Kohler 12RES, Service Manual

Page 1: ...Residential Commercial Generator Sets Models 8 5RES 12RES Controller Advanced Digital Control TP 6196 5 04 Service ...

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Page 3: ...9 2 4 Air Cleaner Element and Precleaner 9 2 5 Cooling System 11 2 6 Exhaust System 11 2 7 Battery 11 2 7 1 Cleaning the Battery 12 2 7 2 Battery Charger 12 2 8 Storage Procedure 12 2 8 1 Lubricating System 12 2 8 2 Fuel System 12 2 8 3 Internal Engine Components Gas Gasoline Fueled Engines 13 2 8 4 Exterior 13 2 8 5 Battery 13 Section 3 Troubleshooting 15 3 1 Introduction 15 3 2 Inital Checks 15 ...

Page 4: ...onnections 46 5 8 Governor System 47 5 8 1 Operation 47 5 8 2 Initial Checks and Operation Test 47 5 8 3 Hunting Surging 47 5 8 4 Governor System Magnetic Pickup Operation Test 48 5 8 5 Frequency Adjustment 50 5 9 Fault Shutdown Tests 51 5 9 1 Controller Fault Shutdown Functions 52 5 9 2 Fault Shutdown Switches 53 5 10 Fuel Systems 54 5 10 1 Gas Piping 54 5 10 2 Fuel Solenoid Valve 54 5 10 3 Fuel ...

Page 5: ...econnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin WARNING Explosio...

Page 6: ... where exhaust gas could seep inside or be drawn into a building through windows air intake vents or other openings Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxideisapoisonousgaspresentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following D Light headedness dizziness D Physical fatigue weakness in joints ...

Page 7: ...electrical circuitstocomplywithapplicablecodes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Discon...

Page 8: ...iles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from thegeneratorsetengineandcancause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen thecrankshaft hardwareorrotorthrubolt whenmaking adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft b...

Page 9: ...ration and service For engine service procedures not covered in this manual refer to the Engine Service Manual TP 2428 List of Related Materials Separate manuals contain operation installation and parts information not provided in this manual separate engine Operation and Service manuals are also available The following table lists the available manual part numbers Document Description Part Number...

Page 10: ...rs Europe Middle East Africa EMEA Kohler Power Systems ZI Senia 122 12 rue des Hauts Flouviers 94517 Thiais Cedex France Phone 33 1 41 735500 Fax 33 1 41 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 E...

Page 11: ...nce free electronic ignition D Digital Spark Advance Module DSAM optimizes engine timing for natural gas or LP fuel 12RES only D Parts subject to the most wear and tear made from precision formulated cast iron D Hydraulic valve adjusters to eliminate the need for valve adjustments D Field convertible fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintain...

Page 12: ...al Aluminum w cast iron liners Cylinder head material Aluminum Piston rings 2 compression 1 oil Crankshaft material Heat treated ductile iron Main bearings number type 2 parent material Governor Electronic Lubrication system Full pressure Oil capacity w filter L qt 1 9 2 0 2 2 1 Oil pressure kPa psi 172 241 25 35 Fuel system LP gas or natural gas LP natural gas minimum supply pressure in H2O oz in...

Page 13: ... 0 14 55 66 0 70 Stator output voltage with separately excited rotor using 12 volt battery minimum Leads 1 2 3 4 132V 11 44 264V 55 66 145V Rotor field voltage current readings at rated output voltage hot No load 12V 2 0 amps Full load 47V 7 4 amps Brush length new 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 lo...

Page 14: ...ke 13 Engine starting battery location 14 Oil drain hose 15 High engine temperature HET sensor located on non service side 16 Oil drain valve 17 Oil filter 18 Air intake alternator 19 Exhaust 20 Spark arrestor not visible in this view 21 Relay interface board RIB 22 SCR module 23 Digital spark advance module leads DSAM leads ignition timing 24 Multi fuel block 25 Secondary fuel regulator assembly ...

Page 15: ...ealer perform generator set service Alternator Service Under normal operating conditions the generator set alternator does not require scheduled service Refer to the service schedule for items that require maintenance Engine Service Perform generator set engine service at the intervals specified by the engine service literature Contact an authorized Kohlerr service distributor dealer to obtain eng...

