controller button presses are acknowledged during the crank
monitors the system during the unloaded exercise cycles.
as described in Section 4.6.2, Low Speed
Diagnostics. 3. EnLd appears on the display once the generator is
running. The AUTO LED will be illuminated. The
4. The generator runs at low speed for 20 minutes and generator is running at low speed with no load.
then shuts down.
4. Press the down arrow button (RDC) or exercise
Note: If the engine temperature has risen to 104_C button (DC) a second time. The generator ramps
(219_F) or higher, the unit will run at full up to normal operating speed (typically 3600 RPM)
speed for 5 minutes to allow engine and the ATS transfers the load.
cooldown before shutting down.
5. E Ld appears on the display. The AUTO LED is
The exercise time is set to the time the down arrow or illuminated. The generator runs at normal
exercise button was pressed. An unloaded, ultra-quiet operating speed for twenty minutes with load.

6. After 20 minutes, the ATS transfers the load back to 4.7 Test
utility power. The engine runs for the cooldown
cycle and then shuts down. An operator can use the buttons on the RDC/DC
controller to test the generator set and transfer switch
The exercise time is set to the time the down arrow (Model RRT only) operation at any time. Unlike the
button (RDC) or exercise button (DC) was initially exercise function, a test does not start or stop
pressed. A loaded, full-speed exercise will occur at the automatically. The operator must use the RDC/DC
same time every seven days. controller to start and stop the test. Follow the
instructions below to run an unloaded or loaded test.
4.6.4 Exerciser Reset and Disable
4.7.1 Unloaded Test
To reset the exerciser to run at a different day and/or
time, or to switch between a loaded and unloaded An unloaded test runs the generator set without
exercise, follow the procedures above to start an signaling the transfer switch to transfer the electrical
unloaded or loaded exercise on the desired time and load from the utility source to the generator set.
day. The previous exercise setting is replaced by the
new time, day, and loaded or unloaded condition. Unloaded Test Procedure
To disable the exerciser, press and hold the OFF and 1. Press the RUN button to start an unloaded test.
DOWN arrow or EXERCISE buttons together for The engine cranks and starts.
3 seconds.
Note: Pressing the OFF button during the crank
cycle stops the cranking. No other buttons
4.6.5 Power Failure During Exercise
are acknowledged during the crank cycle.
Cycle
2. tnLd appears on the display once the generator is
If the utility power is lost during an unloaded exercise,
running. The RUN LED is illuminated. The engine
the ATS transfers to the emergency source, the exercise
runs at normal operating speed (3600 RPM) during
is ended and the control remains in the AUTO mode.
the test sequence.
If the utility power is lost during a loaded exercise, the
3. To end the test, press the AUTO button to shut
exercise is ended. The ATS remains in the emergency
down the generator set and enter AUTO mode.
position and the control goes into the AUTO mode.
When utility power is restored, the ATS will re-transfer to Ending an Unloaded Test
the utility source through normal timing sequences.
There are two ways to end an unloaded test:
D Press the AUTO button to shut down the generator

set and enter AUTO mode.
D Press the OFF button to shut down the generator set

immediately. The cooldown time delay is ignored.
Figure 4-5 describes the effect of pressing the buttons

during a test when there are no active faults.

4.7.2 Loaded Test Immediate Shutdown During a Loaded Test
A loaded test starts the generator set and then signals Press the OFF button to shut the generator set down
the Model RRT transfer switch to transfer the electrical immediately, if necessary. The cooldown time delay is
load from the utility source to the generator set. The load ignored, and the controller goes to OFF mode. The
is transferred back to the utility source before the controller signals the RRT transfer switch to transfer the
generator set shuts down. load back to utility power.
Note: Running the generator set with no load for at least

Loaded Test Procedure 2 minutes is recommended to ensure adequate
1. Press the RUN button to start an unloaded test as engine cooldown. Use the OFF button to stop a
described in Section 4.7.1. tnLd appears on the loaded test only if necessary.
display once the generator is running.
4.7.3 Power Failure During Test Cycle
2. Press the down arrow button (RDC) or the exercise
button (DC) to signal the ATS to transfer the load. If the utility power is lost during an unloaded test, the
The display indicates a loaded test, t Ld. ATS transfers to the emergency source and the test is
ended. The control goes into the AUTO mode.
3. To end the test, press the AUTO button to shut
down the generator set through normal timing If the utility power is lost during a loaded test, the test is
sequences. The engine cooldown cycle runs ended and the ATS remains in the emergency position.
before the generator set engine stops. The The control goes into the AUTO mode.
generator set goes into Auto mode.
When utility power is restored, the ATS re-transfers to
the utility source through normal timing sequences.

4.8 Faults 4.8.4 Resetting the Controller after a
Fault Shutdown
Fault codes and conditions are shown in the table on the
following pages, Figure 4-7. Fault conditions are Always identify and correct the cause of a fault
classified as warnings or shutdowns. shutdown before resetting the controller. Check the
fault code displayed on the controller and refer to
Figure 4-7 to identify and correct the fault condition
4.8.1 Warnings before proceeding. Contact an authorized
The controller displays a fault code but the generator set distributor/dealer for service, if necessary.
does not shut down on a warning. The controller resets
automatically after a warning condition is corrected. Procedure to Reset the Controller after a Fault
Shutdown
4.8.2 Shutdowns 1. Press OFF to turn off the generator set.
Under a fault shutdown condition, the generator set 2. Disconnect the generator set from the load using
shuts down automatically and the controller displays a the line circuit breaker or ATS. See the safety
fault code. In some cases, the engine cooldown cycle precautions at the beginning of this manual before
runs before the engine shuts down. proceeding.
Shutdown switches (such as the low oil pressure switch 3. Identify and correct the cause of the fault
or high engine temperature switch) on the generator set shutdown. See the safety precautions at the
will automatically reset when the problem is corrected. beginning of this manual before proceeding. Refer
However, the fault condition at the controller does not to Section 3, Troubleshooting.
clear until the controller is reset.
4. Start the generator set by pressing RUN. Check
The generator set cannot be restarted until the fault the generator set operation to verify that the cause
condition is corrected and the controller is reset. See of the shutdown has been corrected.
Section 4.8.4 to reset the controller after a fault
shutdown. 5. Press the OFF button to stop the generator set.
6. Reconnect the generator set to the load using the

4.8.3 ATS Communication Errors line circuit breaker or ATS.
An ATS fault can be caused by the following conditions.
7. Press AUTO to put the generator set into automatic
D When a Model RRT transfer switch is used, an ATS mode.
fault indicates that communication with the interface
board on the transfer switch has been lost. The
generator set shuts down. Check the connection to
the ATS interface board.
D When a Model RDT or RSB transfer switch is used,

an ATS fault indicates that connection to the ATS
interface board is detected when it is not expected. A
warning is displayed but the generator set does not
shut down.
If an RDT or RSB transfer switch is replaced with a

Model RRT ATS, disconnect and then reconnect power
to the controller to cause the controller to recognize and
establish communication with the new ATS.

Code Fault W or SD* Condition Check See Section
AF Auxiliary fault SD [ An optional customer-connected Check customer-supplied —
input input is closed. equipment.
HE High engine W or SD [ Engine coolant temperature Check for blocked air inlets and 1.7
temperature exceeds the maximum exhaust outlets.
temperature for more than
5 seconds. Function becomes
active after crank disconnect.
Warning at 300_ F.
Shutdown at 325_ F.
LOP Low oil SD [ The LOP switch indicates low oil Check for leaks in the lubrication —
pressure pressure for more than system.
5 seconds. Function becomes O/M
Check the oil level and add oil if
active 30 seconds after crank the level is low.
disconnect (30 second inhibit). 5.10
Check low oil pressure switch
Note: The low oil pressure connections and operation.
shutdown does not protect Check the oil pump and Engine S/M
against low oil level. Check the lubrication system.
engine oil level regularly as
recommended in the O/M.
OC Overcrank SD Three unsuccessful starting Check the fuel supply valves and 5.11
attempts. pressure.
Check spark plug and battery. O/M
See Troubleshooting Chart, 3.4
generator set cranks but does not
start.
Lr Locked rotor SD No engine rotation is sensed Check mag pickup connections 5.9.4
during cranking. Shuts down 3 and operation.
seconds after the fault is Check for a locked rotor. 5.4
detected.
OF Over frequency SD [ Governed frequency exceeds Check system frequency setting 4.11
110% of the system’s frequency (parameter UU) on controller.
setpoint for more than 5 Measure output frequency and 5.9.5
seconds. Function becomes adjust, if necessary.
active 10 seconds after engine
start (10 second inhibit). Check governor system condition 5.9
and operation.
OS Overspeed SD [ Engine speed exceeds 115% of Check governor settings and 5.9
the normal running speed for operation.
more than 0.3 seconds.
US Underspeed SD [ Engine speed drops below 85% Reduce the load. —
of the normal running speed for
Check for throttle linkage 5.9.2
more than 0.3 seconds.
obstruction.
Check for a loose or disconnected 5.9.2
governor stepper motor harness.
Check for bad leads in the
harness.
Check the stepper motor 5.9.2
operation. 5.9.4
* W = Warning; SD = Shutdown Engine S/M = Engine Service Manual
[ Engine cooldown runs before shutting down. O/M = Generator Set Operation Manual

OU Overvoltage SD [ Output voltage exceeds 120% of Check output voltage and adjust, 5.8
the system nominal voltage for if necessary (parameter 1P,
more than 2 seconds. voltage adjust).
Check controller settings for I/M
system voltage (Parameter Uu).
Check the calibration (SiteTech 4.12
software required). Controller
firmware version 2.04 or higher is
required for calibration.
UF Underfrequency SD [ Governed frequency falls below Reduce the load and restart the —
90% of the system frequency generator set.
setting for more than 5 seconds,
or 1 Hz below the system Check controller setting for I/M
frequency setting for more than system frequency.
60 seconds.
Check the engine governor 5.9.5
Function becomes active 10
settings, and adjust if necessary.
seconds after engine start.
(Parameter 4P, governor speed)
(10 second inhibit).
UU Under voltage SD [ Output voltage falls below 80% Reduce the load and restart the —
of the nominal system voltage for generator set.
more than 10 seconds. Check wiring and connections. 7
Check controller configuration, 4.11
system voltage and frequency
(parameter Uu).
Check AC voltage and adjust, if 5.7
necessary (parameter 1P, voltage
adjust).
Check the calibration (SiteTech 4.12
software required). Controller
firmware version 2.04 or higher is
required for calibration.
Separately excite unit. 5.2
Check stator continuity. 5.3
Hb High battery W Engine starting battery voltage Check the battery rating and Battery mfr’s
voltage rises above 125% of the battery condition. instructions
voltage setting for more than 10
seconds when the engine is
running. Not operative during the
Check the battery charger O/M
engine crank cycle.
operation.
Clears when the battery voltage
returns to an acceptable level.
Lb Low battery W Engine starting battery voltage Check the battery rating and Battery mfr’s
voltage falls below the battery voltage condition. instructions
setting (typically 12 volts) for more O/M
Check the battery charger
than 90 seconds when the engine operation.
is not running. Not operative
during the engine crank cycle. Charge or replace the battery.
Clears when the battery voltage
returns to an acceptable level.
SS Speed sensor SD Engine speed sensor has failed. Check the mag pickup gap and 5.9.4
failure operation.

AC Loss of AC W (1 sec.) Generator output AC sensing is Check for loose connections. Wiring
sensing lost. Starts 10 seconds after Check all AC leads connected to Diagrams
SD (3 sec.)
[
crank disconnect. the controller for continuity.
Warning: after 1 second if no Alternator excitation failure: 5.6
output detected after crank Inspect the brushes and check the
disconnect. FN and FP connections.
Fault: after 3 seconds if voltage Voltage Regulator failure: check Section 7,
was present and then lost. for voltage on the output leads. Wiring
Diagrams
LCb Low cranking W Battery voltage falls below 60% Charge or replace the battery. —
voltage of system battery voltage for
more than 6 seconds while the
starter is engaged.
ATS ATS SD (RRT) [ RRT: Shutdown if ATS interface Check connection to Model RRT I/M
communication W (other connection is lost. transfer switch interface board. Section 7,
error ATS) Wiring
Other ATS: Warning is displayed
Diagrams
if ATS interface board is
connected when it is not Section 4.8.3.
expected.
LrC Loss of voltage SD [ No communication between Replace the controller. 4.14
regulator controller and voltage regulator.
communication
Figure 4-7 Controller Fault Codes
4.9 Event History 2. Press the OFF button to cycle through the engine
hours and subsequent events. After cycling
The last ten controller faults can be viewed from the through all ten events, the control automatically
controller display when the controller is off. Each event turns off. The OFF LED flashes once every 2
is displayed with the fault code followed by the engine seconds.
hours at which time the event occurred. During event
history viewing, the OFF LED flashes once per second. To stop viewing the event history before the last event,
press the down arrow or exercise button. The controller
Procedure to View Event History will turn off.
1. Press and hold the OFF button for 3 seconds. The Not in Auto: The code nIA (Not In Auto) may be shown
first event appears on the screen. The OFF LED in the event history but is not displayed on the controller
flashes once per second. when in run or off modes.

4.10 Model RRT Transfer Switch 3. The generator set is signaled to start.
Operation 4. The generator starts and the emergency source
becomes available.
The RDC/DC generator set/transfer switch controller
manages automatic transfer switch (ATS) functions 5. The normal-to-emergency time delay times out.
when connected to a Kohlerr Model RRT transfer switch
through the ATS interface board. 6. The transfer switch transfers to the emergency
source.
4.10.1 Source Availability 7. The load control contact time delay times out.
The Model RRT transfer switch supplies voltage
8. The load control contact closes.
sensing data to the RDC/DC controller through the ATS
interface board. If the source voltage falls below the
undervoltage dropout setting, the source is considered Normal Source Returns:
to have failed. See Figure 4-8.
1. The emergency-to-normal time delay times out.
Item Setting 2. The contactor transfers to the normal source.
Accuracy ±5%
Undervoltage Dropout 90% of Pickup
3. The engine cooldown time delay times out.
Undervoltage Pickup 90% of Nominal 4. The generator is signaled to stop.
Figure 4-8 Voltage Sensing Parameters
4.10.3 Time Delays
4.10.2 ATS Control Sequence of Time delays are factory-set to the values shown in
Operation Figure 4-9. An authorized distributor/dealer can adjust
time delays using a personal computer and Kohlerr
See Figure 4-9 for time delay settings.
SiteTecht software.
Preferred Source Fails: Time delays described in this section operate only when
the controller is connected to a Kohlerr Model RRT
1. The load control contact opens.
transfer switch.
2. The engine start time delay times out.
Time Delay Setting Description

Engine Start 3 seconds Time delay after utility source is lost until the engine start cycle begins.
Guards against starting the generator set because of a brief change in
the utility source.
Transfer, Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer to
emergency source.
Transfer, Emergency to Normal 2 minutes Time delay after the utility source returns until transfer back to normal.
Ensures that the the utility source is stable before transferring from the
emergency source.
Load Control 5 minutes Allows delayed connection of selected loads to the generator set.
Prevents simultaneous starting of large motors after transfer to the
emergency source. Recommended for delayed starting of air
conditioners.
Engine Cooldown 5 minutes Runs the engine with no load after transfer from the generator set.
Engine stops before the time delay expires if the temperature drops
below the cooled-down temperature level, or if the temperature rises
during the cooldown cycle.
Figure 4-9 Time Delays

4.10.4 Engine and Transfer Time Delays simultaneous starting of large motors after transfer to
the generator set. The load control time delay is fixed at
The engine start and transfer time delays prevent 5 minutes. It is not adjustable.
engine start and load transfer caused by brief variations
in the utility power source. The load must be connected to the load control output
on the interface board of the Model RRT transfer switch.
The engine cooldown time delay allows the engine to See the transfer switch operation and installation
run after the loads have been removed. The engine manual for connection instructions.
stops before the cooldown time delay expires if the
temperature drops below the cooled-down temperature
level, or if the temperature rises during the cooldown 4.10.6 Model RRT ATS Connection
cycle.
See Figure 4-10 for Model RRT transfer switch
connection to the generator set.
4.10.5 Load Control Time Delay
The load control time delay allows delayed starting of
large motor loads (such as air conditioners), preventing
Generator ATS
Set
1 2
GM66565 ADV-7598
Customer
connections
12--24 AWG
1. RES or RESL generator set terminal block TB1

