Professional Documents
Culture Documents
Models:
14RES/RESL
20RES/RESL
Controllers:
RDC Residential Digital Control
DC Digital Control
TP-6735 9/10
Table of Contents
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.
6735
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
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
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.
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.
1--514
1--511
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.
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.
battery, negative (--) lead last.
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.
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.
2.8 Battery
WARNING
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.
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.
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.
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.
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
* 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. See TP-6701, SiteTech Software Operation Manual.
1 1
2
3
4 5
9 9
8 8
7 7
6 6
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.
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.
Automatic Start
The RDC/DC controller receives utility source voltage
sensing data from the Model RRT transfer switch.
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.
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:
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.
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
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.
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.
Generator ATS
Set
1 2
GM66565 ADV-7598
Customer
connections
12--24 AWG
Figure 4-10 Model RRT Transfer Switch Connection to Generator Set Terminal Block
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.
DANGER TP6735
1. Roof
2. Intake panel screws (2 ea.)
3. Intake panel
1
Controller Replacement Procedure
3
GM69754
1. P1 2
2. P3
3. P2
4. 20 amp mini breaker
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
TP563273
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.
WARNING
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.
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)
Software version
number displayed
S A UE
u 2
1 . 0
OFF mode
Generator Set No
Running?
Press
Engine Configuration
Fine Voltage Adjust Adjust Setting
Adjust Adjust
1 P36 Ec 1 3
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
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
2 3
Check the stepper
motor coils.
See step 11.
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.
WARNING
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.
tp6519
1 2
(Enlarged to
show detail)
GM66563
1 6 5
2
5
2
3 8
3 4
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
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
3. Disconnect the generator set engine starting
the fuel system component locations.
battery, negative (--) lead first.
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.
1. Fuel block
2. Fuel metering valves—factory-sealed, do not adjust
3. Fuel inlet, 1/2 in. NPT
4. Hose fitting
5. Plug
Observe the following safety precautions while 8. With the generator set at normal operating
performing the procedure. temperature, apply rated load.
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
hot during operation.
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.
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
battery, negative (--) lead last.
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
259391
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
Remove enclosure 4
1
1
GM72523
1
1
GM72523
2 1. Disconnect latch rods
ADV-7876
GM72523
1. Remove 2 screws
GM72523
1. Remove 2 screws
GM51561
1
1. Engine support
4
TP-6735
1. Exhaust flanges (qty. 2) 3
2. Muffler
3. Alternator vibromounts (qty. 2)
4. Engine vibromounts (qty. 2)
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.
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.
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
GM67344
3 1. Alternator support bracket
3
3 4
2
1 1. End bracket
2. Alternator
3. Alternator frame vibromount
4. Overbolts
3
2
TP-6735
1. Alternator overbolts (qty. 4)
2. Alternator vibromounts (qty. 2)
3. Engine vibromounts (qty. 2)
3 GM67344
Correct Incorrect
New 19.0 mm (0.75 in.) 8 9
3 2 2
Side View
TP5867
TP-6735
1 1. Alternator duct
2. Exhaust duct panels
2
Figure 6-24 Alternator and Exhaust Ducts
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
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:
3 2
1
3
G-585
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
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.
Drive Styles
External Tooth Lock
Hex
Internal Tooth Lock
Hex and Slotted
Internal-External Tooth Lock
Phillipsr
Slotted
Hex Socket
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
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
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
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.