Page 16: ...ighten control and power wiring connections X Yearly Wire cable insulation breakdown X 3 Years or 500 Hrs Engine and Mounting General inspection E E Weekly Air cleaner and precleaner service 2 4 X X Yearly or 100 Hrs Spark plugs 2 3 X Yearly Replace spark plugs 2 3 E R E 500 Hrs Stepper motor coupling and bushing 5 8 R 3 Years or 500 Hrs Generator Compartment condition X X Weekly Inspect brushes a...

Page 17: ...the oil level regularly and add oil as needed to protect against running out of oil See Figure 2 2 for the dipstick and oil fill locations Do not check the oil level when the generator set is running Shut down the generator set and wait several minutes before checking the oil level 2 2 3 Engine Oil Recommendation Use synthetic oil of API American Petroleum Institute Service Class SG or higher Synt...

Page 18: ... hose in its retaining clip 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Apply a light coat of clean oil to the rubber seal of the new oil filter c Install the new oil filter following the instructions provided with the filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner 3 Fill with ...

Page 19: ...er Element and Precleaner The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 2 7 Refer to Section 1 8 Service View for the air cleaner location Wash and oil the precleaner and replace the paper element at the intervals shown in the service schedule Figure 2 1 Service the air cleaner more often if the generator set operates under dusty or di...

Page 20: ...l 4 Replace the paper element if it is dirty bent or damaged Note Do not wash the paper element or clean it with compressed air as both will damage the element 5 Reinstall the air cleaner a Install the precleaner over the paper element b Check the air cleaner base Make sure it is secure and not bent or damaged Remove any dirt or debris from the air cleaner base Wipe the base carefully so that no d...

Page 21: ... skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the batter...

Page 22: ...aintain tight dry electrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water Do not allow the cleaning solution to enter the battery s cells After cleaning flush the battery and cables with clean water and wipe them w...

Page 23: ...gine two or three revolutions to lubricate the cylinders 2 8 4 Exterior Prepare the exterior for storage as follows 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electr...

Page 24: ...TP 6196 5 04 14 Section 2 Scheduled Maintenance Notes ...

Page 25: ...s protect the controller SCR module and relay interface board A battery charger fuse is located in the positive battery lead Always check and replace the fuses before replacing other components D Incorrect controller settings Always check the controller configuration settings before replacing the controller Section 4 5 contains the instructions for checking and changing the controller configuratio...

Page 26: ...heck the continuity of leads FP and FN and the leads from the P14 connector Replace any bad leads Use a pin pusher part 241918 large or 241919 small to remove leads from the connector if necessary If replacing the leads does not solve the problem replace the RIB Section 7 ADV 6835 Section 4 8 Crank relay on relay interface board RIB Check connections to the RIB Check for 12VDC to the RIB on lead 7...

Page 27: ...ection 4 5 Ignition system spark control or ignition coil Test and or replace components Engine S M Digital spark advance module DSAM connections 12RES only Connect for natural gas Disconnect for LP Check for loose connections Section 5 10 5 No engine rotation sensed check for an overcrank fault shutdown Check mag pickup connections mag pickup gap and operation Section 5 8 4 Check for locked rotor...

Page 28: ... 1 Section 5 9 2 Fuel valve fuel regulator Check regulator valve operation Section 2 Section 6 Engine overloaded Reduce electrical load Section 1 2 Loss of generator output voltage to controller Check connections at P15 plug Check continuity of AC sensing leads 11 and 44 Section 7 Magnetic pickup connections Check for loose connections to the mag pickup Section 5 8 Ignition module Test and or repl...

Page 29: ...ure may void the emission certification Section 5 10 Low output Generator overloaded Reduce load Section 1 2 p or excessive drop in Incorrect controller configuration Check and adjust the controller configuration parameters Section 4 5 drop in voltage Incorrect controller voltage settings Check and adjust the controller voltage settings Section 4 5 3 Alternator or control system Perform separate e...

Page 30: ...winding fuse blown lead 55 Replace blown fuse If fuse blows again check stator Section 5 3 SCR module Check auxiliary winding fuse F1 lead 55 Replace SCR module and test voltage Section 5 11 Section 4 9 Controller Check controller settings Check wiring and connections Before replacing controller replace SCR module and check voltage Section 4 5 Section 4 10 Open wiring terminal or pin in buildup ci...

Page 31: ...and faults are described in Section 4 4 Controller configuration and adjustment are covered in Section 4 5 A silicon controlled rectifier SCR module works with the controller to regulate the output voltage See Section 4 9 A relay interface board RIB is used with the ADC controller Section 4 8 describes the standard and optional RIBs 1 GM29253 1 Controller 2 SCR module 3 Ground stud 4 L0 stud 5 Rel...