2. Controller interface module location on the ATS, typical
3. Interface module connector P14
4. ATS1 through ATS4 on generator set field-connection terminal block TB1 GM63552
Figure 4-10 Model RRT Transfer Switch Connection to Generator Set Terminal Block

4.11 Controller Configuration and Do not use settings Uu07--Uu22. These settings may
appear as choices during configuration but do not apply
Adjustment to the 14RES/RESL or 20RES/RESL generator sets.
The first step in troubleshooting the controller is to verify
that the controller is correctly configured for the Definition
generator set. The RDC controller’s configuration Parameter Setting Phases Hz VAC
modes allow selection of the system voltage and System voltage Uu01 1 60 120/240
frequency and generator set configuration. Follow the and frequency * Uu06 1 50 115/230
instructions in the generator set installation manual to Uu07 DO NOT USE
check the controller settings and change them, if Uu11 DO NOT USE
necessary. A Kohler-authorized distributor or dealer
Uu15 DO NOT USE
can also check and adjust the RDC controller
Uu16 DO NOT USE
configuration and settings using a personal computer
and Kohlerr SiteTecht software. Uu19 DO NOT USE
Uu21 DO NOT USE
The DC controller configuration and settings cannot be Uu22 DO NOT USE
viewed or adjusted at the controller. However, a Engine Ec13 14RES/RESL
Kohler-authorized distributor or dealer can check and Configuration *
Ec14 20RES/RESL
adjust the DC controller configuration and settings using
a personal computer and Kohlerr SiteTecht software. Figure 4-11 Controller Configuration Settings
4.11.1 SiteTech Software 4.11.3 Controller Time Out

A personal computer running Kohlerr SiteTecht The controller will automatically exit the configuration
software can be used to configure and adjust the RDC mode without saving any changes after about 1 minute
and DC controllers. See TP-6701, SiteTech Software if no buttons are pressed. Start the configuration
Operation Manual, for PC connection and software procedure again from the beginning if the controller exits
operation instructions. the configuration mode before the settings have been
saved.
Appendix F contains a list of controller parameters that
can be viewed and adjusted using SiteTech. The Changes in voltage and speed adjustments are also lost
Access column in the table shows which parameters if they are not saved before the generator set shuts
can only be viewed (Read or Locked), and which down. The generator set continues to run with the new
parameters can be changed using the software (Write). settings until it shuts down but then reverts to the
previous settings at the next startup. Be sure to save
SiteTech software is also used to update the firmware on your changes immediately after making adjustments.
the RDC and DC controllers. See TP-6701 for
instructions.
4.11.4 Controller Firmware Version
SiteTech can be used to calibrate the voltage. See Number
Section 4.12.
The controller firmware version number is displayed on
the LED screen during the key sequence to enter the
4.11.2 Controller Configuration configuration mode. Press and hold the Select and UP
The controller configuration for each generator Model is buttons together. After about 5 seconds, the firmware
set at the factory. If the controller is replaced, check the version number will be displayed on the controller
configuration of the new controller and change the display. For example, 01.10 will be displayed for
settings, if necessary. See Figure 4-11. Follow the firmware version 1.10.
instructions in the generator set installation manual to
The DC controller firmware version number is displayed
check controller settings and change them if necessary.
during the first 2 seconds of the crank cycle.

4.11.5 Voltage and Frequency 4.12.1 Calibrate Function
Adjustments
The RDC/DC controller can be calibrated using
Voltage and/or frequency adjustments may be required SiteTech. Measure the actual utility voltage across L1
after controller replacement or other service and L2, and enter the measured value into SiteTech as
procedures. See Section 5.8 for instructions to adjust described below. See Figure 4-12.
the generator set output voltage and frequency using
the RDC controller. Use a personal computer and Calibration Procedure
Kohlerr SiteTecht software to make adjustments on
RESL models equipped with the DC controller. 1. Measure the actual utility voltage across L1 and L2.
Use a digital voltage meter and observe the safety
The generator set must be running during these precautions in the generator set installation
adjustments. Use a multimeter to measure generator manual.
set output voltage and frequency during adjustments.
Refer to Sections 5.8, Voltage Adjustment, and 5.9.5, 2. Click on Calibrate in the ribbon at the top of the
Frequency Adjustment, for instructions to measure and SiteTech screen. See Figure 4-12.
adjust the output voltage and frequency.
3. The Device Calibration window appears. Type the
Note: Be sure to save your settings before exiting the measured voltage into the space provided.
configuration mode. The controller reverts to the
4. Click the Calibrate button in the Device Calibration
last saved settings when turneed off.
Window.
After the calibration procedure, view the utility voltage in

4.12 Calibration the Source 1 metering window. Voltage L1--L2 and
The controller can be calibrated for utility voltage using average line-to-line voltage are displayed.
using a personal computer connected to the RDC/DC
controller. Kohlerr SiteTecht software is required for 4.12.2 Calibration Factor
calibration.
The Source 1 Calibration Factor Voltage L1--L2
Note: Controller firmware version 2.04 or higher is parameter in SiteTech shows the ratio of measured
required for calibration. See Section 4.11.4 for voltage to the source 1 system voltage.
instructions to check the firmware version
number.

1
1. Click on Calibrate in the ribbon at the top of the screen.

2. Enter the measured voltage.
3. Click Calibrate in the Device Calibration window.
Figure 4-12 Calibration Using SiteTech Software

4.13 Controller Circuit Board 4.13.2 Controller Fuse F2
The controller board is protected by a 7.5-amp fuse (F2)
4.13.1 Relays and LEDs located on the controller. If the fuse blows repeatedly,
disconnect the following leads one at a time to identify
The K1 flash, K2 crank, and K3 run (fuel) relays are
the cause of the blown fuse:
located on the controller’s logic board. The CRANK and
RUN LEDs are associated with relays 2 and 3 and are D Lead 70A at the fuel valve
visible in the service access area on the front of the D Lead IGN at the ignition module
controller assembly. See Figure 4-13. D Lead 71 at the starter relay
The RUN and CRANK LEDs indicate power to the D Leads FP and FN at the rotor
corresponding relay. If the LED is illuminated but the Repair or replace the component causing the blown
relay is not activated, the relay is faulty. fuse.
Power to the governor stepper motor is tied to the K3 run
relay. If the stepper motor does not operate, check the
K3 relay.
The individual relays are not replaceable. If one or more

relays are faulty, replace the controller.
3 Service Access Area
1. Controller’s service access area

2. Run LED (K3) and crank LED (K2) 4
3. Controller fuse F2
GM62865
4. K1 flash relay
5. K2 crank relay 5 6
6. K3 run relay
Figure 4-13 Relays and LEDs on Controller Circuit Board

4.14 Controller Replacement 1
If the troubleshooting procedures in Section 3 identify a
failed controller, use the procedure in this section for
controller replacement. Always check the controller 2
configuration, fuse, wiring, and connections before
replacing the controller.
Before removing the old controller, you may be able to

save the controller settings to a file using a computer
running SiteTech software. You can then use SiteTech
to load the settings onto the new controller after it is
installed. See TP-6701, SiteTech Software Operation 3
Manual, for instructions to export and import settings.
Note: Export the old controller settings to the new

controller only if you are certain that the settings
are correct. Many controller operation problems
can be traced to incorrect settings.
DANGER TP6735
1. Roof
2. Intake panel screws (2 ea.)
3. Intake panel
Hazardous voltage. Figure 4-14 Enclosure Roof and Door

Will cause severe injury or death.
Disconnect all power sources before 1
opening the enclosure.
1
Controller Replacement Procedure
1. Open the enclosure roof. See Figure 4-14.
2. Press the OFF button on the controller.
3. Remove two (2) screws on the intake panel. See

Figure 4-14.
4. Disconnect power to the battery charger.
5. Disconnect the generator set engine starting

6. Remove the four (4) screws securing the controller

to the junction box and carefully lift the controller.
GM66569
Note connections to the panel and disconnect as 1. Controller screws (qty. 4)
necessary to access the inside of the junction box.
See Figure 4-15. Figure 4-15 Controller in Junction Box
Note: Be careful of the leads and harness

connected to the controller panel.

7. Note the connections on the back of the controller, b. Use a voltmeter to check the output voltage.
and then disconnect. See Figure 4-16 or the wiring Follow the instructions in Sections 4.11.5,
diagram. Voltage and Frequency Adjustments, and 5.8,
Voltage Adjustment, to adjust the output
8. Remove the old controller. voltage and stability.
9. Reconnect all harnesses to the new controller c. Check the output frequency. Follow the
assembly. instructions in Sections 4.11.5, Voltage and
Frequency Adjustments, and 5.9.5, Frequency
10. Install the controller onto the junction box using the Adjustment, to adjust the output frequency and
four (4) screws removed in step 6. stability.
11. Reconnect the engine starting battery, negative (--) d. Use Kohlerr SiteTecht software to enter the
lead last. following generator set information into the new
controller:
12. Reconnect power to the battery charger.
D Genset Model Number (from generator set
13. Replace the air intake end panel and secure with
nameplate)
two screws.
D Genset Serial Number (from generator set
nameplate)
D Engine Model Number (from engine

nameplate)
D Engine Serial Number (from engine

nameplate)
1 15. Press the AUTO button to place the controller in

automatic mode if an ATS or remote start/stop
4
switch is used. Press OFF if no ATS or remote
start/stop switch is used.
16. Close and latch the enclosure roof.
3
GM69754
1. P1 2
2. P3
3. P2
4. 20 amp mini breaker
Figure 4-16 Controller Connections
14. Check controller settings and adjustments. The

RDC controller can be set up using the buttons on
the controller or using Kohlerr SiteTecht
software. Use SiteTecht software to check and
adjust controller settings on the DC controller. See
the generator set installation manual for
instructions to change settings at the RDC
controller.
a. Set the new controller’s voltage/frequency and

unit configuration settings. See Figure 4-11.

Section 5 Component Testing and Adjustment
5.1 Theory of Operation 5.2 Separate Excitation

The generator set utilizes a rotating-field alternator to To determine the cause of no or low AC output, refer to
produce AC voltage. See Figure 5-1. After the engine the troubleshooting flowchart in Figure 5-2. Before
starts and reaches a predetermined speed (RPM), DC beginning the test procedures, read all safety
current from the battery magnetizes the rotor (field). precautions at the beginning of this manual. Many of the
When the magnetized rotor rotates inside the stator test procedures include additional safety precautions.
windings, an electrical voltage develops in the stator.
The controller feeds rectified stator current to the rotor Check the condition of the alternator circuit breaker
through the brushes and slip rings to change the before performing the separate excitation procedure.
strength of the rotor field as the load changes. As the The circuit breaker is located in the service access area
rotor field strength increases, the generator power on the controller. See Figure 5-1. If the breaker is not
output increases (up to the rating shown on the tripped, use the following procedure to separately excite
nameplate). The controller monitors the generator the generator using an external voltage source (a
output voltage through leads 11 and 44 and adjusts the 12-volt automotive battery).
DC current to the rotor to meet load requirements while
maintaining the output voltage. Separately exciting the generator can identify faulty
voltage regulation by the controller or reveal a running
fault in the rotor and/or stator. An external power source
duplicates the role of the voltage regulator and excites
RDC/DC Controller the generator field (rotor). A generator component that
1 appears to be in good condition while stationary may
2
exhibit a running open or short circuit while moving.
Centrifugal forces acting on the windings during rotation
cause a broken circuit to open, or increasing
temperatures cause the insulation to break down,
3
resulting in a running fault. If this test shows that the
rotor and stator are in good condition, test the voltage
regulation using the tests in Section 5.7.
8 7 4
No Generator Output
5
6 TP6735
Output within
Separate Excitation Specifications
1. Circuit breaker 5. Slip rings
2. Power lead (55) 6. Main field (rotor)
3. Excitation to rotor 7. Stator windings
4. Brushes 8. Sensing leads (11--44) Check Wiring, Fuses,
Erratic or No Output Circuit Breaker, and
Figure 5-1 Single-Phase Generator Schematic Controller
Check Rotor Check Stator
TP563273
Figure 5-2 Generator Troubleshooting
TP-6735 9/10 Section 5 Component Testing and Adjustment 57

Grounding electrical equipment. Hazardous voltage can 4. Check for AC output across the stator leads; see
cause severe injury or death. Electrocution is possible Section 5.3, Stator. Compare the readings to the
whenever electricity is present. Ensure you comply with all AC output values shown in Section 1,
applicable codes and standards. Electrically ground the
Specifications. If the readings vary considerably, a
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all faulty stator is likely. Refer to Section 5.3, Stator,
power sources before servicing the equipment. Never contact for further information.
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of 5. If this test shows that the rotor and stator are in
electrocution. good condition, check the wiring and fuses. Check
the controller settings and connections. See
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
Section 4, Controller.
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. 1 2 3
4
Separate Excitation Procedure

FN FP
Perform the following procedure to use an external
voltage source to excite the main field (rotor). - + 6 -
5
+
1. Disconnect the black FN and FP leads from the

alternator at the brush holder terminals.
8 7
TP-6735
2. Connect a DC ammeter, 10-amp fuse, and a
12-volt automotive battery to the positive (FP) and
negative (FN) brush leads as shown in Figure 5-3. 1. FN lead disconnected in step 1
Note and record the ammeter reading. 2. FP lead disconnected in step 1
3. 10-amp fuse
Note: The approximate ammeter reading should 4. DC ammeter
5. 12V battery
be the battery voltage divided by the 6. Brushes
specified rotor resistance. See Section 1, 7. Slip rings
Specifications, for specified rotor resistance 8. Main field (rotor)
values.
Figure 5-3 Separate Excitation Connections
Example:
12 volts (battery voltage) 3 amps
=
4 ohms (rotor resistance) (rotor current)
3. Start the engine and check that the ammeter

reading remains stable. An increasing meter
reading indicates a shorted rotor. A meter reading
decreasing to zero or an unstable reading
suggests a running open. Refer to Section 5.4,
Main Field (Rotor), to test the rotor. If the ammeter
reading is stable, proceed to step 4.
58 Section 5 Component Testing and Adjustment TP-6735 9/10

5.3 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. Be sure the
stator is securely fastened to the stator housing.
Note: Disconnect all stator leads before performing all

stator tests. R14807-14
WARNING Figure 5-4 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 5-5 when
Hazardous voltage. Moving parts. performing the following steps.
4 44
are in place.
3
High voltage test. Hazardous voltage can cause severe

66
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 55
or lead to generator set failure.
2
1 11
and/or equipment damage. Do not contact electrical 6196
repairs. Remove all jewelry before servicing the equipment. Figure 5-5 Single-Phase Alternator Stator Leads
Stator Continuity and Resistance Tests 6. Contact the ohmmeter leads and readjust the
ohmmeter to read zero ohms.
1. Press the OFF button on the controller to turn off
the generator set. 7. Check the cold resistance of the stator windings by
connecting the meter leads to stator leads 1-2, 3-4,
2. Disconnect power to the battery charger. and 55-66. See Section 1.5, Alternator
Specifications, for stator winding resistances.
3. Disconnect the generator set engine starting Most ohmmeters do not provide accurate readings
battery, negative (--) lead first. below 1 ohm. Low resistance readings (continuity)
and no evidence of shorted windings (heat
4. Disconnect all stator leads before performing all
discoloration) indicate a stator in good condition.
stator tests.
See Figure 5-6.
5. To check for stator continuity, set the ohmmeter on
R x 1 scale. First set the ohmmeter zero by holding
the red and black meter leads together and setting
the ohmmeter reading to zero. Then check the
stator continuity by connecting the meter leads to
the stator leads as shown in Figure 5-4.

Leads Continuity Note: Make sure that all stator leads are
disconnected before running the
1 and 2
megohmmeter test.
1 and 11
2 and 11 9. Use a megohmmeter to determine whether the
3 and 4 Yes stator is shorted to ground.
3 and 44
4 and 44
a. Apply 500 volts DC to any stator lead and the
stator frame. Perform the megohmmeter test
55 and 66
following the instructions of the megohmmeter
1 and 3, 4, 44, 55, or 66 manufacturer.
2 and 3, 4, 44, 55, or 66
3 and 1, 2, 11, 55, or 66 b. Repeat the test on the other stator leads until
No
4 and 1, 2, 11, 55, or 66 each coil is tested.
Any stator lead and ground on stator
housing or frame laminations Note: A reading of approximately 500 kOhms
(1/2 megohm) and higher indicates a
Figure 5-6 Continuity Test Results on a Good Stator good stator.
(single-phase)
c. Repair or replace the stator if any reading is
8. If the resistance test proves inconclusive, use a less than approximately 500 kOhms. A reading
megohmmeter to test the stator as described in the of less than 500 kOhms indicates deterioration
next step. of the winding insulation and possible current
flow to ground.
Note: Because ohmmeter accuracy varies,
resistance readings are approximate
readings. Take readings of the rotor and
stator at room temperature.

