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Kohler 8.5 & 12RES Operation/Installation

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1. 4d L ooLZzoaY WIZ HILHVIS 6 t1d QNnOHO 8 71 voz 1904 2 vid IVAN 9 14 71OHINOO AVI3H HSVTd S tld S3ALIVO3N NOILINDI 1OHINOO AVT3H H3lHVIS 5 71 7051409 AV 13H LINVI NOWWOO tLd TOHINOO Av T3H XNAYAINA b vld SNOLLO3NNOO tid ON NOWWOO 9 Ekd ON AVISY S Ekd ONAVIS3H ON LINVI NOWWOO ld NONNO LINVA NOWAOO 2 6 NONNO9 AVT3H NOH L Ekd SNOILO3NNOO FIVAHILNI AV T3H 1 OV 5 9 8 1ndNI OV 2 91 CZN 1ndNI 1 9 SNOILOANNOO SIP 99 DNIGNIM Xn V 9 94 S 9ld 4 SANIN SAIC v 9Ld cs XNY 5 91 1nOAv1dH HSV1H 2 91 5 _1 91 SNOLLO3NNOO 917 QNnOHO 5 4 1097195 H3MOd SNONNILNOO 2 Zd ON 1 SNOLLO3NNOO Zd 6 Sd O N 8 Sd 2 Sd 9 Sd S Sd v Sd 26259 Sd 65654 1 8 SNOILLO3NNOO Sd 26259 56 14 ONNOU9 v Ld NO IVAA 5 1 GQNNOHD IVNSIS HOSN3S 3Hf1 8S3Hd 18 1 ADYNOS HOSN3S 3Hfl SHHd 06 14 HOSN3S HA 60 14 SSOT I3A311NVY1OOO 8 1d ONNOU9 28 Z dOLS LHYLS FLONIY 9 1d dOLS LYVLS 31OW3H 8 14 ve ld Ld 2 INNO Va bd 08 14 ONNOY9 HOSN3S AUNSSIHA 61 1 INNOYD 81 1 HO
2. Introduction RR UAR UAR ACE RUN EC ACA D i Service Assistance 23 2 Rea herr nor ii Section 1 Specifications and Features eee eee eee eens 1 1 Specifications Lipidi la 1 1 2 Generator ra reed er e 1 1 3 Engine uso REG X RIDERE Be eta qam E 1 1 4 Advanced Digital Control 1 1 5 Service VIEWS eer ario Laga leve elisa 2 Section 2 Operation iii i Rr A E A A E E ee eens 3 2 Prestart Checklist Jv ec RR E TIR SE RAE M ER ud is 3 2 2 Exercising the Generator Set esses 3 23 Generator Set Operation ees 3 2 8 1 Controls and Indicators ees 4 2 3 2 Starting the Generator Set 4 2 8 8 Stopping the Generator 4 2 3 4 Fault Shutdowns ene 5 2 3 5 Resetting the Controller after a Fault Shutdown 6 2 8 6 Continuous Power Mode 6 2 4 Circuit Protection suc n e ia nea de kad og 7 2 4 1 Line Circuit Breaker 7 2 4 2 FUSES Aroan Morana detti 7 2 5 iBattery Charger cesa ere bd ie E I e e 7 2 5 1 Battery Charger Operation 8 Section 3 Scheduled Maintenance eee eee eee eee eee eens 9 3 4 Routine Maintenance ett 9 3 2 Service S
3. N WE o 4 DEC 1 DSAM connector location 2 Fuel block 3 Fuel inlet 1 2 in NPT female Figure 6 10 Fuel System Locations Air Inlet Side Fuel block Fuel metering valves factory sealed do not adjust Fuel inlet 1 2 in NPT Hose fitting Plug Figure 6 11 Fuel Block Connections Natural Gas System Shown Section 6 Installation 29 7 Remove the plug from the LP port in the fuel block 17 Move the generator set master switch to the AUTO See Figure 6 11 Clean the plug with a dry cloth or position brush apply fresh pipe sealant and install the plug into the natural gas outlet port To convert from LP vapor to natural gas follow the same fuel conversion procedure moving the hose fitting to the 8 Clean the hose fitting with a dry cloth or brush natural gas port and plugging the LP port For the apply fresh pipe sealant to the threads and install 12RES model disconnect the DSAM leads for LP vapor the fitting into the LP port See Figure 6 12 Note Do not adjust the fuel metering valves 9 Slide the hose onto the hose fitting and secure it with the clamp 10 For 12RES only Connect the digital spark advance module DSAM leads together for natural gas Disconnect the leads for LP See Figure 6 12 11 Connect and turn on the new fuel supply 12 Checkthatthe generator set master switch is in the OF
4. ate ertet eir tate ure 35 6 10 1 Common Fault and Run Relay Board 35 6 10 2 Carburetor Heater ees 36 6 11 Controller Configuration sasssa sssaaa aeaee 37 6 11 1 System Configuration eese 37 6 11 2 Advanced Configuration Mode 37 6 12 Prestart Installation 37 6 13 Warranty Registration eh 37 Appendix A Abbreviations e nr rn A 1 Table of Contents TP 6195 1 04 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death orsubstantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury o
