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Kohler Power Systems 8RESV User Manual

Kohler Power Systems 8RESV
140 pages
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Residential/Commercial Generator Sets
Models:
8RESV/RESVL
10RESV/RESVL
12RESV/RESVL
Controllers:
RDC2 Controller
DC2 Controller
TP-6881 7/15a
Service

Table of Contents

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Kohler Power Systems 8RESV Specifications

General IconGeneral
Model8RESV
TypePortable Generator
Rated Power8 kW
AC Rated Output (Watts)8000 W
AC Maximum Output (Watts)10000 W
Fuel TypeGasoline
Voltage120/240 V
Frequency60 Hz
Starting MethodElectric
Noise Level72 dBA
Starting SystemElectric

Summary

Introduction

List of Related Materials

Lists manuals and documents related to the generator set, including spec sheets, installation, and operation manuals.

Service Assistance

Regional Offices

Contact information for Kohler Power Systems regional offices in EMEA, Asia Pacific, China, India, Japan, and Latin America.

Section 1 Specifications

1.1 Introduction

Overview of generator set specifications, nameplate data, and related documentation.

1.2 Controller Specifications

Details on RDC2 and DC2 controller features, requirements, and environmental specifications.

1.3 Engine Service

Information on the types of Kohler engines used in the generator sets.

1.4 Engine Specifications

Technical specifications for the 8RESV(L) and 10/12RESV(L) generator set engines.

1.5 Alternator Specifications

Technical specifications for the generator set alternators, including electrical and physical data.

1.6 Torque Specifications

Torque values for various fasteners used in the generator set assembly.

1.7 Service View

Labeled diagrams showing generator set components and their locations for service.

Section 2 Scheduled Maintenance

2.1 Service Schedule

A comprehensive table detailing maintenance tasks, frequency, and corresponding manual sections.

2.2 Lubrication System

Procedures and recommendations for checking oil levels, oil changes, and engine oil type.

2.3 Spark Plugs

Procedures for inspecting, adjusting gap, and replacing spark plugs.

2.4 Air Cleaner Service

Procedures for servicing the replaceable paper air cleaner element for all models.

2.5 Cooling System

Information on the generator set's cooling system airflow and intake/exhaust locations.

2.6 Exhaust System

Safety precautions and maintenance related to the exhaust system, including carbon monoxide hazards.

2.7 Stepper Motor Coupling

Procedure for replacing the stepper motor coupling and bushings.

2.8 Fuel System Maintenance

Safety precautions and maintenance procedures for the generator set's fuel system.

2.9 Battery

Safety precautions and procedures for battery maintenance, including electrolyte level and specific gravity.

2.10 Storage Procedure

Steps for preparing the generator set for storage, covering lubrication, fuel, cylinder, exterior, and battery.

Section 3 Controller

3.1 Introduction

Introduction to the RDC2 and DC2 controllers and their functions.

3.2 SiteTech and OnCue Plus Software

Information on using PC software for controller setup, parameter changes, and firmware updates.

3.3 Controller Parameters

Overview of adjustable and non-adjustable controller parameters and how they are organized in SiteTech.

3.4 Controller Firmware

Information on obtaining and updating controller firmware versions.

3.5 Controller Replacement

Procedure for replacing a faulty controller, including required setup after installation.

3.6 Controller Setup

Procedures for setting up the controller after installation or replacement using keypad or software.

3.7 Voltage Calibration

Importance and procedures for performing voltage calibration on the controller.

3.8 Setting the OnCue Plus Password

Procedures for resetting the OnCue Plus password on RDC2 and DC2 controllers.

Section 4 Troubleshooting

4.1 Introduction

Introduction to troubleshooting procedures, required knowledge, and service personnel.

4.2 Theory of Operation, Electronic Start Sequence

Explanation of the electronic start sequence of the generator set, detailing component energization.

4.3 Initial Checks

Basic checks to perform first when troubleshooting, such as connections, battery, and fuel supply.

4.4 USB Port

Information about the controller's USB port for service and software interaction.

4.5 Circuit Protection

Explanation of line circuit breaker, auxiliary winding circuit breaker, and controller internal protection.

4.6 Thermostat Information

Information about the enclosure thermostat and procedures to reset it.

4.7 OnCue Plus Troubleshooting

Reference to the manual for troubleshooting the OnCue Plus Generator Management System.

4.8 Fuel System Troubleshooting

Troubleshooting common fuel system issues, including gas and LPG leaks.

4.9 Fault Messages

Table of fault messages, their descriptions, actions, and recommended checks for the RDC2 controller.

4.10 Status Messages

Table of status messages displayed by the controller or in SiteTech, indicating system status.