5.4 Main Field (Rotor) 5. Check the rotor for continuity and resistance.
Raise the brushes from the slip rings while
The two-pole rotor creates the magnetic field needed to performing ohmmeter tests. Measure the rotor
produce alternating current in the stator windings. resistance (ohms) between the two slip rings; see
Before testing, inspect the rotor for visible damage to Figure 5-7. See Section 1.5 for rotor resistance
pole shoes, insulation, exposed coil windings, and slip readings. If the resistance readings are low,
ring surfaces. Rotate the bearing to check for wear, heat perform a megohmmeter test on rotor as described
discoloration, or noise. in the next step.
Note: Because ohmmeter accuracy varies,

5.4.1 Rotor Continuity and Resistance resistance readings are approximate. Take
Tests readings at room temperature.
WARNING
Hazardous voltage. Moving parts.

are in place.
2-221
R13929-7
High voltage test. Hazardous voltage can cause severe
injury or death. Follow the instructions of the test equipment Figure 5-7 Rotor Resistance Check
manufacturer when performing high-voltage tests on the rotor
or stator. An improper test procedure can damage equipment 6. Perform a megohmmeter test to determine
or lead to generator set failure. whether the rotor is shorted to ground.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
a. Raise and secure the brushes away from the
whenever electricity is present. Ensure you comply with all slip rings by inserting a retaining wire in the
applicable codes and standards. Electrically ground the brush holder hole.
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all b. Using a megohmmeter, apply 500 volts DC to
power sources before servicing the equipment. Never contact one rotor slip ring and the rotor poles or shaft.
electrical leads or appliances when standing in water or on wet Follow the instructions of the megohmmeter
ground because these conditions increase the risk of manufacturer when performing this test.
electrocution.
Note: A reading of approximately 500 kOhms
Rotor Test Procedure (1/2 megohm) or higher indicates a
good rotor.
1. Press the OFF button on the controller to turn off
the generator set. c. Repair or replace the rotor if the reading is less
than approximately 500 kOhms. A reading of
2. Disconnect power to the battery charger. less than 500 kOhms indicates deterioration of
the winding insulation and possible current flow
to ground.
d. Following the test, remove the retainer wire
4. Remove the brush cover from the alternator end
from the brush holder and check the brush
bracket.
positions on the slip rings. See Section 5.6,
Brushes.
e. Reinstall the brush cover on the end bracket.

5.5 Slip Rings
Slip rings acquire a glossy brown finish in normal
operation. Do not attempt to maintain a bright,
newly-machined appearance on the slip rings. Cleaning 1
with a dry, lint-free cloth is usually sufficient. Use very
fine sandpaper (#00) and apply light pressure to remove
roughness. Do not use emery or carborundum paper or 4
cloth. Clean all carbon dust from the generator after
sanding the slip rings. If the rings are black or pitted,
remove the rotor and use a lathe to remove some of the 3
slip ring surface material.
2
5.6 Brushes
3
The brushes transfer current to the slip rings. The
brushes should last the life of the generator. However, 1 4
abrasive dust on the slip rings shortens the life of the
brushes.
Excessive arcing at the brushes could damage the

controller. Weak springs, damaged slip rings, sticking 5
brushes, a loose brush holder, or poor brush contact
causes arcing.
The brushes must be free to move within the holder and

be held in contact with the slip rings by the springs. 6
When correctly positioned, spring pressure on the brush
surface causes the brush to wear evenly. The entire 1 GM67344
brush must ride on the ring or arcing occurs and causes
burned rings or voltage regulator failure. Figure 5-8 Correct Incorrect
shows the correct positioning of the brushes. Add or New 19.0 mm (0.75 in.) 7 8
remove shims as necessary to center the brushes on the
slip rings. Replace the brushes if they show uneven
wear or are worn to one half their original length.
1 2 2
Check the resistance through the brushes. Resistance
through the brushes should be low, 0.1--0.2 ohms
without meter lead resistance. Side View
TP5867
1. Brush(es) 5. Shim
2. Slip rings 6. Spring
3. Brush holder 7. Correctly positioned brush
4. Retainer wire (for 8. Incorrectly positioned brush
service only)
Figure 5-8 Brush Assembly

5.7 Voltage Connections The DC controller is not equipped with a keypad. A
personal computer running Kohler SiteTech software is
required for all adjustments to the DC controller.
5.7.1 Voltage Connections, SiteTech software is available to Kohler authorized
Single-Phase Models distributors and dealers (through their distributor).
Single-phase generator sets are available from the The controller will time out and exit the adjustment mode
factory connected for 115/230 volt 50 Hz or 120/240 volt after approximately 1 minute if no buttons are pressed.
60 Hz. See Figure 5-9 for the factory connections. Any unsaved changes are discarded if the controller
Generator sets are not reconnectable. times out before the settings are saved. Refer to Section
4.11 for instructions to save your settings.
LO (Neutral) LO Voltage Adjustment. Adjusts generator output
GRD between 100 and 130 volts.
Ground
L2
L1 Gain (Stability) Adjustment. Fine tunes regulator
Load circuitry to reduce light flicker.
Side Factory two-pole
circuit breaker Volts/Hz Adjustment (voltage droop). Determines
frequency (Hz) at which generator output voltage begins
Line
to drop. The controller maintains generator output at the
Side specified voltage under load until the generator engine
speed drops to a preset level (see Figure 5-11 for cut-in
frequencies). Then the controller allows the generator
4 3 2 1 voltage and current to drop. The voltage/current drop
Stator Leads enables the engine to pick up the load. When the
60 Hz 50 Hz generator speed returns to normal (60 Hz or 50 Hz) as
L0-L1 120 volt 115 volt load is accepted, the generator output also returns to
L0-L2 120 volt 115 volt normal. See Section 5.8.2 for instructions to adjust the
L1-L2 240 volt 230 volt
voltage droop. (SiteTech software required.)
TP-5867
WARNING
Figure 5-9 115/230 and 120/240 Volt, 3-Wire
Configurations
5.7.2 Voltage Regulation Hazardous voltage. Moving parts.

Voltage regulation is performed by the controller. The
controller monitors generator output voltage and adjusts Operate the generator set only when
the excitation current to the rotor. all guards and electrical enclosures
are in place.
5.8 Voltage Adjustment Short circuits. Hazardous voltage/current can cause

The factory sets the voltage for correct generator and/or equipment damage. Do not contact electrical
operation under a variety of load conditions. Usually, the connections with tools or jewelry while making adjustments or
voltage needs no further adjustment. repairs. Remove all jewelry before servicing the equipment.
Grounding electrical equipment. Hazardous voltage can
Adjust the voltage when necessary according to the cause severe injury or death. Electrocution is possible
following procedure. The adjustment procedure whenever electricity is present. Ensure you comply with all
requires a meter that can measure voltage and applicable codes and standards. Electrically ground the
frequency. generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
Use the RDC controller keypad or a personal computer power sources before servicing the equipment. Never contact
running Kohlerr SiteTecht software to adjust the electrical leads or appliances when standing in water or on wet
voltage, gain, and volts/Hz. This section contains ground because these conditions increase the risk of
instructions to adjust each setting and save the changes electrocution.
using the controller keypad.

5.8.1 Voltage Adjustment Procedure the engine. The magnitude of the voltage reduction is
set by the voltage regulator volts per hertz slope. To
Refer to Figure 5-12 during the adjustment procedure. determine whether droop adjustment is required,
monitor engine speed and output voltage as loads are
1. Connect a digital voltmeter to measure output applied, and watch for the following conditions.
voltage across L1 or L2 and L0. Set the meter to
measure AC volts. D If there is excessive droop in engine speed and little
droop in voltage, increase the volts per hertz value.
D If there is little engine speed droop but excessive
3. Follow the controller instructions in Figure 5-12 to voltage droop, decrease the volts per hertz value.
enter the adjustment mode. Increase or decrease
voltage (parameter 1P) until the output reaches the D Readjust the voltage stability (2P) and voltage (1P)
desired voltage. See Figure 5-10. parameters after adjusting the volts/Hz setting, if
necessary.
Voltage Approximate
Models Measurement Voltage, VAC D Remember to save your settings.
1 phase, 60 Hz L -- L0 120
L-L 240 Frequency Cut-In Frequency
1 phase, 50 Hz L -- L0 115 60 Hz 57.5 Hz
L-L 230 50 Hz 47.5 Hz
Figure 5-10 Voltage Measurement Figure 5-11 Cut-In Frequencies
4. Follow the controller instructions to step to the
voltage gain (parameter 2P) adjustment menu. Volts/Hz Adjustment Procedure
Adjust the voltage gain (2P) until the light flicker 1. Set the voltmeter to measure frequency. Adjust the
minimizes. Save the settings. See Figure 5-12. engine speed to the cut-in frequency shown in
Figure 5-11 by adjusting the engine governor
5. Check and readjust the voltage if necessary.
speed.
6. Save the settings. Refer to Figure 5-12 for
2. Set the voltmeter to measure voltage. Adjust the
instructions.
volts/Hz until the voltage level measured by the
Note: The controller will revert to the previous voltmeter begins to drop. When set, the generator
settings at the next startup if the changes are (as load is applied) attempts to maintain normal
not saved. output until the engine speed drops below the
cut-in frequency.
7. Stop the generator set.
3. Set the voltmeter to measure frequency. Adjust the
engine speed to the operating frequency (50 or
5.8.2 Volts per Hertz (Hz) Adjustments 60 Hz) by adjusting the engine governor speed.
(Droop)
4. Readjust the voltage gain until the light flicker
The volts per hertz (droop) setting can only be adjusted minimizes, if necessary.
using a personal computer running Kohlerr SiteTecht
software. Follow the instructions in this section and refer 5. Check the voltage. Readjust the voltage, if
to TP-6701, SiteTech Software Operation Manual, to necessary.
adjust the Voltage Regulator Volts per Hertz Slope
parameter. 6. Stop the generator set.
When the frequency falls below the cut-in frequency

(see Figure 5-11), output voltage is reduced to relieve

Hold select and up
buttons for 5 seconds
Software version
number displayed
S A UE
u 2
1 . 0
Enter pass code
OFF mode
Generator Set No
Running?
Yes RUN mode
System Voltage Setting

Coarse Voltage Adjust
Adjust
Adjust Uu 1
1 P33
Press
Engine Configuration
Fine Voltage Adjust Adjust Setting
Adjust Adjust
1 P36 Ec 1 3
Coarse Gain Adjust

Adjust
2P 14
Fine Gain Adjust

Adjust
2 P17
Engine Governor
Speed Adjust
Adjust
4 P1 1
Engine Governor
Gain Adjust
5P 05
Save Changes?
S AU E
YE S no
Save Changes Discard Changes
Exit Setup
Figure 5-12 RDC Controller Adjustment

5.9 Governor System overspeed condition. An erratic signal causes the
generator set to govern poorly but not shut down.
The governor system consists of an electromechanical
stepper motor (actuator) and a magnetic pickup. The D Verify that the battery connections are clean and tight.
RDC/DC controller controls the governor system
operation. See Section 7, Wiring Diagrams, for the D Check for dirt buildup on the magnetic pickup. Metal
governor connections. filings or caked-on dirt or grease decreases the output
signal of the magnetic pickup.
5.9.1 Operation D Check for a loose or worn stepper motor/throttle shaft

coupling. Replace the shaft and bushing every 500
The frequency of the alternator output is determined by hours of engine operation.
the speed of the engine. A two-pole alternator must be
driven at 3600 rpm to provide 60 Hertz. (A 50 Hz model D Check the carburetor for dirt, grime, or
must be driven at 3000 rpm.) The engine speed is misadjustment. Check for a loose mixer assembly.
maintained by an electronic governor system that
consists of a magnetic pickup and electric actuator D Check the idle-adjustment screw. The screw should
(stepper motor). The governor system is controller by not prevent the throttle plate from closing completely.
the generator set controller.
D Check the throttle linkage for any binding, dirt,
The magnetic pick-up, which monitors the speed of the damage, or other visible problems.
flywheel ring gear, provides the speed reference signal
to the controller. The controller provides regulated D Observe the stepper motor operation. The stepper
power to the bidirectional stepper motor actuator, which motor should open the throttle fully before cranking,
is linked to the carburetor throttle arm. and pull back after the crank disconnect.
At cranking speed a properly adjusted pick-up should D Check for electronic governor faults. The fuel shutoff
produce a minimum of 3.0 VAC. The magnetic pick-up solenoid deenergizes and the generator set shuts
air gap is factory-set to 0.5 mm (0.020 in.). Failure or down under the following conditions:
loss of the input speed signal from the magnetic pick-up D Closed throttle
will result in erratic speed. D Engine overspeed
D Broken fuel shutoff solenoid lead
A setting on the RDC controller allows adjustment of the D Broken stepper motor leads (erratic performance)
engine speed. See Section 5.9.3.
D Failed actuator linkage (erratic performance)
A gain adjustment may be required if an unstable
(hunting/surging) condition occurs. Adjusting the gain 5.9.3 Hunting/Surging
may require readjustment of the engine speed. See
Often hunting/surging problems thought to be caused
Section 5.9.3.
by the governor are actually caused by engine or
carburetor problems. Check engine speed stability
5.9.2 Initial Checks using the following procedure before testing the
governor.
The factory sets the electronic governor. Under normal
circumstances the electronic governor requires no
further adjustment. Verify that the governor stepper WARNING
motor moves smoothly and steadily during operation. If
the engine operates erratically check the following
connections and conditions before adjusting the
governor.
Hot engine and exhaust system.
D Power to the governor stepper motor is tied to the K3 Can cause severe injury or death.
run relay. If the stepper motor does not operate, Do not work on the generator set until
check the K3 relay. See Section 4.13.1. it cools.
D Verify that the electrical connections are clean and Servicing the exhaust system. Hot parts can cause
tight. severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely
D Check the magnetic pickup connections. Poor hot during operation.
connections may cause an erratic signal or an

1. Open the generator set line circuit breaker. 5.9.4 Governor System/Magnetic
Pickup Operation Test
If the engine continues to operate erratically after the
3. Hold the throttle linkage steady while the engine is previous checks, test the governor system operation
running. See Figure 5-13. If the engine runs at a using the following procedure. The procedure is
steady speed with no hunting or surging when the summarized in the flowchart in Figure 5-14.
throttle is held steady, then the hunting/surging
problems during operation are probably caused by
the governor. Proceed to Section 5.9.4. Check that the
carburetor throttle
4. If the engine speed hunts or surges while the linkage is connected to
throttle is held steady, check the carburetor and the stepper motor as
shown in Figure 5-13.
engine operation. Refer to the engine service
manual for engine diagnostic and service
information. Check for broken or
loose wiring or
connections and other
items in step 2.
14RES/RESL
Check stepper motor

operation at startup. Does
it move to fully open and
then move to and stay in
the fully closed position?
Yes See step 3. No
1
3 Check the magnetic Disconnect the

pickup. magnetic pickup
20RES/RESL See steps 4--6. and check the
stepper motor
1 operation again.
See steps 7--9.
Check the magnetic
pickup connections
to the controller: Check the stepper
red and black leads motor connections
to P1-5 and P1-6, to the controller.
and P1-18. See step 10.
2 3
Check the stepper
motor coils.
See step 11.
1. Electronic governor stepper motor

2. Carburetor throttle linkage
3. Carburetor
Troubleshoot the
controller.
See step 12.
Figure 5-13 Stepper Motor and Carburetor
tp5867
Figure 5-14 Governor System Operation Test

Procedure Summary (Section 5.9.4)

Governor System Operation Test Procedure
1. Verify that the carburetor throttle linkage is
connected to the stepper motor as shown in 1
Figure 5-13.
2. Look for broken or loose wiring or plug connections

if the stepper motor moves erratically. Check the
condition of the throttle linkage, and verify that the
throttle plate closes completely.
5
3. Check the operation of the stepper motor at
startup.
4
a. If the throttle moves to the fully open throttle
3
position and then steps to and remains in the 2
fully closed position, the engine speed input is
probably missing. The engine starts and then 1. Ignition module
A-358000B-C
2. Air gap, 0.5 mm (0.020 in.)
shuts down on an overspeed fault. Proceed to
3. Top of flywheel ring gear tooth
step 4 to check the magnetic pickup. 4. Locknut
5. Magnetic pickup
b. If the throttle linkage moves erratically or not at
all at during startup, proceed to step 7 to check Figure 5-16 Magnetic Pickup Air Gap
the stepper motor.
a. Stop the generator set. Remove housing
4. Verify the operation of the magnetic pickup by panels as required to gain access to the front of
connecting a voltmeter to the magnetic pickup the engine.
leads. See Figure 5-15.
b. Remove the engine blower housing.
If the air gap is correct, the voltage should be
3.0 volts AC RMS minimum during engine c. Use a feeler gauge to check the gap. The gap
cranking. should be 0.5 mm (0.020 in.).
d. Adjust the air gap, if necessary, by loosening

the locknut and turning the pickup. See
Figure 5-16.
e. Hold the pickup in position and retighten the

locknut.
f. Verify the magnetic pickup air gap after

tightening the locknut.
g. Reinstall the engine blower housing.
h. Reinstall the junction box and housing panels

removed to gain access to the front of the
engine.
6. After adjusting the air gap, check the voltage again

6519 as described in step 4. If the voltage does not
measure 3.0 VAC minimum, replace the magnetic
Figure 5-15 Magnetic Pickup Leads
pickup.
5. If the voltmeter displays less than 3.0 volts AC,
7. To test controller’s governing function, disconnect
check the air gap as described in the following
the magnetic pickup leads and open the generator
steps before replacing the sensor. Verify that the
set circuit breaker.
magnetic pickup air gap is 0.5 mm (0.020 in.).
Measure the air gap at 3 or 4 places to get an
accurate reading. See Figure 5-16.