Page 32: ...e for setup and adjustment only 3 Upanddownarrowbuttons useforsetupandadjustmentonly 4 Generator set master switch GM28707A C Figure 4 2 ADC Controller Controller Display Item Description Crank indication Displays CC_1 CC_2 or CC_3 to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Runtime hours Displays total generator set ...

Page 33: ...ranking cycle is programmed into the controller s application code and is not adjustable in the field The factory sets the cranking cycle for three cycles of 15 seconds on time and 15 seconds off time If the cranking cycle seems shorter than the factory setting check the engine starting battery 4 3 2 Starting Sequence Remote Start When the master switch is set to the AUTO position the generator se...

Page 34: ...s displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than one minute when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Check the battery rating and condition Check the...

Page 35: ... is detected Check mag pickup connections and operation Check for a locked rotor 5 8 4 5 4 OF Overfrequency Shutdown occurs when the governed frequency exceeds 110 of the system s frequency i f h d Thi Check system frequency setting parameter UU on controller 4 5 0 y q y setpoint for more than 5 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Measure output f...

Page 36: ...ges unless the controller is replaced The controller s advanced configuration mode allows the user to set the data input type for engine senders toggle the battery voltage between 12 and 24 volts and change the controller communications setting for optional meters not offered for standby models Check these settings after controller replacement and change them if necessary to match the settings sho...

Page 37: ... the ADC controller to adjust the output voltage and engine speed frequency Voltage and or frequency adjustments may be required after controller replacement or other service procedures The generator set must be running during these adjustments Use a multimeter to measure the generator set output voltage and frequency during adjustments Refer to Sections 5 7 2 Voltage Adjustment and 5 8 5 Frequenc...

Page 38: ...4 0 A d n c Press Now release the Select button or To enter advanced configuration mode Go to Figure 4 8 or To proceed to the save mode without entering the advanced configuration mode Go to Figure 4 9 Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communications Press S A V E E d 0 5 E c 0 5 Shaded boxes show which number i...

Page 39: ...save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Figure 4 8 Advanced Configuration Mode engine data input types battery voltage and engine communications To save changes To discard changes without saving or X in the runtime hours display above denotes any number from 0 to 9 S A V E Y...

Page 40: ... or lower the voltage stability gain in smaller increments To enter volts Hz adjustment mode To raise or lower the volts Hz 00 low 09 high or Hold Wait about 5 seconds until the display changes from runtime hours to the program version number Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password x x x x x x 1 P 1 P 2 P Shaded boxes ...

Page 41: ...ne adjustment mode To raise or lower the engine governor stability gain in smaller increments 4 P 4 P or or or Continued from Figure 4 10 Press 5 P 5 P Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model S A V E To enter SAVE mode Go to Figure 4 12 x x x x x x x...

Page 42: ...rst Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical ...

Page 43: ...ontroller s back cover to access the jumper a Note the labels on the three leads connected to the generator set master switch for reconnection later Disconnect the leads at the pink connectors See Figure 4 13 b Remove the cover screws and remove the controller s back cover See Figure 4 13 4 Locate the P7 connector near the top of the controller See Figure 4 13 Remove the jumper from pins 1 and 2 o...

Page 44: ...4 and the brush leads FP and FN 2 Pull the board straight off the mounting stand offs 3 Snap the new board onto the stand offs and reconnect P14 and the brush leads The generator set may be equipped with an optional RIB which contains the K4 auxiliary run relay and K1 common fault relay in addition to the standard relays The optional relay board kit includes a wiring harness for connection of cust...

Page 45: ...st lamp or voltmeter D 12 volt DC power source D 100 500 ohm resistor D Jumper 1 Set the ohmmeter to the RX1 scale 2 Connect the ohmmeter from to on the SCR module You should read high resistance in one direction and low resistance in the other reverse the leads GM28483 G1 G2 AC2 AC1 Figure 4 16 Silicon Controlled Rectifier SCR Module 3 Connect the ohmmeter from AC1 to on the SCR module You should...

Page 46: ...ller s configuration settings match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings Refer to Section 4 5 for instructions to check the controller configuration and to change the settings if necessary After the controller configuration has been checked and set to match the generator set use a voltmeter...

Page 47: ...igure 4 20 d Loosen and remove four controller mounting screws at the front of the controller See Figure 4 21 Remove the controller from the compartment e Place the new controller into position and install the four mounting screws f Attach connectors P1 P15 and P16 to the new controller g Replace the cover on the controller compartment h Replace the front panel on the air intake end of the enclosu...

