Kohler 12 kW Emergency Power System - 12RES-L - Page 3 - Answered Questions & Fixed issues

Hi and welcome to FixYa, I am Kelly.
I can not tell you how to get it out of it's current mounting position without seeing it. (Just being honest) And the wiring is different for each RV depending on what electrical system the ORIGINAL owner opted for. My experience with RV generator is that you can usually slide them out on rails just far enough to disconnect the wires. Just do yourself a HUGE favor and draw your own wiring diagram.
Number the wires 1 through 8 (
Ok.... here is the diagnostic and service manual:
http://www.kohlerpower.com/onlinecatalog/pdf/tp6196.pdf
See the troubleshooing steps on page 25 and also see sections 4-4 and 4-5 to determine why it is shutting down. First thing check the oil level! The engine has a Low Oil Level and low oil pressure Pressure Sensor. Either one will shut off fuel. Read in section 5 also....

The squalling noise your hearing is probably dry starter bearings. There is not a quick fix for this other than to disassemble the starter and lubricate it. If the bearings in fact dried out you will have to also wipe off the armature shaft area where the bearings are. If you just lubricate it without disassembly it will eventually lock up from the left over residue.

The fuel system is discussed on page 66 of the manual link. This appears to be an LPG powered unit. If it is not LPG powered find your engine number and I will get your engine service manual also so you can locate the fuel pump. (I think this is either the CH or CV740-0035 engine) If I remember correctly the fuel pump is vacuum powered on this engine if it a diesel or gas model. The diesel engine also has a fuel injection pump in addition to a fuel pump. (just depends on what sub model of the 12 RES-L you have. The L usually designates it as an LPG unit.)

The parts list is here:
http://www.kohler.com.sg/onlinecatalog/pdf/tp6399.pdf

Air Filter: (Page 17)
9 24 083 09-S Element, air filter ( or use this page to locate a Kohler dealer:
http://www.kohlerengines.com/wheretobuy/landing.htm

Thanks for choosing FixYa,

Kelly

Check that when you run it, it is not in fact making correct voltage (within about 10% is good), also make sure the engine is coming up to full speed, 3600 or 1800. You could check this with a multimeter that measure hertz. On the main output leads when the genset is running make sure it is getting close to 60 hz. or if you are in an area that uses 50 hz. check for that respectively. There are a couple things that would affect this, one would be your SCR module. There is a test procedure for this which you could find here. http://www.scribd.com/doc/50171916/tp6196-1 . I don't work on marine units, mostly standby so these manuals are for residential. Check your fuses, could even go as far as checking the wiring in the back and wiring and condition of the brushes and sliprings. These actually build field voltage to make 240 or 120 volts whatever your unit is configured to make. The brushes need to sit flat on the slip rings and on a unit with 10 hrs. the sliprings I can't imagine would be very dirty but check that as well. If you have an ADC2100 controller use this manual to go into the controller to verify that it is set for the correct voltage that the machine is built to make. The only other fairly simple thing to check that I've had issues with is if Kohler mounted a fuse block on the side of the cabinet mounted to the genset with no vibration isolation. Check these fuses while attempting to run the unit and make sure you getting steady voltage out of them as sometimes they will vibrate causing pulsed voltage to come out of them and can give you an intermittent UU, UF, or OC fault (undervoltage, underfrequency, overcrank).

Is there a fault?? All UL listed generators including Kohler are required to lockout on a fault on shut down. This really sounds like a problem with your 2-wire auto start connection between your automatic transfer switch and genset. RDT model automatic transfer switch it is the 2 middle wires on the green connector and terminals 3&4 in the generator. close to run and open to shut down. Any open at any time will cause the unit to shut down. The 12 will shut down instantly upon an open because your 5 minute cool down is built into the transfer switch.

Check for a burned fuse or tripped breaker to the cranking circuit.

The monitoring system of our Kohler propane generator has sent a "UU" message. What does this mean as it causes the generator to shut down 10 seconds after starting? Also how can this be corrected?

Means that the engine has turned over for too long without starting. It times out to protect the starter and battery wiring.

Possible bad starter if the battery has 12.46 volts and the battery is charged to that voltage.
Maybe try to tap the starter while it tries to start in order to get the starter to turn. If that doesn't work, consider using an ammeter to measure the amps that the starter is drawing. If it doesn't draw much current, like 1 or 2 Amps, then it is a bad solenoid on the starter. If it draws a high amount of amperage like 75 to 125 Amps and doesn't turn then it's also a bad starter. It could be just a solenoid connected to the starter, but if it's like an automobile, changing the starter and solenoid together is the usual way of fixing a starting problem.

You should have two wire remote Start/Stop. It may need to be shortened in order to start.

You have to reset it because it locked out on on under frequency. Just pullout the fuse on the control panel and then reinstall it a couple of seconds later. Now it will reset the fault codes. Hope that helps.

Hello. The over voltage fault shutdown occurs when the AC voltages exceed the overvoltage limit. Most of the time the problem is with the limit sensor is set too low or has become faulty and needs to be replaced. J.

ENABLES FAULT SHUTDOWN WHEN AC VOLTAGES EXCEEDS OVERVOLT LIMIT

OC means OVERCRANK safety circuit stopped the auto start-up so you wouldn't burn up the starter. There is a reason the generator didn't start. Low battery, not enough fuel pressure, clogged air filter, bad starter... You just have to eliminate as many as you can visually. Rebooting the generator should clear the OC condition and you can try to start it manually.

Sounds like a short in one of the windings to me. Can you verify that the engine rpm is not exceeding specs? If you can modify the engine speed Id say slow it down and see what the voltage read is.

Here is the code explained direct from Kohler's manual. I'd disconnect the generator load first.
UU Undervoltage Shutdown occurs if the voltage falls below 80% of the nominal system voltage for more than seconds. Check wiring and connections.
Reduce the load and restart the generator set. —
Check wiring and Check controller configuration, system voltage
and frequency (parameter UU).

Check AC voltage and adjust, if necessary. 5.7
Replace the SCR module and test voltage again. 4.9
Separately excite unit. 5.2
Check stator continuity

See web site for manual :http://www.kohlerpower.com/onlinecatalog/pdf/tp6196.pdf

If the succession is 3-5 sec crank - 3-10 sec pause, it is OK, but the cranking is not successful (the reason should be investigated).
If the succession is more rapid 1 - 2 sec you may have bad PCB control.

The alternator, for producing 120/240vac, is located at the other end of the engine. The alternator for charging the battery is part of the AC alternator.

Charging circuit breaker? Don't know that one, I thought they were fused near where the battery was installed.

Plug an electric drill into your output power at the generator IF you have a plug at the generator. (Output power CB must be on.) IF not the closest point to the generator and then pull the drill switch and turn the drill in the reverse direction. That will flash the field. 1/2 inch drrill works best but with some effort a heavy duty 3/8 drill will work. Just rotate it quickly... when the generator starts working it will try to yank the drill from your grip so keep that in mind. (Trigger Sw on drill ON)

Kelly

hunting is usually caused by fuel starvation not an electronic fault

sounds like a relay should be latching one it has started

Check battery volatge while you are cranking engine if voltage drops below 9 vdc you have a bad battery. If it doesn't you probable have a bad starting solenoid or a bad ground at the starting solenoid.

What you need to know is there enough fuel going to the regulator. It should be 7 to 11 inches Water Column. If not your problem may be not enough fuel. That includes when the heater in your house kicks on and what ever gas appliance you may have. Once you verify that you need to figure out if you have the proper pressure coming out of the regular on the inside of the generator. Next I would look at compression of the cylinders. It may need new piston rings.