8. Manually move the throttle shaft/governor stepper PIN 3, BLK
motor fully counterclockwise (closed throttle).
PIN 2, YEL
9. Start the generator set. The stepper motor should
step clockwise to the wide open throttle position.
The stepper motor should remain in the clockwise PIN 5, GRN
(not used)
(throttle fully open) position. If the stepper motor
does not operate as described here, proceed to the
next steps to check the governor and stepper
motor. PIN 4,
RED
PIN 1,
WHT
PIN 6, BLUE
(not used) SB555
10. Stop the generator set by pressing the OFF button

on the controller. Check the stepper motor Figure 5-17 Actuator Coil Group
connections to the controller. See the wiring
12. If there is power and a good ground connection to
diagrams in Section 7.
the controller and the stepper motor coil
11. Check the stepper motor coil resistance across resistances are good, but the stepper motor does
pins 2 and 3 and across pins 1 and 4. Only two not operate as described in step 9, the problem is
stepper motor leads of each coil group are used with the controller. Check controller connections,
(BLK-YEL and RED-WHT). See Figure 5-17. The fuses, wiring, and settings. Refer to the
resistance per half coil is 38.5 ohms. If one of the troubleshooting procedures in Section 3.
coils has a significantly higher resistance or is
shorted, replace the stepper motor.

5.9.5 Frequency Adjustment 6. Repeat steps 4 and 5 to obtain the rated frequency
and stable operation.
The engine speed determines the generator output
frequency; 60 Hz units operate at 3600 rpm and 50 Hz 7. Save the settings. Refer to Section 5.8 for
units run at 3000 rpm. Adjust the engine governor to instructions.
change the output frequency using the following
procedure. Note: The controller will revert to the previous
settings at the next startup if the changes are
The RDC controller can be adjusted using the controller not saved within one minute after the last
keypad or using a personal computer running Kohler change.
SiteTech software. The DC controller has no keypad,
and must be adjusted using SiteTech software. 8. Apply rated load to the generator set and observe
the frequency reading. The no load and full load
Note: See Section 5.8 for instructions to adjust engine frequencies should be within 0.4 Hz of the rated
governor speed (frequency) and gain. generator frequency; if not, check that the
carburetor throttle plate opens completely without
Frequency Adjustment Procedure sticking and check the carburetor adjustment. If
these procedures do not correct the problem,
1. Open the generator set line circuit breaker. replace the controller.
2. Attach a frequency meter to the AC output leads. 9. Check for hunting and surging at full load. Increase
the gain (parameter 5P) until the engine hunts and
3. Start and run the generator set until it reaches surges. Then decrease the gain in small steps
normal operating temperature (at least 10 minutes). using the governor gain fine adjust parameter until
the engine operation stabilizes. Save the controller
4. Use the RDC controller to adjust the electronic
changes.
governor speed (parameter 4P) to obtain a
frequency reading of 60 Hz (or 50 Hz on 50 Hz 10. Remove the load and observe the frequency. The
models). frequency should return to the value stated in
step 4. Gain adjustment may affect the generator
Note: Often hunting/surging problems thought to set speed/frequency. If the frequency has
be caused by the governor are actually
changed, repeat step 4.
caused by engine or carburetor problems. If
the generator set speed is unstable, hunts, Note: Speed adjustments have no effect on gain
or surges, check for the cause using the adjustments. It is not necessary to repeat
procedure in Section 5.9.3 before the gain adjustments (steps 5 and 8) after
proceeding. adjusting the engine speed.
5. Check stability with the generator set running and Check the overspeed shutdown operation when
with no load applied. If the generator set speed is investigating a shutdown problem. See Section 5.10.1
unstable, hunts, or surges, decrease the gain for the overspeed shutdown test procedure.
(parameter 5P) until the generator set becomes
stable with no hunting or surging. Observe the
frequency reading.

5.10 Fault Shutdown Tests Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The
Verify the operation of the generator set overspeed, engine and exhaust system components become extremely
overcrank, and low oil pressure shutdowns by
performing the following tests. If these tests are Open the generator set output circuit breaker before
inconclusive, test individual shutdown circuit beginning the test. (See Figure 4-1 for the circuit
components (wiring harness, switch, etc.) as described breaker location.)
elsewhere in this section.
Connect a digital voltmeter (DVM) to measure the
WARNING output frequency. Start the generator set and manually
adjust the engine speed by moving the throttle linkage.
Note: Be careful not to touch the hot silencer when

reaching in to adjust the throttle linkage.
Hazardous voltage. Moving parts. Increase the engine speed (parameter 4P) to at least
Can cause severe injury or death. 115% of the rated engine speed, 69 Hz on 60 Hz models
Operate the generator set only when or 58 Hz on 50 Hz models. Verify that the generator set
all guards and electrical enclosures shuts down on an overspeed fault (OS). If the
are in place. overspeed shutdown does not operate, the generator
set should shut down on an overfrequency fault (OF)
Short circuits. Hazardous voltage/current can cause after approximately 5 seconds.
and/or equipment damage. Do not contact electrical If the controller does not indicate an overspeed fault
connections with tools or jewelry while making adjustments or (OS), check the wiring to the magnetic pickup (red and
repairs. Remove all jewelry before servicing the equipment. black leads, P1-5 and P1-6). Check the magnetic
pickup air gap and voltage output; see Section 5.9.4.
5.10.1 Controller Fault Shutdown
Functions Low Oil Pressure (LOP) Shutdown
Check the operation of the fault functions programmed Connect a jumper wire from the LOP switch (lead 13) to
in the controller by performing the following tests. If the the generator set ground. Start the generator set. Verify
controller does not operate as described, check the that the generator set shuts down after approximately
controller configuration settings; see Section 4.11.2. 25--35 seconds of operation. Remove the jumper wire
Also check the controller wiring and connections. from the LOP switch and ground. Start the generator set
and run it for at least 25--35 seconds to verify that the
generator set does not shut down.
Overspeed Shutdown
The overspeed setting is factory-set and is not Overcrank Shutdown
adjustable. Verify that the following controller
configuration parameters are set correctly for your unit. Disconnect the starter motor lead at the starter solenoid
See the generator set installation manual for the terminal and the fuel solenoid valve. Press the RUN
settings. button on the controller. Observe that the generator set
simulates cranking for 15 seconds and then rests for 15
D System voltage/frequency parameter (UU)
seconds. Check that the generator set shuts down after
D Engine configuration parameter (EC) the third crank/rest cycle.
WARNING
Hot engine and exhaust system.

it cools.

High Engine Temperature Shutdown 5.10.2 Fault Shutdown Switches
Disconnect the harness (connector P5) at the engine Check the low oil pressure and high engine temperature
temperature sensor (CTS). See Figure 5-18 for the shutdown switches on the engine by performing the
CTS location. Connect a jumper wire across the following tests. If the sensor does not function as
temperature sensor (CTS) connections in connector P5. described, replace it.
See Figure 5-19. Press RUN to start the generator set.
After 5 seconds, verify that the controller display shows WARNING
HE, indicating a high engine temperature fault. If a
Model RRT transfer switch is connected, the generator
set will run for 5 minutes in engine cooldown mode. The
display will alternate HE and COOL.
Press the OFF button on the controller and remove the Hazardous voltage. Moving parts.
jumper wire. Start the generator set and verify that the Can cause severe injury or death.
generator set does not enter the engine cooldown cycle Operate the generator set only when
or shut down on an HE fault. Reconnect P5 to the CTS. all guards and electrical enclosures
are in place.
Servicing the generator set when it is operating. Exposed

moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.
and/or equipment damage. Do not contact electrical
repairs. Remove all jewelry before servicing the equipment.
Temperature Sensor (CTS)

1
GM66561 The temperature sensor (CTS) is used to monitor
1. CTS location engine temperature for the high engine temperature
fault shutdown (HE). See Figure 5-18 for the coolant
Figure 5-18 Temperature Sensor CTS Location
temperature sensor location. Press the OFF button on
the controller to stop the generator set and allow the
generator set to cool. Disconnect the CTS and use an
ohmmeter to measure the resistance across the sensor.
The sensor resistance varies with temperature and
should be within the values shown in Figure 5-20. If the
resistance is very low (indicating a short circuit) or very
high (indicating an open circuit), replace the CTS.
Note: The CTS is located in the engine oil pan. Drain

the engine oil before removing the switch.
Temperature, _C (_F) Resistance, Ohms

GM69754 30 (86) 2100--2400
Figure 5-19 Temperature Sensor Connector P5 100 (212) 180--200
Figure 5-20 Temperature Sensor CTS Resistance
Readings

Low Oil Pressure (LOP) Switch Remove the LOP switch and install an oil pressure
gauge to verify that the engine oil pressure is within the
The low oil pressure (LOP) switch is located under the range specified in Section 1, Specifications, before
engine air cleaner. See Figure 5-21. testing or replacing the LOP switch. To test the LOP
switch, reinstall the switch and start the generator set. If
the unit shuts down, disconnect lead 13 from the LOP
switch and reset the controller. Restart the generator set
and verify that it does not shut down. A successful
restart indicates a faulty LOP switch. Replace switch.
tp6519
1. Oil pressure switch 1
Figure 5-21 Oil Pressure Switch Location (under the

air cleaner)

5.11 Fuel Systems Refer to the troubleshooting instructions in Section 3,
Troubleshooting, to identify generator set operation
problems that may be caused by an inadequate fuel
WARNING supply, incorrect adjustments, or damaged fuel system
components. Then use the instructions in this section to
check fuel system components.
5.11.1 Fuel Solenoid Valve

Explosive fuel vapors.
Can cause severe injury or death. A solenoid valve upstream of the regulator and the
flexible fuel connector provides automatic fuel on/off
Use extreme care when handling,
storing, and using fuels. control. See Figure 5-22. The engine starting battery
powers the solenoid valve and the engine starting
controls open the valve when the engine cranks or runs.
The fuel supplier provides and maintains manual
shut-off valves and the primary regulator. See the
Fuel Valve Operation Test Procedure
generator set installation manual for fuel pipe size
recommendations. Verify that the fuel system capacity 1. Disconnect the positive (+) battery lead from the
is adequate to supply the generator set plus all other gas gas valve terminal.
appliances.
2. Apply 12 VDC to the gas valve terminal and listen
A factory-installed secondary regulator and 12 VDC for an audible click, indicating that the valve
solenoid valve are located in the front air intake actuates.
compartment. The controller energizes the fuel
solenoid valve to open at startup and deenergizes the 3. Replace the gas valve if it does not actuate in
valve to close at shutdown. The secondary fuel step 2.
regulator reduces fuel pressure for delivery to the fuel
block. The fuel flows from the fuel block to the
carburetor in a gaseous state. The carburetor mixes the
fuel with intake air for consumption by the engine.
1 2
(Enlarged to
show detail)
3 DSAI Lead Connection
GM66563
1. Regulator 3. Fuel inlet, 1/2 in. NPT female

2. Fuel block (not shown) or LP orifice location (see 4. Fuel solenoid valve and digital spark advance ignition (DSAI)
Figure 5-24) leads
Figure 5-22 Fuel System

5.11.2 Digital Spark Advance Ignition 5.11.3 Fuel Regulators
(DSAI) Timing The typical gaseous fuel system uses two regulators.
The digital spark advance ignition (DSAI) optimizes the The primary regulator reduces the line pressure to an
engine timing for the selected fuel, natural gas or LP. allowable inlet pressure for the secondary regulator.
The DSAI timing leads are located near the fuel solenoid The fuel supplier provides and maintains the primary
valve. See Figure 5-22. Connect the DSAI leads regulator. The secondary regulator is factory-installed
together for natural gas fuel. Disconnect the leads if LP on the generator set and is designed for a maximum inlet
is used. See Figure 5-22 or Figure 5-23. pressure of 2.7 kPa (6 oz./in.2) or 280 mm (11 in.) water
column.
See the engine service manual for ignition system
Note: Do not attempt to adjust the fuel mixture or engine
service information.
speed by adjusting the regulators.
DSAI Timing Lead Connection The fuel lockoff prevents fuel flow when the engine is not
Natural Gas Connect operating. See Figure 5-24. Do not try to adjust the fuel
LP Disconnect pressure, fuel mixture, or engine speed using the fuel
lockoff.
Figure 5-23 DSAI Lead Connection
Checking the Fuel Pressure
Use a gauge or manometer to check the fuel pressure at
the secondary regulator inlet. See Figure 5-24.
Measure the fuel pressure with the generator set
running at rated load. The fuel pressure should be
5--11 in. water column or 1.2--2.7 kPa. Contact the fuel
supplier if the inlet pressure is not within the specified
range.
1 6 5
2
5
2
3 8
3 4
14RES/RESL 20RES/RESL Regulator, side view

TP-6735
1. Fuel block (14RES/RESL) 5. Hose fitting 7. Regulator vent hose (20RES/RESL only)
2. Secondary regulator 6. LP orifice fits inside 8. Inlet pressure check location
3. Fuel lockoff (do not adjust) hose fitting (20RES/RESL)
4. Fuel inlet, 1/2 in. NPT
Figure 5-24 Fuel Regulators

5.11.4 Fuel Conversion, 20RES/RESL Procedure to Convert from NG to LP, 20RES/RESL
For LP vapor fuel, an orifice is used in the fuel line. The 1. Press the OFF button on the generator set
unit is typically shipped set up for natural gas, with the controller.
loose orifice tied near the fuel solenoid valve. To convert
to LP vapor, install the orifice and disconnect the spark 2. Disconnect the power to the battery charger.
advance leads as described below. See Figure 5-22 for
the fuel system component locations.
1 2 4. Turn off the fuel supply.

LP setup
shown 5. Remove the hose clamp and fuel hose from the
hose fitting. See Figure 5-25.
3
6. Insert the orifice into the hose fitting. See
Figure 5-25.
7. Slide the hose onto the hose fitting and secure it

with the clamp.
8. Disconnect digital spark-advance module (DSAI)

4 leads 65 and N5 for LP. See Figure 5-28 and
Figure 5-26.
9. Connect and turn on the new fuel supply.
10. Check that the generator set is off. Check that the
GM66563 OFF LED on the controller is flashing.
5
1. LP orifice 11. Reconnect the generator set engine starting
2. Hose fitting
3. Regulator
battery leads, negative (--) lead last.
4. Fuel inlet, 1/2 in. NPT female
5. Vent hose 12. Reconnect power to the battery charger.
Figure 5-25 Fuel Regulator and LP Orifice, 13. Start the generator set by pressing the RUN button
20RES/RESL on the generator set controller.
14. Check for leaks using a gas leak detector.
15. Run the generator set and check the operation.