Page 48: ...ry charger 11 Replace the roof and tighten the four roof screws 12 Follow the instructions in Section 4 5 2 to change the new controller s configuration settings to match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings 13 Use a voltmeter to check the output voltage Follow the instructions in Sections ...

Page 49: ...rforming the separate excitation procedure The inline fuse is located in lead 55 of the wiring harness See Figure 5 1 If the fuse is not blown use the following procedure to separately excite the generator using an external voltage source a 12 volt automotive battery Separately exciting the generator can identify faulty voltage regulation by the ADC controller or reveal a running fault in the roto...

Page 50: ...negative FN brush leads as shown in Figure 5 3 Note and record the ammeter reading Note The approximate ammeter reading should be the battery voltage divided by the specified rotor resistance See Section 1 Specifications for specified rotor resistance values Example 12 volts battery voltage 4 ohms rotor resistance 3 amps rotor current 3 Start the engine and check that the ammeter reading remains s...

Page 51: ...ttery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Disconnect all stator leads before performing all stator tests 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...

Page 52: ...nating current in the stator windings Before testing inspect the rotor for visible damage to pole shoes insulation exposed coil windings and slip ring surfaces Rotate the bearing to check for wear heat discoloration or noise 5 4 1 Rotor Continuity and Resistance Tests Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in ...

Page 53: ...roximate Take readings at room temperature 2 221 R13929 7 Figure 5 7 Rotor Resistance Check 6 Perform a megohmmeter test to determine whether the rotor is shorted to ground a Raise and secure the brushes away from the slip rings by inserting a retaining wire in the brush holder hole b Using a megohmmeter apply 500 volts DC to one rotor slip ring and the rotor poles or shaft Follow the instructions...

Page 54: ...r Weak springs damaged slip rings sticking 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 When correctly positioned spring pressure on the brush surface causes the brush to wear evenly The entire brush must ride on the ring or arcing occurs and causes burned rings or volta...

Page 55: ... to normal 60 Hz or 50 Hz as load is accepted the generator output also returns to normal Hazardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving rotor WARNING Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact ...

Page 56: ... to the operating frequency 50 or 60 Hz by adjusting the engine governor speed parameter 4P through the ADC controller 9 Readjust the voltage gain parameter 2P until the light flicker minimizes if necessary 10 Check the voltage Readjust the voltage parameter 1P if necessary 11 Save the settings Refer to Section 4 5 for instructions Note The controller will revert to the previous settings at the ne...

Page 57: ... and tight D Check the magnetic pickup connections Poor connections may cause an erratic signal or an overspeed condition An erratic signal causes the generator set to govern poorly but not shut down D Verify that the battery connections are clean and tight D Check for dirt buildup on the magnetic pickup Metal filings or caked on dirt or grease decreases the output signal of the magnetic pickup D ...

Page 58: ...put is probably missing The engine starts and then shuts down on an overspeed fault Proceed to step 4 to check the magnetic pickup b If the throttle linkage moves erratically or not at all at startup proceed to step 7 to check the stepper motor 4 Verify the operation of the magnetic pickup by connecting a voltmeter to the magnetic pickup leads See Figure 5 13 If the air gap is correct the voltage ...

Page 59: ... items in step 2 Check stepper motor operation at startup Does it move to fully open and then move to and stay in the fully closed position See step 3 Check the magnetic pickup See steps 4 6 Check the stepper motor coils See step 11 Yes No Disconnect the magnetic pickup and check the stepper motor operation again See steps 7 9 Troubleshoot the ADC controller See step 12 Check the magnetic pickup c...

Page 60: ... PIN 2 YEL PIN 5 GRN not used PIN 4 RED PIN 1 WHT PIN 6 BLUE not used SB555 Figure 5 16 Actuator Coil Group 5 8 5 Frequency Adjustment The engine speed determines the generator output frequency 60 Hz units operate at 3600 rpm and 50 Hz units run at 3000 rpm Adjust the engine governor to change the output frequency using the following procedure Note Engine governor speed frequency and gain adjustme...

Page 61: ...en investigating a shutdown problem See Section 5 9 1 for the overspeed shutdown test procedure 5 9 Fault Shutdown Tests Verify the operation of the generator set overspeed overcrank and low oil pressure shutdowns by performing the following tests If these tests are inconclusive test individual shutdown circuit components wiring harness switch etc as described elsewhere in this section Hazardous v...

