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Kohler 11RMY, Service Manual

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Industrial Generator Sets

Models:

8.5RMY

11RMY

Controllers:

Relay

TP-5867 11/02d

Service

Summary of Contents for 11RMY

Page 1: ...Industrial Generator Sets Models 8 5RMY 11RMY Controllers Relay TP 5867 11 02d Service...

Page 2: ...eadily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set...

Page 3: ...e Battery 14 2 7 2 Checking Battery Electrolyte Level 14 2 7 3 Checking Electrolyte Specific Gravity 14 2 8 Storage Procedure 15 2 8 1 Lubricating System 15 2 8 2 Fuel System 15 2 8 3 Internal Engine...

Page 4: ...uel Systems 53 6 11 1 Gas Piping 53 6 11 2 Fuel Solenoid Valve 53 6 11 3 Fuel Regulators 53 6 11 4 Fuel Conversion Single Fuel Models 54 6 11 5 Fuel Metering Valve Adjustment 54 6 11 6 Fuel Conversion...

Page 5: ...ttery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an aut...

Page 6: ...Use extreme care when handling storing and using fuels WARNING The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handli...

Page 7: ...quipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect th...

Page 8: ...nds feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replaceguards screens and covers before operating the generator set Notice NOTICE This generator...

Page 9: ...ents 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...

Page 10: ...nal office Africa Europe Middle East London Regional Office Langley Slough England Phone 44 1753 580 771 Fax 44 1753 580 036 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic...

Page 11: ...t of the field to monitor and stabilize voltage See Figure 1 1 for alternator specifications Alternator Specification 8 5 11RMY Frequency Hz 50 60 Phase Single Phase Number of leads 4 Excitation metho...

Page 12: ...e Service Manual Model Voltage Phase Hz Generator Model Standby kW kVA Nat Gas Standby kW kVA LP Gas 8 5RMY 120 240 1 60 2F4 7 0 7 0 8 5 8 5 8 5RMY 110 220 1 50 2F4 6 3 6 3 7 5 7 5 11RMY 120 240 1 60...

Page 13: ...ve Spark plug gap mm in 0 76 0 030 Spark plug tightening torque Nm ft lb 24 4 29 8 18 22 Ignition system Capacitor Discharge Smart Spark Capacitor Dis charge Starter motor cranking current at 70_ F El...

Page 14: ...il check 4 Oil drain hose 5 Oil fill 6 Spark plugs 7 Air cleaner 8 Fuel valve Do not adjust on emission certified models 9 Controller 10 Nameplate 11 Gas regulator assembly 12 Rodent screens 13 Engine...

Page 15: ...6 Spark plugs 7 Air cleaner 8 Controller 9 Nameplate 10 Multi fuel block 11 Gas regulator assembly 12 Fuel solenoid valve 13 Rodent screens 14 Engine starting battery location 15 Engine oil cooler 16...

Page 16: ...TP 5867 11 02 6 Section 1 Specifications Notes...

Page 17: ...thorized distributor dealer perform generator set service Alternator Service Under normal operating conditions the generator set alternator does not require scheduled service Refer to the service sche...

Page 18: ...on It does not protect against damage because of operating with the oil level below the safe range it is not a low oil level shutdown 2 2 2 Oil Level Check Check the oil level regularly and add oil as...

Page 19: ...peration X X Six Months Tighten control and power wiring connections X Yearly Wire cable insulation breakdown X 3 Years or 500 Hrs Engine And Mounting General inspection D Weekly Air cleaner service D...

Page 20: ...ing clip A 358000A C 1 2 3 1 Oil drain hose 2 Oil fill 3 Oil filter Figure 2 5 Engine Service Side 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter w...

Page 21: ...service schedule Service the air cleaner more often if the generator set operates under dusty or dirty conditions Refer to Maintenance and Service Parts in the Introduction section of this manual for...

Page 22: ...ith the cover retaining knob finger tighten only e Check the element cover for damage and fit Replace all damaged air cleaner components Check the condition of the rubber seals and replace them if nec...