4.11 Troubleshooting Chart

A chart listing common generator set problems, possible causes, tests, corrective actions, and references.

4.12 Controller Troubleshooting

Specific troubleshooting steps for controller display, communication, and configuration issues.

Section 5 Component Testing and Adjustment

5.1 Introduction

Introduction to testing and adjusting components, and using troubleshooting in Section 4.

5.2 Theory of Operation

Explanation of how the rotating-field alternator produces AC voltage and the start sequence.

5.3 Alternator Excitation

Procedures and information for testing alternator excitation and troubleshooting low/no voltage.

5.4 Stator

Procedures for testing the stator for continuity, resistance, and shorts.

5.5 Main Field (Rotor)

Procedures for testing the rotor for continuity, resistance, and shorts.

5.6 Slip Rings

Information on the maintenance and cleaning of slip rings.

5.7 Brushes

Procedures for inspecting and replacing brushes and brush holders.

5.8 Voltage Connections

Diagram of factory wiring configurations for 120/240 Volt, 3-Wire output.

5.9 Voltage Adjustments

General information and safety precautions for adjusting generator output voltage.

5.10 Governor System

Overview of the governor system, its operation, and initial checks.

5.11 Frequency Adjustment

Procedure for adjusting the generator output frequency by changing engine speed.

5.12 Fault Shutdown Tests

Tests for overspeed, overcrank, and low oil pressure shutdowns, and controller fault functions.

5.13 Fuel Systems

Information and safety precautions for the fuel system, including solenoid valve, CDI, and regulators.

5.14 Fuel Conversion

Procedure for converting the fuel system between natural gas and LPG.

5.15 Starter and Run Relay

Location and testing procedures for the starter and run relays.

5.16 Continuity Checks

Procedures and tables for checking component continuity using an ohmmeter.

Section 6 Disassembly/Reassembly

6.1 Initial Steps

Initial steps required before disassembling the generator set, including safety and draining.

6.2 Disassembly

Detailed procedures for disassembling the generator set enclosure, electrical leads, and alternator.

6.3 Reassembly

Procedures for reassembling the generator set, including mounting plate, silencer, alternator, and enclosure.

Section 7 Drawings and Diagrams

Figure 7-2 Wiring Diagrams and Schematics

List of available wiring diagrams and schematics with corresponding page numbers.

Figure 7-3 Dimension Drawing ADV-8539, Sheet 1

Dimensional drawing of the generator set, showing overall dimensions and key features (Sheet 1).

Figure 7-4 Dimension Drawing ADV-8539, Sheet 2

Dimensional drawing of the generator set, showing internal component locations (Sheet 2).

Figure 7-5 Dimension Drawing ADV-8539, Sheet 3

Dimension drawing illustrating clearance requirements for generator set installation (Sheet 3).

Figure 7-6 Dimension Drawing ADV-8774, Sheet 1

Dimensional drawing of the generator set, showing overall dimensions and key features (Sheet 1).

Figure 7-7 Dimension Drawing ADV-8774, Sheet 2

Dimensional drawing of the generator set, showing internal component locations (Sheet 2).

Figure 7-8 Dimension Drawing ADV-8774, Sheet 3

Dimension drawing illustrating clearance requirements for generator set installation (Sheet 3).

Figure 7-9 Schematic Diagram, ADV-8552

Schematic diagram of the generator set's electrical system, showing connections and components.

Figure 7-10 Point-to-Point Wiring Diagram, GM89012

Point-to-point wiring diagram illustrating the physical routing of wires and connections.

Appendix A Abbreviations

List of Abbreviations

A comprehensive list of abbreviations used throughout the manual with their meanings.

Appendix B Common Hardware Application Guidelines

Steps for Common Hardware Application

Guidelines for identifying and applying common hardware, including bolt length and washer rules.

Appendix C General Torque Specifications

American Standard Fasteners Torque Specifications

Torque values for American Standard fasteners assembled into cast iron, steel, and aluminum.

Metric Fasteners Torque Specifications

Torque values for metric fasteners assembled into cast iron, steel, and aluminum.

Appendix D Common Hardware Identification

Screw/Bolts/Studs Head Styles

Illustrations and names for various screw, bolt, and stud head styles.

Nuts Nut Styles

Illustrations and names for various nut styles.

Washers Washer Styles

Illustrations and names for various washer styles.

Hardness Grades

Identification of American Standard and Metric hardness grades for hardware.

Sample Dimensions

Examples of sample dimensions for American Standard and Metric hardware.

Appendix E Common Hardware List

American Standard Hardware

List of part numbers and dimensions for common American Standard hardware items.

Metric Hardware

List of part numbers and dimensions for common Metric hardware items.

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