Page 62: ...the engine speed parameter 4P to at least 115 of the rated engine speed 69 Hz on 60 Hz models or 58 Hz on 50 Hz models Verify that the generator set shuts down on an overspeed fault OS If the overspeed shutdown does not operate the generator set should shut down on an overfrequency fault OF after approximately 5 seconds If the controller does not indicate an overspeed fault OS check the wiring to ...

Page 63: ...e Views for the coolant temperature sensor location Set the generator set master switch to the OFF position 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 17 If the resistance is very low indicated a short circuit or very high indic...

Page 64: ...he end of the pipe where it connects to the fuel inlet of the generator set Add 2 4 m 8 ft for each bend in the pipe Compare the total length with the chart in Figure 5 19 If the piping is longer than the maximum length shown in the chart replace it with a larger pipe size Bleed the air from the gas lines after installation Figure 5 20 lists the maximum gas flow rates for each model 8 5RES 12RES P...

Page 65: ... Fuel Conversion The multi fuel system allows conversion from natural gas to LP vapor or vice versa in the field while maintaining emissions standard compliance A trained technician or authorized distributor dealer can convert the fuel system Two fuel connections on the fuel block allow field conversion between natural gas and LP vapor The fuel metering valves are factory set and sealed to comply ...

Page 66: ...ck See Figure 5 21 6 Remove the hose fitting from the natural gas outlet port in the fuel block See Figure 5 21 7 Remove the plug from the LP port in the fuel block See Figure 5 21 Clean the plug with a dry cloth or brush apply fresh pipe sealant and install the plug into the natural gas outlet port 8 Clean the hose fitting with a dry cloth or brush apply fresh pipe sealant to the threads and inst...

Page 67: ...sealed block with the new part Refer to the generator set Parts Catalog for the fuel block part number Only trained authorized service technicians may adjust the fuel metering valves The adjustment procedure requires a digital volt meter DVM UEGO oxygen sensor service kit GM29385 and a load bank capable of the rated kW for the fuel being used Always use an oxygen sensor when adjusting the fuel met...

Page 68: ... Place the generator set master switch in the OFF position 13 Disconnect the generator set engine starting battery negative lead first 14 Allow the generator set exhaust system to cool 15 Disconnect the DVM leads from the oxygen sensor 16 Remove the oxygen sensor from the exhaust manifold 17 Apply a small amount of antiseize compound to exhaust plug and reinstall the plug into the exhaust manifold...

Page 69: ...ause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment To further check generator set components disconnect the battery and remove wiring harness plugs from the controller circuit board Use an ohmmeter to check the continuity of the components listed in Figure 5 29 ...

Page 70: ... P16 6 stator leads 55 and 66 R x 1 OFF RESET Zero ohms continuity If no continuity check fuse F1 and wiring Controller fuse and wiring P1 24 and battery positive R x 100 OFF RESET Zero ohms continuity If no continuity is found check fuse F3 and wiring Auxiliary winding fuse 20 amp fuse P16 3 and stator lead 55 R x 100 OFF RESET Zero ohms continuity If no continuity is found check for an open circ...

Page 71: ... from service and remove the generator set enclosure a Remove the enclosure service side door See Figure 6 1 b Place the generator set master switch in the OFF position c Remove 4 roof screws Lift the roof up and off See Figure 6 1 d Remove 5 screws to remove the front panel Remove the plastic caps to access the 2 side screws See Figure 6 2 e Disconnect power to the battery charger f Disconnect th...

Page 72: ...e the locations of the alternator lead connections for reconnection later See Figure 6 4 a Disconnect alternator leads 1 and 4 from the line circuit breaker b Disconnect alternator leads 2 and 3 from the load connection terminal L0 c Disconnect brush leads FP and FN and stator leads 55 and 66 from the SCR module d Disconnect the 3 pin plug P15 from the mating connector on the ADC controller 1 GM29...

Page 73: ...s securing the alternator air inlet duct to the base and remove the duct 5 Remove the alternator end bracket a Remove the nuts securing the alternator end vibromount mounting plate to the skid See Figure 6 7 b Raise the alternator end of the generator set enough to place a thin block of wood beneath the rear of the engine See Figure 6 8 ADV 6823 1 1 Engine exhaust muffler 2 Muffler bolts 3 Heat sh...