Page 23: ...quid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any ti...

Page 24: ...olyte level before each startup Remove the filler caps and verify that the electrolyte level reaches the bottoms of the filler holes see Figure 2 12 Refill as necessary with distilled water or clean t...

Page 25: ...ure Correction 2 8 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if...

Page 26: ...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 p...

Page 27: ...c Check continuity Sections 4 Controller Troubleshooting and 9 Wiring Diagrams Defective controller circuit board Check circuit board operation Section 4 Controller Troubleshooting Overcrank shutdown...

Page 28: ...pect fuel lines suddenly Fuel lines too long Check fuel line length Section 6 11 1 Gas Piping Air cleaner clogged Replace element Section 2 4 Air Cleaner Element and Precleaner Fuse blown in controlle...

Page 29: ...leaner p Generator overloaded Reduce load O M Faulty spark plug s Replace and regap plug s Section 2 3 Spark Plugs Faulty spark plug wire s Replace spark plug wires Engine S M Engine not running at ra...

Page 30: ...tery connections Defective battery Check battery electrolyte level and specific gravity batteries with filler caps only Section 2 7 Battery High generator output voltage Engine speed too high Check en...

Page 31: ...tor set Reduce load O M No battery voltage to voltage regulator during cranking and terminals on regulator Check for DC voltage at voltage regulator terminals listed Sections 6 3 Voltage Regulator and...

Page 32: ...TP 5867 11 02 22 Section 3 Troubleshooting Notes...

Page 33: ...5 X GM16902 GA1 X GM24829 GA1 X 11RMY PA 195022 X PA 195026 X GM16902 GA2 X GM24829 GA2 X Figure 4 1 Generator Set Controllers A 358076 L GRD 68 68 67 67 FP FP FN FN 70 70 7N 7N 3 4 32 32 1 Remote sta...

Page 34: ...on during generator start run stop and fault shutdown modes Use this as a starting point for controller fault identification Use the LEDs on the controller circuit board to assist in the troubleshooti...

Page 35: ...ay schematic 8 P1 connector 9 K2 relay 10 K1 relay 11 Circuit board part number 12 LED2 13 LED5 11 Figure 4 6 Basic Controller Circuit Board 358095 13 GM10064 11 3 10 2 6 8 14 12 5 1 Overspeed adjustm...

Page 36: ...itions listed below the fault shutdown relay energizes and the corresponding LED lights The relay s normally open contacts close The normally closed relay contacts open to deenergize the K25 relay The...

Page 37: ...l coating transparent insulation from component terminals Use Figure 4 9 and the controller circuit board illustration see Figure 4 6 or Figure 4 7 The controller circuit board has light emitting diod...

Page 38: ...GM10064 1 Overspeed adjustment potentiometer R17 2 Cyclic crank potentiometers 1 2 Figure 4 11 Integrated Controller Circuit Board Cyclic Crank Potentiometer Location 4 4 1 Adjustment The ON and OFF...

Page 39: ...et master switch in the OFF position 2 Disconnect power to the battery charger if equipped 3 Disconnect the generator set engine starting battery negative lead first 4 Remove the generator set housing...

Page 40: ...TP 5867 11 02 30 Section 4 Controller Troubleshooting Notes...

Page 41: ...ections of start stop switch N 4 47 D Check battery condition and connections No Yes Is there voltage at the cyclic crank relay or starter relay No Yes Faulty relay Replace circuit board D Load test b...

Page 42: ...pressure Check for overspeed governor voltage regulator and overcrank conditions Engine fault check fuel supply spark plug ignition coil etc Check for 12 volts DC at fuel valve No Engine wiring harnes...

Page 43: ...rams Generator set must be running while performing this test Test magnetic pickup operation as described in Section 7 Magnetic Pickup If specified voltage is present and magnetic pickup tests good re...

Page 44: ...TP 5867 11 02 34 Section 5 Generator Relay Controller Troubleshooting Notes...