Use the controller to adjust the output and stability if
necessary.
16. Press the OFF button to shut down the generator

set.
To convert from LP vapor to natural gas, remove the fuel

orifice and connect the DSAI leads together.
Fuel DSAI Leads 65 and N

Natural Gas Connect lead 65 to N
LP Disconnect
Figure 5-26 DSAI Connections

5.11.5 Fuel Conversion, 14RES/RESL 6. Remove the hose fitting from the natural gas outlet
port in the fuel block. See Figure 5-27.
Two fuel connections on the fuel block allow field-
conversion between natural gas and LP vapor. The fuel 7. Remove the plug from the LP port in the fuel block.
metering valves are factory-set and sealed to comply See Figure 5-27.
with applicable emission standards and to provide the
best possible hot and cold starting. 8. Clean the plug with a dry cloth or brush, apply fresh
pipe sealant, and install the plug into the natural
Note: Do not adjust the factory-sealed fuel-metering gas outlet port.
adjustments on the fuel block. Changing the fuel-
metering adjustments may violate federal or state 9. Clean the hose fitting with a dry cloth or brush,
laws. apply fresh pipe sealant to the threads, and install
the fitting into the LP port.
Use the following procedure to convert from natural gas
(NG) to LP vapor, moving the fuel connection from the Note: Do not adjust the fuel metering valves.
natural gas to the LP port, plugging the natural gas port,
and disconnecting the leads for the digital spark 10. Slide the hose onto the hose fitting and secure it
advance ignition (DSAI). See Figure 5-22 for the fuel with the clamp.
system component locations.
11. Disconnect the DSAI leads for LP. See Figure 5-22
for the location of the DSAI leads.
Procedure to convert from NG to LP, 14RES/RESL
Fuel DSAI Leads 65 and N
controller. Natural Gas Connect lead 65 to N
LP Disconnect
2. Disconnect the power to the battery charger.
Figure 5-28 DSAI Connection
12. Connect and turn on the new fuel supply.
13. Check that the generator set is off. Check that the
4. Turn off the fuel supply.
OFF LED on the controller is flashing.
5. Remove the hose clamp and fuel hose from the
hose fitting in the fuel block. See Figure 5-27.
battery leads, negative (--) lead last.
1 15. Reconnect power to the battery charger.

5
2 16. Start the generator set by pressing the RUN button
on the generator set controller.
4 Natural gas
setup shown 17. Check for leaks using a gas leak detector.
18. Run the generator set and check the operation.

Use the controller to adjust the output and stability if
necessary.
19. Press the OFF button to to shut down the generator

set.
To convert from LP vapor to natural gas, follow the same

3 fuel conversion procedure, moving the hose fitting to the
natural gas port and plugging the LP port. Connect the
DSAI leads for natural gas. See Figure 5-28.
GM66563
1. Fuel block
2. Fuel metering valves—factory-sealed, do not adjust
3. Fuel inlet, 1/2 in. NPT
4. Hose fitting
5. Plug
Figure 5-27 Fuel Block, 14RES/RESL

5.11.6 Fuel Metering Valve Adjustment, 3. Remove the oxygen sensor plug from the exhaust
14RES/RESL Only manifold and install the oxygen sensor. See
Figure 5-29 for location.
The fuel system is factory-adjusted to comply with
applicable emission standards and to provide the best
possible hot and cold starting. The fuel metering valves
are sealed to prevent field adjustments. If the fuel
metering valve requires adjustment, do not break the
seals on the factory-installed fuel metering valve. 1
Obtain a new fuel metering valve to replace the
factory-installed valve, and adjust the fuel mixture
according to the instructions in this section. See
Figure 5-27 for the fuel metering valve location. Refer to
the generator set Parts Catalog for the fuel metering
valve part number.
GM74908
Note: Adjusting the factory-installed fuel metering 1. Oxygen sensor mounting location
valves on emissions-certified generator sets will
void the emission certification. Figure 5-29 Oxygen Sensor Mounting Location on
the 14RES/RESL
Use a universal exhaust gas oxygen (UEGO) sensor to
check the fuel mixture after replacing the fuel regulator, 4. Connect the oxygen sensor to the engine starting
carburetor, or silencer. Use the following procedure to battery, control module, and voltmeter as shown in
check the fuel mixture after the engine has reached Figure 5-31.
normal operating temperature.
5. Reconnect power to the battery charger.
Only trained, authorized service technicians may adjust
the new fuel metering valve. The adjustment procedure 6. Press the RUN button on the controller to start the
requires a digital voltmeter (DVM), UEGO oxygen generator set.
sensor service kit GM29385, and a load bank capable of
the rated kW for the fuel being used. Always use an 7. Allow the generator set to run until the engine
oxygen sensor when adjusting the fuel metering valves. reaches normal operating temperature.
Observe the following safety precautions while 8. With the generator set at normal operating
performing the procedure. temperature, apply rated load.
9. Connect one of the DVM leads to the oxygen

WARNING sensor lead. Connect the other DVM lead to
ground and measure the output voltage of the
oxygen sensor (potential to ground).
10. Adjust the fuel metering valve as required to obtain

Hot engine and exhaust system. the output from the oxygen sensor specified in
Can cause severe injury or death. Figure 5-30. The output of the oxygen sensor
Do not work on the generator set until reads high when the mixture is fuel-rich and close
it cools. to zero volts when the mixture is lean.
Servicing the exhaust system. Hot parts can cause Oxygen Sensor Reading,
severe injury or death. Do not touch hot engine parts. The VDC
engine and exhaust system components become extremely Model Natural Gas LP
14RES/RESL 2.70±0.05 2.70±0.05
Fuel Mixture Check/Fuel Metering Valve Figure 5-30 Acceptable Oxygen Sensor Readings
Adjustment Procedure
11. When the fuel mixture is correct, use thread sealant
1. Press the OFF button on the RDC/DC controller. to seal the metering valve adjustment screws.
2. Disconnect power to the battery charger.

12. Remove the load and allow the generator set to run 17. Remove the oxygen sensor from exhaust manifold.
unloaded to cool for at least 5–10 minutes.
18. Apply a small amount of antiseize compound to
13. Stop the generator set by pressing the OFF button exhaust plug and reinstall the plug into the exhaust
on the controller. manifold.
14. Disconnect the generator set engine starting 19. Check that the generator set is off by checking the
battery, negative (--) lead first. OFF LED on the controller.
15. Allow the generator set exhaust system to cool. 20. Reconnect the generator set engine starting
16. Disconnect the DVM leads from the oxygen
sensor. 21. Reconnect power to the battery charger.
GM-28981-
4
1. Battery power supply connection
2. Digital voltmeter (DVM) connection
3. Air/fuel control module connection
4. Oxygen sensor connection
Figure 5-31 UEGO Sensor Interface Harness GM28981 Electrical Connections

5.12 Starter Relay
The starter relay is located under the controller. See
Figure 5-32.
259391
Figure 5-33 Starter Relay
Relay Terminal Lead

30 14P
85 N7
86 71
87 14S
87A NC
GM66566
1. Starter relay Figure 5-34 Starter Relay Connections
Figure 5-32 Starter Relay Location
The starter relay contains an internal diode across the

relay coil. See Figure 5-33. Continuity checks across
the coil terminals will show continuity (low resistance) in
one direction and an open circuit in the other.
Figure 5-34 shows the starter relay connections.

5.13 Continuity Checks controller circuit board. Use an ohmmeter to check the
continuity of the components listed in Figure 5-35. Also
see Section 7, Wiring Diagrams.
WARNING
Figure 5-35 gives resistance readings for functional
components. A zero reading on the ohmmeter indicates
continuity. No ohmmeter reading indicates very high
resistance or an open circuit. A measurement that
Hazardous voltage. Moving parts. varies significantly from the value shown in the table
Can cause severe injury or death. indicates a faulty component; replace faulty
Operate the generator set only when components.
are in place. Note: Disconnect the generator set battery before
performing continuity checks to prevent damage
to the ohmmeter.
and/or equipment damage. Do not contact electrical For rotor and stator resistance and continuity checks,
connections with tools or jewelry while making adjustments or see Section 5.3, Stator, and Section 5.4, Main Field
repairs. Remove all jewelry before servicing the equipment. (Rotor).
To further check generator set components, disconnect

the battery and remove wiring harness plugs from the
Ohmmeter Ohmmeter Generator Set Ohmmeter Readings for Operative

Component Connections Scale State Components
P1 wiring harness P1-2 and ground Rx1 OFF Zero ohms (continuity)
Any other reading indicates a poor
ground connection.
P2-6 and P2-7 (stator Rx1 OFF Zero ohms (continuity). If no
leads 11 and 44) continuity, check wiring.
P2-3 and P2-4 (stator Rx1 OFF Zero ohms (continuity). If no
leads 55 and 66) continuity, check fuse F1 and wiring.
Controller fuse and P1-1 and battery positive R x 100 OFF Zero ohms (continuity). If no
wiring (+) continuity is found, check fuse F3 and
wiring.
Auxiliary winding P2-3 and stator lead 55 R x 100 OFF Zero ohms (continuity). If no
breaker (20-amps) continuity is found, check for an open
circuit and/or a blown fuse.
Low oil pressure (LOP) Lead 13 and ground R x 100 OFF Zero ohms (continuity). No continuity
switch * (engine block) indicates a faulty switch and/or wiring.
Temperature sensor P1-9 and P1-10 R x 1000 OFF 180--2500 ohms, depending on
(CTS) * engine temperature. See
Section 5.10.2. Zero ohms or an
open circuit indicates faulty wiring or
a faulty switch.
* See Section 5.10.2, Fault Shutdown Switches
Figure 5-35 Continuity Checks

5.14 Circuit Protection See Figure 5-36 for fuse part numbers. Always identify
and correct the cause of a blown fuse before restarting
If the generator set circuit breaker trips or the fuses blow the generator set. Refer to Section 3, Troubleshooting,
repeatedly, see Section 3, Troubleshooting, for possible for conditions that may indicate a blown fuse. Replace
causes. blown fuses with identical replacement parts.
5.14.1 Line Circuit Breaker Rating,

Fuse/Breaker Amps Label Part Number
A line circuit breaker interrupts the generator output in Auxiliary winding 20 BRDCB Resettable
the event of a fault in the wiring between the generator mini-breaker
and the load. The line circuit breaker location is shown Starter/Fuel/Flash 7.5 F2 GM66129
in Figure 1-1. If the circuit breaker trips, reduce the load (Violet)
and switch the breaker back to the ON position. With the
Controller (Brown) 3 F3 GM66128
breaker in the OFF position the generator set runs but
the generator output is disconnected from the load. Battery charger 10 — AGS 10
Figure 5-36 Circuit Protection

5.14.2 Fuses and Mini-Breaker
Two fuses and a mini-breaker protect the alternator and
electrical controls. The fuses and breaker are located in
the service access area of the RDC/DC controller. A
battery charger fuse is located in the positive battery
lead. Check for and replace any blown fuses or reset the
breaker before replacing other components.

Section 6 Disassembly/Reassembly
This section provides instructions for the disassembly

and reassembly of the generator set alternator. Before
WARNING
beginning the generator disassembly or reassembly
procedure, carefully read all safety precautions at the
beginning of this manual.
The engine and generator set may use both American Hot engine and exhaust system.
Standard and metric hardware. Use the correct size Can cause severe injury or death.
tools to prevent rounding of the bolt heads and nuts.
it cools.
WARNING
6.1 Initial Steps

Perform the following steps before disassembling the
generator set.
Accidental starting.
Can cause severe injury or death. 1. Disconnect AC power to the generator set by
Disconnect the battery cables before opening the upstream circuit breaker. (AC power is
working on the generator set. connected to the generator set for AC-powered
Remove the negative (--) lead first accessories.)
when disconnecting the battery.
Reconnect the negative (--) lead last 2. Shut off the fuel supply. Disconnect the fuel system
when reconnecting the battery. if necessary to tilt the generator set. Ventilate the
area to clear fumes.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the 3. Allow the generator set and engine to cool.
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the 4. Verify that any hoists or lifting devices used in the
OFF position. (2) Disconnect the power to the battery charger. disassembly or reassembly procedure are rated for
(3) Remove the battery cables, negative (--) lead first. the weight of the generator set, which is
Reconnect the negative (--) lead last when reconnecting the approximately 227 kg (500 lb.).
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.
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
TP-6735 9/10 Section 6 Disassembly/Reassembly 83

6.2 Disassembly
1 2 3
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.
Remove enclosure 4
Remove the generator set enclosure as described in the

following steps. See Figure 6-1.
1. Open the enclosure roof.

Right Side
controller. 5
Front (air
1. Roof intake end)
3. Remove 6 nuts and remove the roof. See 2. Rear panel (exhaust end)
Figure 6-2. 3. Left side panel
4. Front panel (air intake end)
5. Right side panel ADV7341
Figure 6-1 Enclosure
1
1
GM72523
1. Remove three nuts on each side
Figure 6-2 Roof Removal
84 Section 6 Disassembly/Reassembly TP-6735 9/10

4. Remove the exhaust duct panel over the muffler by 6. Disconnect the latch rods at the red plastic
removing four screws. See Figure 6-3. connectors. See Figure 6-4.
5. Remove the top exhaust panel.

1
1
1
GM72523
2 1. Disconnect latch rods
Figure 6-4 Door Latch Detail
7. See Figure 6-5. Reach inside the enclosure to

move each latch hinge aside. Remove two nuts on
GM66564
each side (total of four nuts).
1. Exhaust duct panel. Remove 4 screws
2. Top exhaust panel. Remove 2 screws.
8. Remove one screw near the controller area.
9. Pull the right side panel up and off.

Figure 6-3 Heat Shield
Note: Part of the right side panel is cut away

in this view to reveal the fasteners.
1. Remove 4 nuts inside the enclosure (2 left and 2 right). GM72523

2. Remove screw.
Figure 6-5 Right Side Panel

10. Remove the front panel. See Figure 6-6. 16. From the inside of the enclosure, remove four nuts
securing the left side panel. See Figure 6-8.
17. Pull the panel up and off.

1
1
ADV-7876
GM72523
1. Remove 2 screws
Figure 6-6 Front Panel (air intake end panel)
11. Unplug the carburetor heater (if equipped) from the

120VAC receptacle.
12. Unplug the battery charger from the 120VAC

receptacle.

14. Disconnect output leads or load circuit cables at the

field-connection terminal block. 1. Left side panel
2. Remove 4 nuts
15. Remove two nuts and lift off the exhaust end panel.
See Figure 6-7. Figure 6-8 Left Side Panel
GM72523
1. Remove 2 screws
Figure 6-7 Rear Panel (exhaust end panel)

18. Remove the remaining exhaust duct panels and Generator Disassembly
alternator air inlet duct. See Figure 6-9.
20. Disconnect the following alternator wiring inside
the controller junction box. See the wiring
2 2 diagrams in Section 7.
a. Disconnect lead 55 from the mini-breaker on

the controller.
b. Disconnect P2 from the controller.
c. Disconnect leads 2 and 3 from neutral stud L0.
d. Disconnect leads 1 and 4 from the circuit

breaker.
21. Remove the bolts securing the two alternator end

vibromounts to the skid. Loosen the two engine
vibromounts. See Figure 6-10.
1
22. Raise the alternator end of the generator set
2
enough to place a wood support beneath the rear of
TP-6735
the engine. The wood support must be long
1. Alternator duct enough to span the opening in the base. See
2. Exhaust duct panels Figure 6-11.
Figure 6-9 Exhaust and Alternator Ducts
Note: Use a hoist or lifting device that is rated for
19. Disconnect the muffler from the engine at the two the weight of the generator set. See
flange connections and remove the muffler. See Section 6.1.
Figure 6-10.
Note: Use new exhaust gaskets when re-installing

the muffler.
GM51561
1
1. Engine support
Figure 6-11 Wood Support
4
TP-6735
1. Exhaust flanges (qty. 2) 3
2. Muffler
3. Alternator vibromounts (qty. 2)
4. Engine vibromounts (qty. 2)
Figure 6-10 Muffler and Vibromounts

23. Remove the alternator support bracket from the 1 2
alternator shell. See Figure 6-12.
1
TP-6735 4 3
1. Alternator support bracket
1
Figure 6-12 Alternator Support Bracket 2 5
24. Remove the cable tie that attaches the brush leads
to the end bracket. See Figure 6-13.
25. Check the brushes. See Figure 6-13. 7
Note: The brushes are spring-loaded. Be sure to

insert a retaining wire to hold the brushes as
described below.
a. Raise the brushes in the brush holder and 6

insert a small piece of wire into the brush holder 2
retainer wire hole. GM67344
1. Brush holder 5. Retainer wire

b. Remove the brush holder from the end bracket. 2. Brush(es) 6. Spring
3. Cable tie 7. Shim
4. Slip rings
c. Inspect the brushes. Replace brushes if they
show uneven wear or when they are worn to
Figure 6-13 Alternator End Bracket and Brush
half of their original size. See Section 5.6,
Assembly
Brushes.