Page 74: ... bracket from the convoluted conduit leading to the controller Set the end bracket assembly aside GM29253B P 4 5 2 3 2 2 2 1 1 1 Brush cover screws 2 Overbolt and centering washer 3 Brush holder 4 Brush retainer wire hole 5 Thrubolt 6 Alternator mounting plate Figure 6 9 Alternator End Bracket 6 Check the brushes a Remove the brush holder from the end bracket See Figure 6 9 b Inspect the brushes R...

Page 75: ... 1 Reinstall the generator adapter onto the engine a Attach the generator adapter and alternator adapter guard to the engine using four 7 16 14 x 1 0 hex cap bolts and washers See Figure 6 12 b Torque the bolts to 40 Nm 28 ft lb 2 Install the rotor See Figure 6 11 a Apply a small amount of antisieze compound to the end of the engine crankshaft for rotor assembly installation b Install the rotor on...

Page 76: ...t in step 3a See Figure 6 14 e Thread the four overbolts with locating washers through the end bracket and into the generator adapter Position the locating tab of each washer to the outer edge of the oblong OBROUND hole on the end bracket See Figure 6 15 The overbolts should be parallel to the outside of the alternator If the overbolts are slanted rotate the locating washer 1 2 turn Do not final t...

Page 77: ...Install the brush holder onto the end bracket Verify that the brushes are not sticking in the holder 1 GM29253B P 1 OBROUND holes for overbolts 4 1 Figure 6 15 End Bracket b 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 17 See Section 5 6 Brushes for more informati...

Page 78: ...tor exhaust support using M8 hardware 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 with M8 hardware d Torque the nuts securing the engine muffler flange to the engine to 24 Nm 216 in lb ADV 6823 1 1 Engine exhaust muffler 2 Muffler bolts 3 Heat shield 4 Flange conn...

Page 79: ...sassembly instrructions a Install the non service side housing panel b Install the alternator end housing panel c Install the generator set housing roof 12 Return the generator set to operation a Check that the generator set master switch is in the OFF position b Reconnect the generator set engine starting battery negative lead last c Reconnect power to the battery charger if equipped 13 Turn on t...

Page 80: ...TP 6196 5 04 70 Section 6 Disassembly Reassembly Notes ...

Page 81: ...the updated reprint or in other cases when the manual is a suitable substitute for a manual under development Model No Spec No 8 5RES GM29253 GA1 GM29253 GA3 12RES GM29253 GA2 GM29253 GA4 Figure 7 1 Generator Set Specification Numbers 7 2 Controller Wiring Diagram Reference Figure 7 2 lists the wiring diagram numbers and locations Wiring Diagram Description Drawing Number Figure Schematic Diagram ...

Page 82: ...TP 6196 5 04 72 Section 7 Diagrams and Drawings Figure 7 3 8 5 12RES Schematic Diagram Single Phase Sheet 1 ADV 6835A E ...

Page 83: ...TP 6196 5 04 73 Section 7 Diagrams and Drawings Figure 7 4 8 5 12RES Schematic Diagram Single Phase Sheet 2 ADV 6835B E ...

Page 84: ...TP 6196 5 04 74 Section 7 Diagrams and Drawings Figure 7 5 8 5 12RES Point to Point Wiring Diagram Single Phase GM29358 D ...

Page 85: ...rmer Cu copper cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO dual inlet end outlet DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss DIP dual inline package DPDT double p...

Page 86: ...ion optional OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phillips head crimptite screw PHH Phillips hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts ...

Page 87: ...op of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a...

Page 88: ... 0 32 68 0 50 95 0 70 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 ...

Page 89: ...nal External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krome Co Phillipsr screw is a registered trademark of Phillips Screw Company Sample Dimensions 1 4 20 x 1 Major Thread Diameter In Fractional Inches Or Screw Number Size Length In Inches Screws and Bolts...

Page 90: ...24 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 129 2...

Page 91: ... 50 x 25 M961 10030 60 M10 1 25 x 30 M933 10030 60 M10 1 50 x 30 M933 10030 82 M10 1 50 x 30 M961 10035 60 M10 1 25 x 35 M933 10035 60 M10 1 50 x 35 M933 12016 60 M12 1 75 x 16 M933 12020 60 M12 1 75 x 20 M933 12025 60 M12 1 75 x 25 M933 12025 82 M12 1 75 x 25 M961 12030 60 M12 1 25 x 30 M933 12030 60 M12 1 75 x 30 M933 12035 60 M12 1 75 x 35 M961 12040 82 M12 1 25 x 40 M933 12040 60 M12 1 75 x 40...

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Page 96: ... Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455 ...