Page 45: ...oltage regulator s 10 amp fuse before performing the separate excitation procedure See Figure 4 2 or Figure 4 3 for the fuse location If the fuse is not blown use the following procedure to separately...

Page 46: ...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...

Page 47: ...wer sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicableco...

Page 48: ...adjustment connect a 10 kOhm 1 2 watt minimum rheostat customer provided across terminals 33 and 66 on the PowerBoost IIIE voltage regulator See Figure 6 6 The rheostat provides a 5 volt adjustment r...

Page 49: ...il the regulator reaches the desired output voltage 5 Rotate the stability potentiometer clockwise until the light flicker minimizes 6 Readjust the voltage adjustment potentiometer if necessary 7 Set...

Page 50: ...ance 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 ho...

Page 51: ...the stator leads as shown in Figure 6 10 Note Leads 1 2 3 and 4 are the generator output leads Leads 33 44 and 55 are the voltage regulator sensing and supply leads Refer to the schematic in Figure 6...

Page 52: ...ed 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 Whe...

Page 53: ...at each component This verifies that the switches function and that voltage is present at each component 6 7 3 Continuity Checks To further check generator set components disconnect the battery and re...

Page 54: ...is found check for an open circuit and or a blown fuse Voltage regulator circuit 10 amp fuse P10 5 and stator lead 55 at the fuse holder relay controller R x 100 OFF RESET Zero ohms continuity If no...

Page 55: ...he generator set shuts down after approximately 25 35 seconds of operation Remove the jumper wire from the LOP switch and ground Start the generator set and run it for at least 25 35 seconds to verify...

Page 56: ...f the input speed signal from the magnetic pick up will result in a low or idle speed condition A potentiometer on the governor controller allows adjustment of the engine speed within the 50 60Hz rang...

Page 57: ...otor 2 Carburetor throttle linkage 3 Carburetor mounting holes 3 Figure 6 16 Stepper Motor and Carburetor 6 9 4 Governor System Operation Test If the engine continues to operate erratically after the...

Page 58: ...Procedure Summary 5 If the voltmeter displays less than 1 75 volts AC check the air gap as described in the following steps before replacing the sensor Verify that the magnetic pickup air gap is 1 02...

Page 59: ...t 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 followi...

Page 60: ...4 6 or Figure 4 7 to identify the potentiometer used to adjust the overspeed setting Do not use the overspeed potentiometer on the governor Perform the following procedure with the generator set runni...

Page 61: ...steel piece should be at least 4 sq cm 1 4 sq in The voltmeter reading should equal the source voltage 7 Remove the iron or steel from the sensing surface The voltmeter should indicate no voltage 8 R...

Page 62: ...6 7 11 10 9 6 7 11 10 13 11 19 10 17 9 16 13 11 19 M1 M4 M3 M2 MP MP AD 70A M1 M4 M3 M2 MP MP AD 70A P9 J9 P4 J4 P7 J7 J5 P5 70A To P5 2 70A 3 3 70 7 6 5 4 3 2 1 TP5867722 1 Governor controller circui...

Page 63: ...ate for each model Maximum Pipe Length m ft Pipe Size 8 5RMY 11RMY 3 4 in NPT 18 3 60 9 2 30 1 in NPT 61 200 30 100 1 1 4 in NPT 91 5 300 68 6 225 Figure 6 25 Maximum Natural Gas Pipe Length Generator...

Page 64: ...alve when changing fuels When switching from natural gas to LP gas or vice versa verify that the engine speed meets specifications The electronic governor should compensate for different types of fuel...

Page 65: ...the RUN position to start the generator set 9 Allow the generator set to run until the engine reaches normal operating temperature 10 With the generator set at normal operating temperature apply 90 1...

Page 66: ...iolate federal or state laws The manufacturer ships the generator set with the fuel system connected for natural gas To convert to LP gas use the following procedure to move the fuel line from the nat...

Page 67: ...Clean the hose fitting with a dry cloth or brush apply fresh pipe sealant to the threads and install the fitting into the LP or natural gas port Note Do not adjust the fuel metering valves 9 Slide the...

