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Portable Generator
Power Systems 8RESV
Kohler Power Systems 8RESV User Manual
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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
2
Table of Contents
Table of Contents
3
Safety Precautions and Instructions
5
Introduction
9
List of Related Materials
9
Service Assistance
10
Section 1 Specifications
11
Introduction
11
Controller Specifications
11
Engine Service
11
Engine Specifications
11
Alternator Specifications
12
Torque Specifications
12
Service View
13
Section 2 Scheduled Maintenance
15
Service Schedule
16
Service Schedule
17
Lubrication System
18
Low Oil Pressure Shutdown
18
Oil Check
18
Engine Oil Recommendation
18
Oil Change Procedure
18
Resetting the Maintenance Timer
20
Spark Plugs
20
Air Cleaner Service
21
Air Cleaner, 8RESV/RESVL Models
21
Air Cleaner, 10/12RESV/RESVL Models
22
Cooling System
23
Exhaust System
23
Stepper Motor Coupling
24
Fuel System Maintenance
24
Battery
25
Checking Electrolyte Level
26
Checking Specific Gravity
26
Storage Procedure
27
Lubricating System
27
Fuel System
27
Cylinder Lubrication
27
Exterior Preparation
27
Battery
27
Section 3 Controller
29
Introduction
29
Sitetech and Oncue Plus Software
29
Controller Parameters
30
Controller Parameters Table
30
Notes on Selected Parameters
30
Controller Firmware
44
Controller Replacement
45
Controller Replacement Procedure
45
Controller Setup
47
Voltage Calibration
50
Calibration Using the RDC2 Controller Keypad and Menus
50
Calibration Using Sitetech
52
Setting the Oncue Plus Password
53
RDC2 Controller
53
DC2 Controller
53
Section 4 Troubleshooting
55
Introduction
55
Theory of Operation, Electronic Start Sequence
55
Initial Checks
56
USB Port
56
Circuit Protection
56
Thermostat Information
57
Oncue Plus Troubleshooting
57
Fuel System Troubleshooting
57
Fault Messages
58
Status Messages
63
Troubleshooting Chart
66
Controller Troubleshooting
73
Section 5 Component Testing and Adjustment
75
Introduction
75
Theory of Operation
75
Alternator Excitation
76
No to Low Voltage Operation
76
Erratic Voltage Regulation
77
Separate Excitation
77
Stator
78
Main Field (Rotor)
80
Slip Rings
82
Brushes
82
Voltage Connections
83
Voltage Adjustments
83
Voltage Regulator Average Voltage Adjustment
84
Volts/Hz Slope and Cut-In Frequency
85
Voltage Regulator Gain
85
Governor System
86
Operation
86
Initial Checks
86
Hunting/Surging
87
Governor System Operation Test
88
Frequency Adjustment
90
Engine Speed Gain Adjustment for the Governor
91
Engine Speed Adjustment for Governor
91
Advanced Speed Control
91
Fault Shutdown Tests
93
Controller Fault Shutdown Functions
93
Fault Shutdown Switches
95
Fuel Systems
97
Fuel Solenoid Valve
98
Capacitive Discharge Ignition (CDI) Timing
98
Fuel Regulators
99
Fuel Conversion
99
Fuel Selector Valve Adjustment Screw
102
Starter and Run Relay
102
Continuity Checks
103
Section 6 Disassembly/Reassembly
105
Initial Steps
106
Disassembly
107
Reassembly
113
Section 7 Drawings and Diagrams
119
Appendix A Abbreviations
129
Appendix B Common Hardware Application Guidelines
131
Appendix C General Torque Specifications
132
Appendix D Common Hardware Identification
134
Appendix E Common Hardware List
135
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Kohler Power Systems 8RESV Specifications
General
Brand
Kohler
Model
Power Systems 8RESV
Category
Portable Generator
Language
English
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