26. Remove the alternator overbolts and centering b. Loosen the rotor assembly by striking the side
washers. See Figure 6-14. of the rotor with a soft-faced hammer to loosen
it from the tapered crankshaft fitting. See
3 4 Figure 6-15. Rotate the rotor and strike it on
2 alternate sides until it can be rocked slightly
1
back and forth.
Note: Do not strike the slip rings.
c. Remove the thrubolt and the rotor. Set the rotor

assembly aside.
Note: Do not strike the slip

rings when removing
the rotor.
2
5
1. End bracket (brush assembly shown attached)
2. Stator windings (outer)
3. Rotor (inner). Also see Figure 6-15. 1 GM67344
4. Stator shell
5. Overbolts (qty. 4) 1. Rotor thrubolt
2. Slip rings
Figure 6-14 Alternator Assembly 3. Generator adaptor (14RES/RESL only)
27. Using a soft-faced hammer, strike the sides of the Figure 6-15 Rotor Assembly with Thrubolt
end bracket with medium-force blows to remove
the end bracket from the stator or remove the end 31. 14RES/RESL only: Remove the four generator
bracket from the stator using a puller. Set the end adapter mounting bolts to remove the generator
bracket assembly aside. adapter, if necessary. See Figure 6-16.
28. 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.
29. Carefully pull the stator from the rotor. See

Figure 6-14. 1
30. Remove the rotor as follows:
a. Loosen but do not remove the rotor thrubolt.

Use a strap wrench on the rotor to keep the
rotor from turning during loosening, if GM60283
necessary. See Figure 6-15. 1. Adapter mounting holes
Figure 6-16 Generator Adapter (14RES/RESL)

6.3 Reassembly 3. Install the stator and end bracket.
1. 14RES/RESL only: Reinstall the generator a. Re-attach the alternator support bracket to the
adapter onto the engine, if necessary. alternator shell. The hole in the bracket must
face the engine. See Figure 6-18.
a. Attach the generator adapter to the engine
using four 7/16-14 x 1.0 in. hex cap bolts and
washers. See Figure 6-16. 1
b. Torque the bolts to 40 Nm (28 ft. lb.).
2. Install the rotor. See Figure 6-17.
a. Clean the crankshaft stub and mating surface

on the fan hub. Do not use antiseize compound
when reassembling the rotor.
b. Install the rotor onto the engine crankshaft.
c. Thread the thrubolt with hardened washer

through the actuator and rotor into the
crankshaft. Do not tighten the thrubolt at this
time.
GM67344
3 1. Alternator support bracket
Figure 6-18 Alternator Support Bracket
b. Align the stator so that the alternator support

bracket is at the bottom. Install the stator
assembly around the rotor.
c. Align the alignment mark on the top of the stator

2
with the center of the slot in the generator
adapter.
1 GM67344
d. Route the leads connected to the alternator end
1. Rotor thrubolt bracket through the opening in the base of the
2. Hardened washer alternator frame.
3. Fan
Figure 6-17 Rotor Assembly

e. Place the end bracket onto the stator assembly,
lining up the alignment marks on the top of the
stator and end bracket. See Figure 6-19.
1 2
f. Thread the four overbolts with locating washers
through the end bracket and into the generator
adapter. See Figure 6-19 and Figure 6-20.
Position the locating tab of each washer to the
outer edge of the oblong (OBROUND) hole on
the end bracket. The overbolts should be
parallel to the outside of the alternator. If the 4
overbolts are slanted, rotate the locating
washer 1/2 turn. Do not final tighten the
overbolts at this time. 6519
3
3 4
2
1 1. End bracket
2. Alternator
3. Alternator frame vibromount
4. Overbolts
Figure 6-20 Generator Set, Right Side
4. Secure the generator set to the skid.
a. Raise the alternator end of the generator set

and remove the wood support block(s).
b. Lower the end of the generator set and reinstall

the screws and washers that secure the
vibromounts to the skid. Tighten all four
vibromounts (for the alternator and engine) to
5.4 Nm (4 ft. lbs.). Do not overtighten. See
Figure 6-21.
5. Tighten the four alternator assembly overbolts to

5 14.9 Nm (11 ft. lb.). See Figure 6-21.
1. End bracket (brush assembly shown attached)
2. Stator windings (outer) 6. Tighten the rotor thrubolt to 85 Nm (63 ft. lb.). It
3. Rotor (inner). Also see Figure 6-15. may be necessary to keep the engine flywheel from
4. Stator shell
turning while torquing the rotor thrubolt.
5. Overbolts (qty. 4)
Figure 6-19 End Bracket and Brush Assembly 1
3
2
TP-6735
1. Alternator overbolts (qty. 4)
3. Engine vibromounts (qty. 2)
Figure 6-21 Vibromounts and Overbolts

7. Reinstall the end bracket components. 3
1
a. Inspect the brushes. If brushes show uneven
wear or are worn to less than half their original
length, replace them. See Section 5.6.
b. Install the brush holder with shim onto the end

bracket. Verify that the brushes are not sticking
in the holder. 4
c. Verify that the brushes are centered on the slip
rings. If required, insert spacers between the
mounting surface and brush holder to center
the brushes on the slip rings. See Figure 6-22.
2
See Section 5.6, Brushes, for more
information.
5
d. Use the cable tie to secure the brush leads to 1
the end bracket. 4
3
3 GM67344
Correct Incorrect
New 19.0 mm (0.75 in.) 8 9
3 2 2
Side View
TP5867
1. Brush holder 6. Shim

2. Slip ring (s) 7. Spring
3. Brush(es) 8. Correctly positioned brush
4. Retainer wire 9. Incorrectly positioned brush
5. Cable tie
Figure 6-22 Brush Assembly and Positioning

8. Install the exhaust system. See Figure 6-23.
2 2
a. Install the heat shield onto the alternator
exhaust support.
b. Using new gaskets, connect the engine

exhaust muffler to the engine at the flanges. Do
not final tighten the mounting hardware.
c. Secure the muffler mounting tab to the heat

shield.
d. Torque the nuts securing the engine muffler

flange to the engine to 24 Nm (17.7 ft. lb.).
9. Reinstall the alternator and exhaust duct panels

shown in Figure 6-24. 1
2
TP-6735
1 1. Alternator duct
2. Exhaust duct panels
2
Figure 6-24 Alternator and Exhaust Ducts
10. Reconnect the following alternator wiring inside the

controller junction box. See the wiring diagrams in
Section 7.
a. Reconnect lead 55 to the mini-breaker on the

controller.
b. Reconnect P2 to the controller.
c. Reconnect leads 2 and 3 to neutral stud L0.
d. Reconnect leads 1 and 4 to the circuit breaker.

4 e. Reconnect any other controller connections
TP-6735
1. Exhaust flanges (qty. 2) 3
2. Muffler that were removed during disassembly.
4. Engine vibromounts (qty. 2) 11. Press the OFF button on the generator set
controller.
Figure 6-23 Exhaust System
13. Reconnect the carburetor heater (if equipped) to

the 120VAC receptacle.
14. Reconnect the battery charger to the 120VAC

receptacle.
15. Reconnect output leads or load circuit cables at the

field-connection terminal block.

16. Reinstall the enclosure panels in reverse order of
removal. See Figure 6-25 and refer to the 1
disassembly instructions, if necessary.
a. Install the left side panel.
b. Install the exhaust end panel.
c. Install the front panel.
d. Install the right side panel and reconnect the GM72523

1. Reconnect latch rods
door latch rods. See Figure 6-26.
Figure 6-26 Door Latch Detail
e. Install the exhaust panels shown in
Figure 6-27.
1
1
f. Install the front panel.
g. Install the generator set housing roof.
17. Re-apply the 120VAC power supply to the

generator set by closing the upstream circuit
breaker.
2
18. Turn on the fuel supply. Press RUN to start the
generator set and check for leaks with the engine
running.
GM66564
19. Press OFF to turn off the generator set. Then press
AUTO if an automatic transfer switch or remote
1. Exhaust duct panel (4 screws)
start/stop switch is used. 2. Top exhaust panel (2 screws)
20. Lower and secure the roof.

Figure 6-27 Exhaust Duct Top Panels
1 2 3
Right Side
5
Front (air
1. Roof intake end)
2. Rear panel (exhaust end)
3. Left side panel
4. Front panel (air intake end)
5. Right side panel ADV7341
Figure 6-25 Generator Set Enclosure

Section 7 Wiring Diagrams
Figure 7-1 lists the wiring diagram numbers and locations.
Wiring Diagram Description Drawing Number Page

Schematic Diagram ADV-7697 96
Point-to-Point Wiring Diagram GM69754 97
Figure 7-1 Wiring Diagrams and Schematics
TP-6735 9/10 Section 7 Wiring Diagrams 95

-
Figure 7-2 Schematic Diagram, ADV-7697
96 Section 7 Wiring Diagrams TP-6735 9/10

-
Figure 7-3 Point-to-Point Wiring Diagram, GM69754
TP-6735 9/10 Section 7 Wiring Diagrams 97

Notes
98 Section 7 Wiring Diagrams TP-6735 9/10

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute est. estimated
ABDC after bottom dead center CG center of gravity E-Stop emergency stop
AC alternating current CID cubic inch displacement etc. et cetera (and so forth)
A/D analog to digital CL centerline exh. exhaust
ADC advanced digital control; cm centimeter ext. external
analog to digital converter CMOS complementary metal oxide F Fahrenheit, female
adj. adjust, adjustment substrate (semiconductor) fglass. fiberglass
ADV advertising dimensional cogen. cogeneration FHM flat head machine (screw)
drawing com communications (port) fl. oz. fluid ounce
Ah amp-hour coml commercial flex. flexible
AHWT anticipatory high water Coml/Rec Commercial/Recreational freq. frequency
temperature conn. connection FS full scale
AISI American Iron and Steel cont. continued
Institute ft. foot, feet
CPVC chlorinated polyvinyl chloride ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure
crit. critical ft./min. feet per minute
alt. alternator
CRT cathode ray tube ftp file transfer protocol
Al aluminum
CSA Canadian Standards g gram
ANSI American National Standards Association
Institute (formerly American ga. gauge (meters, wire size)
Standards Association, ASA) CT current transformer gal. gallon
AO anticipatory only Cu copper gen. generator
APDC Air Pollution Control District cUL Canadian Underwriter’s genset generator set
Laboratories
API American Petroleum Institute GFI ground fault interrupter
CUL Canadian Underwriter’s
approx. approximate, approximately Laboratories GND, ground
AQMD Air Quality Management District cu. in. cubic inch gov. governor
AR as required, as requested cw. clockwise gph gallons per hour
AS as supplied, as stated, as CWC city water-cooled gpm gallons per minute
suggested
cyl. cylinder gr. grade, gross
ASE American Society of Engineers
D/A digital to analog GRD equipment ground
ASME American Society of
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dB(A) decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg., ° degree HET high exhaust temp., high
auto. automatic dept. department engine temp.
aux. auxiliary DFMEA Design Failure Mode and hex hexagon
avg. average Effects Analysis Hg mercury (element)
AVR automatic voltage regulator dia. diameter HH hex head
AWG American Wire Gauge DI/EO dual inlet/end outlet HHC hex head cap
AWM appliance wiring material DIN Deutsches Institut fur Normung HP horsepower
e. V. (also Deutsche Industrie hr. hour
bat. battery Normenausschuss)
BBDC before bottom dead center HS heat shrink
DIP dual inline package hsg. housing
BC battery charger, battery DPDT double-pole, double-throw
charging HVAC heating, ventilation, and air
DPST double-pole, single-throw conditioning
BCA battery charging alternator
DS disconnect switch HWT high water temperature
BCI Battery Council International
DVR digital voltage regulator Hz hertz (cycles per second)
BDC before dead center
E, emer. emergency (power source) IC integrated circuit
BHP brake horsepower
ECM electronic control module, ID inside diameter, identification
blk. black (paint color), block engine control module
(engine) IEC International Electrotechnical
EDI electronic data interchange Commission
blk. htr. block heater
EFR emergency frequency relay IEEE Institute of Electrical and
BMEP brake mean effective pressure
e.g. for example (exempli gratia) Electronics Engineers
bps bits per second
EG electronic governor IMS improved motor starting
br. brass
EGSA Electrical Generating Systems in. inch
BTDC before top dead center Association in. H2O inches of water
Btu British thermal unit EIA Electronic Industries in. Hg inches of mercury
Btu/min. British thermal units per minute Association in. lb. inch pounds
C Celsius, centigrade EI/EO end inlet/end outlet Inc. incorporated
cal. calorie EMI electromagnetic interference ind. industrial
CAN controller area network emiss. emission int. internal
CARB California Air Resources Board eng. engine int./ext. internal/external
CB circuit breaker EPA Environmental Protection I/O input/output
cc cubic centimeter Agency
IP iron pipe
CCA cold cranking amps EPS emergency power system
ISO International Organization for
ccw. counterclockwise ER emergency relay Standardization
CEC Canadian Electrical Code ES engineering special, J joule
cert. certificate, certification, certified engineered special
JIS Japanese Industry Standard
cfh cubic feet per hour ESD electrostatic discharge
TP-6735 9/10 Appendix 99

k kilo (1000) MTBO mean time between overhauls rms root mean square
K kelvin mtg. mounting rnd. round
kA kiloampere MTU Motoren-und Turbinen-Union ROM read only memory
KB kilobyte (210 bytes) MW megawatt rot. rotate, rotating
KBus Kohler communication protocol mW milliwatt rpm revolutions per minute
kg kilogram μF microfarad RS right side
kg/cm2 kilograms per square N, norm. normal (power source) RTU remote terminal unit
centimeter NA not available, not applicable RTV room temperature vulcanization
kgm kilogram-meter nat. gas natural gas RW read/write
kg/m3 kilograms per cubic meter NBS National Bureau of Standards SAE Society of Automotive
kHz kilohertz NC normally closed Engineers
kJ kilojoule NEC National Electrical Code scfm standard cubic feet per minute
km kilometer NEMA National Electrical SCR silicon controlled rectifier
kOhm, kΩ kilo-ohm Manufacturers Association s, sec. second
kPa kilopascal NFPA National Fire Protection SI Systeme international d’unites,
kph kilometers per hour Association International System of Units
kV kilovolt Nm newton meter SI/EO side in/end out
kVA kilovolt ampere NO normally open sil. silencer
kVAR kilovolt ampere reactive no., nos. number, numbers SN serial number
kW kilowatt NPS National Pipe, Straight SNMP simple network management
kWh kilowatt-hour NPSC National Pipe, Straight-coupling protocol
kWm kilowatt mechanical NPT National Standard taper pipe SPDT single-pole, double-throw
kWth kilowatt-thermal thread per general use SPST single-pole, single-throw
L liter NPTF National Pipe, Taper-Fine spec specification
LAN local area network NR not required, normal relay specs specification(s)
L x W x H length by width by height ns nanosecond sq. square
lb. pound, pounds OC overcrank sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet OD outside diameter sq. in. square inch
LCB line circuit breaker OEM original equipment SS stainless steel
manufacturer std. standard
LCD liquid crystal display
OF overfrequency stl. steel
ld. shd. load shed
opt. option, optional tach. tachometer
LED light emitting diode
OS oversize, overspeed TD time delay
Lph liters per hour
OSHA Occupational Safety and Health TDC top dead center
Lpm liters per minute Administration
LOP low oil pressure TDEC time delay engine cooldown
OV overvoltage TDEN time delay emergency to
LP liquefied petroleum oz. ounce normal
LPG liquefied petroleum gas p., pp. page, pages TDES time delay engine start
LS left side PC personal computer TDNE time delay normal to
Lwa sound power level, A weighted PCB printed circuit board emergency
LWL low water level pF picofarad TDOE time delay off to emergency
LWT low water temperature PF power factor TDON time delay off to normal
m meter, milli (1/1000) ph., ∅ phase temp. temperature
M mega (106 when used with SI PHC Phillipsr head Crimptiter term. terminal
units), male (screw) THD total harmonic distortion
m3 cubic meter PHH Phillipsr hex head (screw) TIF telephone influence factor
m3/hr. cubic meters per hour PHM pan head machine (screw) TIR total indicator reading
m3/min. cubic meters per minute PLC programmable logic control tol. tolerance
mA milliampere PMG permanent magnet generator turbo. turbocharger
man. manual pot potentiometer, potential typ. typical (same in multiple
max. maximum ppm parts per million locations)
MB megabyte (220 bytes) PROM programmable read-only UF underfrequency
MCCB molded-case circuit breaker memory UHF ultrahigh frequency
MCM one thousand circular mils psi pounds per square inch UL Underwriter’s Laboratories, Inc.
meggar megohmmeter psig pounds per square inch gauge UNC unified coarse thread (was NC)
MHz megahertz pt. pint UNF unified fine thread (was NF)
mi. mile PTC positive temperature coefficient univ. universal
mil one one-thousandth of an inch PTO power takeoff US undersize, underspeed
min. minimum, minute PVC polyvinyl chloride UV ultraviolet, undervoltage
misc. miscellaneous qt. quart, quarts V volt
MJ megajoule qty. quantity VAC volts alternating current
mJ millijoule R replacement (emergency) VAR voltampere reactive
mm millimeter power source VDC volts direct current
mOhm, mΩmilliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, MΩmegohm RAM random access memory VGA video graphics adapter
MOV metal oxide varistor RDO relay driver output VHF very high frequency
MPa megapascal ref. reference W watt
mpg miles per gallon rem. remote WCR withstand and closing rating
mph miles per hour Res/Coml Residential/Commercial w/ with
MS military standard RFI radio frequency interference w/o without
ms millisecond RH round head wt. weight
m/sec. meters per second RHM round head machine (screw) xfmr transformer
MTBF mean time between failure rly. relay
100 Appendix TP-6735 9/10