Page 68: ...TP 5867 11 02 58 Section 6 Component Testing and Adjustment Notes...

Page 69: ...et as follows 1 Move the generator set master switch to the OFFposition 2 Disconnectthepowertothebatterycharger 3 Remove the battery cables negative lead first Reconnect the negative lead last when re...

Page 70: ...ividual performing the reconnection to meet all the electrical codes See Figure 7 2 for four lead reconnectable single phase generator set voltage options 60 Hz 50 Hz 120 Volts 110 Volts 120 240 Volts...

Page 71: ...o or purchase a new ammeter scaled twice the existing ammeter and install the new ammeter 4 3 2 1 Stator Leads LO GRD LO Neutral Ground Load Side Line Side Two pole circuit breaker L1 TP 5867 L0 L1 60...

Page 72: ...TP 5867 11 02 62 Section 7 Generator Reconnection Notes...

Page 73: ...witch in the OFF position b Remove eight screws to remove the battery compartment panel c Disconnect power to the battery charger if equipped d Disconnect the generator set engine starting battery neg...

Page 74: ...a Remove two bolts securing the alternator vibromount mounting plate to the skid See Figure 8 5 b Raise the alternator end of the generator set enough to place a thin block of wood beneath the rear of...

Page 75: ...t See Figure 8 8 a Mark the leads connected to the speed sensor and disconnect the leads b Remove the screws and washers securing the speed sensor to the speed sensor bracket c Install the new speed s...

Page 76: ...and washers b Torque the bolts to 28 ft lb 38 Nm See Figure 8 10 2 Install the rotor See Figure 8 9 a Apply a small amount of antisieze compound to the end of the engine crankshaft for rotor assembly...

Page 77: ...mounting surface and brush holder to center the brushes on the slip rings See Figure 8 13 See Section 6 6 Brushes for more information c Set the gap between the magnetic actuator and the speed sensor...

Page 78: ...8 in lb 10 Nm TP56328 1 2 3 4 5 6 1 Exhaust duct top 2 Engine muffler 3 1 4 20 hardware 4 Exhaust duct bottom 5 1 4 20 x 0 625 in bolts and 1 4 washers 6 3 8 16 hardware Figure 8 15 Exhaust Muffler Du...

Page 79: ...3 Battery compartment panel 4 Mounting pad 5 Alternator end housing panel Figure 8 17 Generator Set Weather Housing 10 Return the generator set to operation a Check that the generator set master swit...

Page 80: ...TP 5867 11 02 70 Section 8 Disassembly Reassembly Notes...

Page 81: ...termine the correct version number for a given model number and spec number Find that version number in the Controller Wiring Diagrams Reference and determine the wiring diagrams by choosing the type...

Page 82: ...TP 5867 11 02 72 Section 9 Wiring Diagrams Notes...

Page 83: ...TP 5867 11 02 73 Section 9 Diagrams and Drawings Relay Controller Schematic Diagram 1 Phase ADV 6297 B...

Page 84: ...TP 5867 11 02 74 Section 9 Diagrams and Drawings Relay Controller Point to Point Wiring Diagram 1 Phase 358093 E...

Page 85: ...TP 5867 11 02 75 Section 9 Diagrams and Drawings Relay Controller Schematic Diagram 1 Phase ADV 6297 E...

Page 86: ...TP 5867 11 02 76 Section 9 Diagrams and Drawings Relay Controller Point to Point Wiring Diagram 1 Phase GM10164 A...

Page 87: ...TP 5867 11 02 77 Section 9 Diagrams and Drawings Relay Controller Schematic Diagram ADV 6524...

Page 88: ...TP 5867 11 02 78 Section 9 Diagrams and Drawings 6 Relay Controller Point to Point Wiring Diagram GM10619...

Page 89: ...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 cur...

Page 90: ...on 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...

Page 91: ...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...

Page 92: ...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...

Page 93: ...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 Kro...

Page 94: ...4 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...

Page 95: ...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...

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Page 98: ...er 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 Headquart...

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