Appendix B Common Hardware Application Guidelines
Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.
Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread
use Figure 1 as a guide. As a general rule, a minimum (weld nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
the preferred method. hardware is greater than 1/2 inch in diameter, or
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
preloading (torque) of the bolt in all other applications. spiralock nut. See Figure 2.
See Appendix C, General Torque Specifications, and 3. Follow these SAE washer rules after determining
other torque specifications in the service literature. exit hole type:
a. Always use a washer between hardware and a

Preferred Nut/Bolt Clearance slot.
1 2 b. Always use a washer under a nut (see 2 above
for exception).
c. Use a washer under a bolt when the female

thread is fixed (weld nut).
4. Refer to Figure 2, which depicts the preceding

hardware configuration possibilities.
Unacceptable Nut/Bolt Clearance
3 2
1
3
G-585
1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut
3. Below top of nut
Figure 1 Acceptable Bolt Lengths
5
4
6
G-585
1. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types
Figure 2 Acceptable Hardware Combinations

Appendix C General Torque Specifications
American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled into
Torque Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) —
10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) —
10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) —
1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132)
1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144)
5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264)
5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288)
3/8-16 Nm (ft. lb.) 24.0 (18) 38.0 (28) 53.0 (39)
3/8-24 Nm (ft. lb.) 27.0 (20) 42.0 (31) 60.0 (44)
7/16-14 Nm (ft. lb.) 39.0 (29) 60.0 (44) 85.0 (63)
7/16-20 Nm (ft. lb.) 43.0 (32) 68.0 (50) 95.0 (70) See Note 3
1/2-13 Nm (ft. lb.) 60.0 (44) 92.0 (68) 130.0 (96)
1/2-20 Nm (ft. lb.) 66.0 (49) 103.0 (76) 146.0 (108)
9/16-12 Nm (ft. lb.) 81.0 (60) 133.0 (98) 187.0 (138)
9/16-18 Nm (ft. lb.) 91.0 (67) 148.0 (109) 209.0 (154)
5/8-11 Nm (ft. lb.) 113.0 (83) 183.0 (135) 259.0 (191)
5/8-18 Nm (ft. lb.) 128.0 (94) 208.0 (153) 293.0 (216)
3/4-10 Nm (ft. lb.) 199.0 (147) 325.0 (240) 458.0 (338)
3/4-16 Nm (ft. lb.) 222.0 (164) 363.0 (268) 513.0 (378)
1-8 Nm (ft. lb.) 259.0 (191) 721.0 (532) 1109.0 (818)
1-12 Nm (ft. lb.) 283.0 (209) 789.0 (582) 1214.0 (895)
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into Cast Iron or Steel Assembled into
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)
M8 x 1.25 15.0 (11) 23.0 (17) 33.0 (24)
M8 x 1.00 16.0 (11) 24.0 (18) 34.0 (25)
M10 x 1.50 30.0 (22) 45.0 (34) 65.0 (48)
M10 x 1.25 31.0 (23) 47.0 (35) 68.0 (50)
M12 x 1.75 53.0 (39) 80.0 (59) 115.0 (85)
M12 x 1.50 56.0 (41) 85.0 (63) 122.0 (90) See Note 3
M14 x 2.00 83.0 (61) 126.0 (93) 180.0 (133)
M14 x 1.50 87.0 (64) 133.0 (98) 190.0 (140)
M16 x 2.00 127.0 (94) 194.0 (143) 278.0 (205)
M16 x 1.50 132.0 (97) 201.0 (148) 287.0 (212)
M18 x 2.50 179.0 (132) 273.0 (201) 390.0 (288)
M18 x 1.50 189.0 (140) 289.0 (213) 413.0 (305)
Notes:
1. 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.
2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.
3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to
prevent stripped threads.
4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength
and a friction coefficient of 0.125.

Appendix D Common Hardware Identification
Screw/Bolts/Studs Nuts Hardness Grades

Head Styles Nut Styles American Standard
Hex Head or Machine Head Hex Head Grade 2
Hex Head or Machine Head

Lock or Elastic Grade 5
with Washer
Flat Head (FHM) Square Grade 8
Grade 8/9 (Hex Socket

Round Head (RHM) Cap or Acorn
Head)
Metric
Pan Head Wing
Number stamped on
5.8
Hex Socket Head Cap or Washers hardware; 5.8 shown
Allent Head Cap
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt Plain
Sheet Metal Screw Split Lock or Spring
Stud Spring or Wave
Drive Styles
External Tooth Lock
Hex
Internal Tooth Lock
Hex and Slotted
Internal-External Tooth Lock
Phillipsr
Slotted
Hex Socket
Allent head screw is a trademark of Holo-Krome Co.

Phillipsr screw is a registered trademark of Phillips Screw Company.
Sample Dimensions
American Standard (Screws, Bolts, Studs, and Nuts) Plain Washers
1/4-20 x 1 9/32 x 5/8 x 1/16
Length In Inches (Screws and Bolts) Thickness
Threads Per Inch External Dimension
Major Thread Diameter In Fractional Inches Or Screw Number Size Internal Dimension
Metric (Screws, Bolts, Studs, and Nuts)
M8-1.25 x 20 Lock Washers
Length In Millimeters (Screws and Bolts) 5/8
Distance Between Threads In Millimeters Internal Dimension
Major Thread Diameter In Millimeters

Appendix E Common Hardware List
The Common Hardware List lists part numbers and dimensions for common hardware items.
American Standard
Part No. Dimensions Part No. Dimensions Part No. Dimensions Type
Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts
X-465-17 1/4-20 x .38 X-6238-14 3/8-24 x .75 X-6009-1 1-8 Standard
X-465-6 1/4-20 x .50 X-6238-16 3/8-24 x 1.25
X-465-2 1/4-20 x .62 X-6238-21 3/8-24 x 4.00 X-6210-3 6-32 Whiz
X-465-16 1/4-20 x .75 X-6238-22 3/8-24 x 4.50 X-6210-4 8-32 Whiz
X-465-18 1/4-20 x .88 X-6210-5 10-24 Whiz
X-465-7 1/4-20 x 1.00 X-6024-5 7/16-14 x .75
X-6024-2 7/16-14 x 1.00 X-6210-1 10-32 Whiz
X-465-8 1/4-20 x 1.25
X-465-9 1/4-20 x 1.50 X-6024-8 7/16-14 x 1.25 X-6210-2 1/4-20 Spiralock
X-465-10 1/4-20 x 1.75 X-6024-3 7/16-14 x 1.50 X-6210-6 1/4-28 Spiralock
X-465-11 1/4-20 x 2.00 X-6024-4 7/16-14 x 2.00 X-6210-7 5/16-18 Spiralock
X-465-12 1/4-20 x 2.25 X-6024-11 7/16-14 x 2.75 X-6210-8 5/16-24 Spiralock
X-465-14 1/4-20 x 2.75 X-6024-12 7/16-14 x 6.50
X-6210-9 3/8-16 Spiralock
X-465-21 1/4-20 x 5.00 X-129-15 1/2-13 x .75 X-6210-10 3/8-24 Spiralock
X-465-25 1/4-28 x .38 X-129-17 1/2-13 x 1.00 X-6210-11 7/16-14 Spiralock
X-465-20 1/4-28 x 1.00 X-129-18 1/2-13 x 1.25 X-6210-12 1/2-13 Spiralock
X-125-33 5/16-18 x .50 X-129-19 1/2-13 x 1.50 X-6210-15 7/16-20 Spiralock
X-125-23 5/16-18 x .62 X-129-20 1/2-13 x 1.75 X-6210-14 1/2-20 Spiralock
X-125-3 5/16-18 x .75 X-129-21 1/2-13 x 2.00
X-129-22 1/2-13 x 2.25 X-85-3 5/8-11 Standard
X-125-31 5/16-18 x .88 X-88-12 3/4-10 Standard
X-125-5 5/16-18 x 1.00 X-129-23 1/2-13 x 2.50
X-129-24 1/2-13 x 2.75 X-89-2 1/2-20 Standard
X-125-24 5/16-18 x 1.25
X-125-34 5/16-18 x 1.50 X-129-25 1/2-13 x 3.00
X-125-25 5/16-18 x 1.75 X-129-27 1/2-13 x 3.50
X-125-26 5/16-18 x 2.00 X-129-29 1/2-13 x 4.00 Washers
230578 5/16-18 x 2.25 X-129-30 1/2-13 x 4.50 Bolt/
X-125-29 5/16-18 x 2.50 X-463-9 1/2-13 x 5.50
X-129-44 1/2-13 x 6.00 Part No. ID OD Thick. Screw
X-125-27 5/16-18 x 2.75
X-125-28 5/16-18 x 3.00 X-129-51 1/2-20 x .75 X-25-46 .125 .250 .022 #4
X-125-22 5/16-18 x 4.50 X-129-45 1/2-20 x 1.25 X-25-9 .156 .375 .049 #6
X-125-32 5/16-18 x 5.00 X-129-52 1/2-20 x 1.50 X-25-48 .188 .438 .049 #8
X-125-35 5/16-18 x 5.50 X-25-36 .219 .500 .049 #10
X-125-36 5/16-18 x 6.00 X-6021-3 5/8-11 x 1.00 X-25-40 .281 .625 .065 1/4
X-125-40 5/16-18 x 6.50 X-6021-4 5/8-11 x 1.25 X-25-85 .344 .687 .065 5/16
X-6021-2 5/8-11 x 1.50 X-25-37 .406 .812 .065 3/8
X-125-43 5/16-24 x 1.75 X-6021-1 5/8-11 x 1.75 X-25-34 .469 .922 .065 7/16
X-125-44 5/16-24 x 2.50 273049 5/8-11 x 2.00
X-125-30 5/16-24 x .75 X-25-26 .531 1.062 .095 1/2
X-6021-5 5/8-11 x 2.25 X-25-15 .656 1.312 .095 5/8
X-125-39 5/16-24 x 2.00 X-6021-6 5/8-11 x 2.50
X-125-38 5/16-24 x 2.75 X-25-29 .812 1.469 .134 3/4
X-6021-7 5/8-11 x 2.75
X-25-127 1.062 2.000 .134 1
X-6238-2 3/8-16 x .62 X-6021-12 5/8-11 x 3.75
X-6238-10 3/8-16 x .75 X-6021-11 5/8-11 x 4.50
X-6238-3 3/8-16 x .88 X-6021-10 5/8-11 x 6.00
X-6238-11 3/8-16 x 1.00 X-6021-9 5/8-18 x 2.50
X-6238-4 3/8-16 x 1.25
X-6238-5 3/8-16 x 1.50 X-6239-1 3/4-10 x 1.00
X-6238-1 3/8-16 x 1.75 X-6239-8 3/4-10 x 1.25
X-6238-6 3/8-16 x 2.00 X-6239-2 3/4-10 x 1.50
X-6238-17 3/8-16 x 2.25 X-6239-3 3/4-10 x 2.00
X-6238-7 3/8-16 x 2.50 X-6239-4 3/4-10 x 2.50
X-6238-8 3/8-16 x 2.75 X-6239-5 3/4-10 x 3.00
X-6238-9 3/8-16 x 3.00 X-6239-6 3/4-10 x 3.50
X-6238-19 3/8-16 x 3.25 X-792-1 1-8 x 2.25
X-6238-12 3/8-16 x 3.50 X-792-5 1-8 x 3.00
X-6238-20 3/8-16 x 3.75 X-792-8 1-8 x 5.00
X-6238-13 3/8-16 x 4.50
X-6238-18 3/8-16 x 5.50
X-6238-25 3/8-16 x 6.50

Metric
Hex head bolts are hardness grade 8.8 unless noted.
Part No. Dimensions Part No. Dimensions Part No. Dimensions

Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), Hex Head Bolts (Full Thread),
M931-05055-60 M5-0.80 x 55 continued continued
M931-06040-60 M6-1.00 x 40 M960-16090-60 M16-1.50 x 90 M933-12016-60 M12-1.75 x 16
M931-06055-60 M6-1.00 x 55 M931-16090-60 M16-2.00 x 90 M933-12020-60 M12-1.75 x 20
M931-06060-60 M6-1.00 x 60 M931-16100-60 M16-2.00 x 100 M961-12020-60F M12-1.50 x 20
M931-06060-SS M6-1.00 x 60 M931-16100-82 M16-2.00 x 100* M933-12025-60 M12-1.75 x 25
M931-06070-60 M6-1.00 x 70 M931-16120-60 M16-2.00 x 120 M933-12025-82 M12-1.75 x 25*
M931-06070-SS M6-1.00 x 70 M931-16150-60 M16-2.00 x 150 M961-12030-60 M12-1.25 x 30
M931-06075-60 M6-1.00 x 75 M933-12030-82 M12-1.75 x 30*
M931-06090-60 M6-1.00 x 90 M931-20065-60 M20-2.50 x 65 M961-12030-82F M12-1.50 x 30*
M931-06145-60 M6-1.00 x 145 M931-20090-60 M20-2.50 x 90 M933-12030-60 M12-1.75 x 30
M931-06150-60 M6-1.00 x 150 M931-20100-60 M20-2.50 x 100 M933-12035-60 M12-1.75 x 35
M931-20120-60 M20-2.50 x 120 M961-12040-82 M12-1.25 x 40*
M931-08035-60 M8-1.25 x 35 M931-20140-60 M20-2.50 x 140 M933-12040-60 M12-1.75 x 40
M931-08040-60 M8-1.25 x 40 M931-20160-60 M20-2.50 x 160 M933-12040-82 M12-1.75 x 40*
M931-08045-60 M8-1.25 x 45
M931-08050-60 M8-1.25 x 50 M931-22090-60 M22-2.50 x 90 M961-14025-60 M14-1.50 x 25
M931-08055-60 M8-1.25 x 55 M931-22120-60 M22-2.50 x 120 M933-14025-60 M14-2.00 x 25
M931-08055-82 M8-1.25 x 55* M931-22160-60 M22-2.50 x 160 M961-14050-82 M14-1.50 x 50*
M931-08060-60 M8-1.25 x 60 M931-24090-60 M24-3.00 x 90
M931-08070-60 M8-1.25 x 70 M961-16025-60 M16-1.50 x 25
M931-24120-60 M24-3.00 x 120 M933-16025-60 M16-2.00 x 25
M931-08070-82 M8-1.25 x 70* M931-24160-60 M24-3.00 x 160
M931-08075-60 M8-1.25 x 75 M961-16030-82 M16-1.50 x 30*
M931-24200-60 M24-3.00 x 200 M933-16030-82 M16-2.00 x 30*
M931-08080-60 M8-1.25 x 80
M931-08090-60 M8-1.25 x 90 M933-16035-60 M16-2.00 x 35
M931-08095-60 M8-1.25 x 95 Hex Head Bolts (Full Thread) M961-16040-60 M16-1.50 x 40
M931-08100-60 M8-1.25 x 100 M933-16040-60 M16-2.00 x 40
M933-04006-60 M4-0.70 x 6 M961-16045-82 M16-1.50 x 45*
M931-08110-60 M8-1.25 x 110
M931-08120-60 M8-1.25 x 120 M933-05030-60 M5-0.80 x 30 M933-16045-82 M16-2.00 x 45*
M931-08130-60 M8-1.25 x 130 M933-05035-60 M5-0.80 x 35 M933-16050-60 M16-2.00 x 50
M931-08140-60 M8-1.25 x 140 M933-05050-60 M5-0.80 x 50 M933-16050-82 M16-2.00 x 50*
M931-08150-60 M8-1.25 x 150 M933-16060-60 M16-2.00 x 60
M933-06010-60 M6-1.00 x 10 M933-16070-60 M16-2.00 x 70
M931-08200-60 M8-1.25 x 200 M933-06012-60 M6-1.00 x 12
M931-10040-82 M10-1.25 x 40* M933-06014-60 M6-1.00 x 14 M933-18035-60 M18-2.50 x 35
M931-10040-60 M10-1.50 x 40 M933-06016-60 M6-1.00 x 16 M933-18050-60 M18-2.50 x 50
M931-10045-60 M10-1.50 x 45 M933-06020-60 M6-1.00 x 20 M933-18060-60 M18-2.50 x 60
M931-10050-60 M10-1.50 x 50 M933-06025-60 M6-1.00 x 25 M933-20050-60 M20-2.50 x 50
M931-10050-82 M10-1.25 x 50* M933-06030-60 M6-1.00 x 30 M933-20055-60 M20-2.50 x 55
M931-10055-60 M10-1.50 x 55 M933-06040-60 M6-1.00 x 40
M931-10060-60 M10-1.50 x 60 M933-06050-60 M6-1.00 x 50 M933-24060-60 M24-3.00 x 60
M931-10065-60 M10-1.50 x 65 M933-24065-60 M24-3.00 x 65
M933-07025-60 M7-1.00 x 25 M933-24070-60 M24-3.00 x 70
M931-10070-60 M10-1.50 x 70
M931-10080-60 M10-1.50 x 80 M933-08010-60 M8-1.25 x 10
M931-10080-82 M10-1.25 x 80* M933-08012-60 M8-1.25 x 12 Pan Head Machine Screws
M931-10090-60 M10-1.50 x 90 M933-08016-60 M8-1.25 x 16
M931-10090-82 M10-1.50 x 90* M933-08020-60 M8-1.25 x 20 M7985A-03010-20 M3-0.50 x 10
M931-10100-60 M10-1.50 x 100 M933-08025-60 M8-1.25 x 25 M7985A-03012-20 M3-0.50 x 12
M931-10110-60 M10-1.50 x 110 M933-08030-60 M8-1.25 x 30 M7985A-04010-20 M4-0.70 x 10
M931-10120-60 M10-1.50 x 120 M933-08030-82 M8-1.25 x 30* M7985A-04016-20 M4-0.70 x 16
M931-10130-60 M10-1.50 x 130 M7985A-04020-20 M4-0.70 x 20
M931-10140-60 M10-1.50 x 140 M933-10012-60 M10-1.50 x 12
M961-10020-60 M10-1.25 x 20 M7985A-04050-20 M4-0.70 x 50
M931-10180-60 M10-1.50 x 180 M7985A-04100-20 M4-0.70 x 100
M931-10235-60 M10-1.50 x 235 M933-10020-60 M10-1.50 x 20
M931-10260-60 M10-1.50 x 260 M933-10025-60 M10-1.50 x 25 M7985A-05010-20 M5-0.80 x 10
M960-10330-60 M10-1.25 x 330 M961-10025-60 M10-1.25 x 25 M7985A-05012-20 M5-0.80 x 12
M933-10025-82 M10-1.50 x 25* M7985A-05016-20 M5-0.80 x 16
M931-12045-60 M12-1.75 x 45 M961-10030-60 M10-1.25 x 30 M7985A-05020-20 M5-0.80 x 20
M960-12050-60 M12-1.25 x 50 M933-10030-60 M10-1.50 x 30 M7985A-05025-20 M5-0.80 x 25
M960-12050-82 M12-1.25 x 50* M933-10030-82 M10-1.50 x 30* M7985A-05030-20 M5-0.80 x 30
M931-12050-60 M12-1.75 x 50 M961-10035-60 M10-1.25 x 35 M7985A-05080-20 M5-0.80 x 80
M931-12050-82 M12-1.75 x 50* M933-10035-60 M10-1.50 x 35 M7985A-05100-20 M5-0.80 x 100
M931-12055-60 M12-1.75 x 55 M933-10035-82 M10-1.50 x 35*
M931-12060-60 M12-1.75 x 60 M961-10040-60 M10-1.25 x 40 M7985A-06100-20 M6-1.00 x 100
M931-12060-82 M12-1.75 x 60*
M931-12065-60 M12-1.75 x 65 Flat Head Machine Screws
M931-12075-60 M12-1.75 x 75
M931-12080-60 M12-1.75 x 80 M965A-04012-SS M4-0.70 x 12
M931-12090-60 M12-1.75 x 90 M965A-05012-SS M5-0.80 x 12
M931-12100-60 M12-1.75 x 100 M965A-05016-20 M5-0.80 x 16
M931-12110-60 M12-1.75 x 110 M965A-06012-20 M6-1.00 x 12
* This metric hex bolt’s hardness is grade 10.9.

Metric, continued
Part No. Dimensions Type
Hex Nuts
M934-03-50 M3-0.50 Standard
M934-04-50 M4-0.70 Standard
M934-04-B M4-0.70 Brass
M934-05-50 M5-0.80 Standard
M934-06-60 M6-1.00 Standard
M934-06-64 M6-1.00 Std. (green)
M6923-06-80 M6-1.00 Spiralock
M982-06-80 M6-1.00 Elastic Stop
M934-08-60 M8-1.25 Standard
M6923-08-80 M8-1.25 Spiralock
M934-10-60 M10-1.50 Standard
M934-10-60F M10-1.25 Standard
M6923-10-80 M10-1.50 Spiralock
M6923-10-62 M10-1.50 Spiralock[
M934-12-60 M12-1.75 Standard
M934-12-60F M12-1.25 Standard
M6923-12-80 M12-1.75 Spiralock
M6923-16-80 M16-2.00 Spiralock
M934-18-80 M18-2.5 Standard
M934-20-80 M20-2.50 Standard
M934-22-60 M22-2.50 Standard
M934-24-80 M24-3.00 Standard
M934-30-80 M30-3.50 Standard
Washers
Bolt/
Part No. ID OD Thick. Screw
M125A-03-80 3.2 7.0 0.5 M3
M125A-04-80 4.3 9.0 0.8 M4
M125A-05-80 5.3 10.0 1.0 M5
M125A-06-80 6.4 12.0 1.6 M6
M125A-08-80 8.4 16.0 1.6 M8
M125A-10-80 10.5 20.0 2.0 M10
M125A-12-80 13.0 24.0 2.5 M12
M125A-14-80 15.0 28.0 2.5 M14
M125A-16-80 17.0 30.0 3.0 M16
M125A-18-80 19.0 34.0 3.0 M18
M125A-20-80 21.0 37.0 3.0 M20
M125A-24-80 25.0 44.0 4.0 M24
[ This metric hex nut’s hardness is grade 8.

Appendix F Controller Parameters (SiteTech)
The following table lists controller parameters that can Parameters are factoy-set according to the generator
be viewed and adjusted using Kohlerr SiteTecht set model. Use SiteTech to change settings if necessary
software. The Access column in the table shows which during service or after controller replacement.
parameters can only be viewed (Read or Locked), and
which parameters can be changed using the software
(Write).
Adjustment Default
Group Parameter Access Units Range Setting
Identity Vendor Read — Kohler
Company
Product Read — RDC (38)
Firmware Version Read — —
Engine Metering Engine Speed Read R/min — —
Engine Target Speed Read R/min — —
Engine Oil Pressure Read kPa — —
Battery Voltage Read V — —
Lube Oil Temperature Read _C — —
Genset Controller Read _C — —
Temperature
Engine Low Oil Pressure Read — Off (0)
Switch
Engine Speed Governor Engine Speed Write 0--99 50
Adjustment
Engine Speed Gain Write 0--99 50
Adjustment
Generator Metering Generator Voltage L1-L2 Read V — —
Generator Frequency Read Hz — —
Generator Metering Read — —
Firmware Version
Genset Info Genset Model Number Write — *
Genset Serial Number Write — *
Alternator Part Number Write — *
Engine Part Number Write — *
Engine Model Number Write — *
Engine Serial Number Write — *
Genset State Read — Off (0)
Genset Run Time Genset Controller Total Read h — —
Operation Time
Engine Total Run Time Read h — —
Engine Total Run Time Read h — —
Loaded
Engine Total Number Of Read — —
Starts
Genset Personality Profile Engine Number Of Locked — —
Flywheel Teeth
Engine Cooled Down Locked _C — 65
Temperature
Engine Crank Disconnect Read R/min — —
Speed
Engine Run Speed Locked R/min — —
* Factory set. Enter these numbers on a new controller after controller replacement.

Adjustment Default
Genset System Configuration Genset System Voltage Write V 110--600 *
Genset System Write Hz 50/60 60
Frequency
Genset Voltage Phase Write 0--3 *
Connection
Genset System Battery Locked V 12/24 12
Voltage
Measurement System Write English (0) English (0)
Metric (1)
Voltage Regulator Voltage Regulator Write V 108--660 *
Average Voltage
Adjustment
Voltage Regulator Volts Write % 1--10 5
Per Hertz Slope
Voltage Regulator Volts Write Hz 42--62 57.5
Per Hertz Cut In
Frequency
Voltage Regulator Gain Write 1--255 128
Voltage Regulator Read — —
Firmware Version
Engine Timing Engine Start Delay Write s 0--300 0
Engine Cool Down Delay Write s 0--600 300
Engine Crank On Delay Write s 10--30 15
Engine Crank Pause Write s 1--60 15
Delay
Engine Number Of Crank Write 1--6 3
Cycles
Genset Protection After Crank Disconnect Read s — 30
Fault Inhibit Delay
Genset Low Battery Read s — 90
Voltage Warning Delay
Genset High Battery Read s — 10
Voltage Warning Delay
Genset Low Battery Write % 80--105 100
Voltage Warning Limit
Genset High Battery Write % 110--135 125
Voltage Warning Limit
Genset Battery Low Read s — 6
Cranking Voltage
Warning Delay
Genset Battery Low Read % — 60
Cranking Voltage
Warning Limit
* Factory set. Enter these numbers on a new controller after controller replacement.

Adjustment Default
Engine Protection Engine High Oil Read s — 5
Temperature Shutdown
Delay
Engine Low Oil Pressure Read s — 5
Shutdown Delay
Engine Locked Rotor Write s 1--5 5
Shutdown Delay
Genset Low Engine Write % 75--95 85
Speed Shutdown Limit
Genset High Engine Write % 105--120 115
Speed Shutdown Limit
Generator Protection Loss Of AC Sensing Read s — 3
Shutdown Delay
Genset Low Voltage Write s 5--30 10
Shutdown Delay
Genset High Voltage Write s 2--10 2
Shutdown Delay
Genset Low Voltage Write % 70--95 80
Shutdown Limit
Genset High Voltage Write % 105--135 120
Shutdown Limit
Genset Short Term Low Read s — 10
Frequency Shutdown
Delay
Genset Long Term Low Read s — 60
Frequency Shutdown
Delay
Genset High Frequency Read s — 10
Shutdown Delay
Genset Low Frequency Write % 80--95 90
Shutdown Limit
Genset High Frequency Write % 102--140 110
Shutdown Limit
ATS Metering Summary ATS Contactor Position Read — —
ATS Sources Available Read — —
Source 1 Metering Source 1 Voltage L1-L2 Read V — —
Source 1 Voltage Read V — —
Average Line To Line
ATS Connection Configuration ATS Source Read — —
Source 1 System Configuration Source 1 System Voltage Write V 110--600 240
Source 1 System Write Hz 48--62 60
Frequency
Source 1 Voltage Write s 0.1--9.9 0.5
Debounce Delay
Source 1 Low Voltage Write % 85--100 90
Pickup
Dropout
Source 1 Calibration Source 1 Calibration Write 0.65--1.5 1.0
Factor Voltage L1-L2

Adjustment Default
Source 2 System Configuration Source 2 Voltage Write s 0.1--9.9 0.5
Debounce Delay
Pickup
Dropout
ATS Exercise Exercise Interval Write Weekly (5) Weekly (5)
2 Weeks (6)
Exercise Run Duration Write min 10--30 20
Exercise Mode Write Unloaded (1) Unloaded (1)
Economy (2)
Loaded (3)
ATS Delays ATS Transfer From Write s 1--10 3
Preferred Delay
ATS Transfer From Write s 1--600 120
Standby Delay
ATS Source 2 Engine Write s 1--10 3
Start Delay

KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6735 9/10 7 Jurong Pier Road
Singapore 619159
E 2010 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

14 - 20res Kohler Home Generator

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Service

Residential/Commercial Generator Sets

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

TP-6735 9/10 Table of Contents

4.5 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Table of Contents TP-6735 9/10

5.8 Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

TP-6735 9/10 Table of Contents

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

TP-6735 9/10 Safety Precautions and Instructions 7

8 Safety Precautions and Instructions TP-6735 9/10

TP-6735 9/10 Safety Precautions and Instructions 9

10 Safety Precautions and Instructions TP-6735 9/10

This manual provides troubleshooting and repair List of Related Materials

The equipment service requirements are very important

For engine service procedures not covered in this

Figure 1 Model 20RES

TP-6735 9/10 Introduction 11

For professional advice on generator set power China

12 Service Assistance TP-6735 9/10

1.1 Introduction 1.4 Engine Specifications

TP-6735 9/10 Section 1 Specifications 13

1.6 Torque Specifications

14 Section 1 Specifications TP-6735 9/10

1. Field-connection terminal block 14. Governor assembly

Figure 1-1 Generator Set Service View

TP-6735 9/10 Section 1 Specifications 15

16 Section 1 Specifications TP-6735 9/10

See the Safety Precautions and Instructions at the

Alternator Service. Under normal operating conditions

WARNING 2.1 Service Schedule

Operate the generator set only when

TP-6735 9/10 Section 2 Scheduled Maintenance 17

Figure 2-1 Service Schedule

18 Section 2 Scheduled Maintenance TP-6735 9/10

Model Oil Capacity, L (qt.)

1. Drain the oil.

g. Open the oil drain valve on the engine.

h. Remove the dipstick and oil fill cap. Allow time

i. Close the oil drain valve. Replace the cap on

j. Replace the dipstick.

2. Replace the oil filter.

a. Clean the area around the oil filter. Remove the

c. Apply a light coat of clean oil to the rubber seal

TP-6735 9/10 Section 2 Scheduled Maintenance 19

3. Fill with oil.

a. Fill the engine to the F mark on the dipstick.

b. Reinstall the dipstick and the oil fill cap.

f. Start and run the generator set for a minute to

g. Stop the generator set, wait 1 minute, and then

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

2.2.5 Oil Cooler, 14RES/RESL

20 Section 2 Scheduled Maintenance TP-6735 9/10

4. Reinstall the spark plug into the cylinder head.

1 Figure 2-7 Checking the Spark Plug Gap

Figure 2-6 Oil Cooler Location, 20RES/RESL

Figure 2-8 Adjusting the Spark Plug Gap

TP-6735 9/10 Section 2 Scheduled Maintenance 21

3. Disconnect the battery, negative (--) lead first.

5. Saturate the precleaner with new engine oil.