5. 32018 ANIONS 983 FUNIVHIANIL 1491009 SLO 30010 90 aua931 li ET H3OuvHO dSVHd JI NIS ZS8S AQV 1135 SNOLLO3NNOO HOLVH3N39 HOS 310N one vis NI 11 18 N Z9 499 9 340938 3dVL uii s sagas 2 k 3NION3 gt mi A 85 i 050 S9 BAT BA Nus 3unbss T noi NOI 3NION3 AINO CIL NOI 99 1HMbr8 c 3C E I 339 ONIALL 1 NOLLINOI gt SZHO M 683 N J1O3NNOO LON OG J1O3NNOO LON oa svodi 193NNO9 LON OG N OL 99 LOSNNOO SVD IVENLVN SHO 1913 NINO SVO LVN HOdVA d7 d 170 083 VOLI ENOOO voz ILON MIYOS HINTS Teavodl voi swan VOZ 14 NOLLONNr wis 99 HOLIMS H34SNVU L NO SLOVLNOO 18915 INIONI HO HOLIMS 15915 510 24 S IVNIWH3I HINOLSNO 0 1 v 62 1 d La RE ented ia Ges NA N A X ss a za a eas avo ann id ST vis w
6. GNLS H3TIOH1NOO 07 OH1NOO NOILINDI NOI ANNOYS XOA H3TIOHLNOO ana Ad 3SNI 4 FUNIVYIANIL LNV1009 SLO 3aoia dd uaxvaus LInoulo 89 QN3931 MI 21 68 amomo ASONVIS DL 193NNO9 LON OG 193NNO9 LON OG Svo dl 193NNO9 LON OG N OL S9 LOANNOO 99 IVENLVN 3dAL 1303 DI NOLLINOI NOI 3070H Hsnua 02 QCON3 ANO RED BLKWHT gt V 59 nl WHT RED RED WHT 33s ONINIL NOLLINOI 3NION3 SeHO vor svi woz 14160 6079 1 v 002 2 NOISE avo 33S SNOILO3NNOO ACA CA A A A A A A A A A S Rh ASWHd STONIS 685 AQV HO1VH3N39 HOS 310N bw sli tego LBS uo teo ma t n18 9 neo yna 9 J 1 94 re 9 91d 980 59 99 A 7134 99 7314 99 734 29 55 91d N4 dd N gt H 21 Hswd ATH HSVTA S t la 714 14 4
7. Introduction scorie Lei 19 4 2 Generator Set Troubleshooting esee 19 4 3 Fault Godes il ner IR eret teu aaa 20 4 4 Controller Troubleshooting III 20 4 5 Battery Charger Troubleshooting sees 20 Section 5 Wiring Diagrams 0 0 cece I HH hh n n n nnn 21 5 1 Specification Numbers 21 5 2 Controller Wiring Diagram Reference 21 Section 6 Installation 2 cse cee rl hanc ee eee ee ee ve 25 6 1 General ie tucks Venio MX Pee dE ei ndo 25 6 22 Weight iaia ale bale wld Joie pude 25 6 3 Generator Set Inspection ees 25 6 4 Mo nting zs oS AL MLD bL 25 6 5 Exhaust Requirements eee 25 6 6 Air Requirements e a a 27 6 7 Power Supply zT OST ee i he Vi iS 27 6 8 Fuel System dipana S Wt Vere doo 27 6 8 1 Fuel Supply dotate tres at 27 682 Fuel Pipe pe ae eta lai 28 6 83 Fuel Conversion een 28 6 9 Electrical Connections 31 6 9 1 AC Load Lead lt 31 6 9 2 Remote Start Connection optional 32 6 9 3 Continuous Power Mode Jumper 32 6 9 4 Battety v oer ER ams trac lea due 33 6 95 Battery Charger en 34 6210 ACCESSONES i erbe
8. f Start and run the generator set for a minute to allow the oil pressure to reach the operating range g Stop the generator set wait 1 minute and then recheck the oil level Add oil to bring the level up to the F mark on the dipstick 4 Check for leaks a Check for oil leaks b Fixleaks and recheck the oil level c Reinstall the housing side panel 3 4 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine 2 Remove the spark plug and check its condition Replace the spark plug if it is worn or if its reuse is questionable 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 3 3 and Figure 3 4 Figure 3 4 Adjusting the Spark Plug Gap 12 Section 3 Scheduled Maintenance 3 5 Air Cleaner Element and Precleaner The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 3 5 Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure 3 5 1 Precleaner Service Use the following procedure to wash and reoil the precleaner as indicated in the service sched
9. 13 8 kPa 3 5 psi 1 5 psi because of oil pump failure or other malfunction The shutdown feature does not protect against damage caused by operating with the oil level below the safe range it is not a low oil level shutdown Check the oil level regularly and add oil as needed 3 3 2 Check The generator set is shipped with oil Before operating a new generator set check the engine oil in the crankcase See 1 5 Service Views Verify that the oil level is at the F mark on the dipstick Add oil that has a viscosity appropriate for the climate See Section 3 3 3 Engine Oil Recommendation 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 3 3 3 Engine Oil Recommendation Use API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner Select the viscosity based on the air temperature at the time of operation See Figure 3 2 10W 30 5W 20 5W 30 F 20 0 20 3240 60 80 100 30 20 10 0 10 20 30 40 Temperature Range Expected Before Next Oil Change Figure 3 2 Engine Oil Selection TP 6195 1 04 3 3 4 Oil Change Procedure Drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position b Disconnect the powe
10. 6 rid ualuvis 710H1NOO XNWNINI E Ld i 70H1NOO 174 WOO Z kLd TOHLNOO ATH LUVIS E bldle 019 NOUIS 1VBA 9 pLdhe Zid ASNAS ov ISNIS OV 12 14 MO1HOSN3S AWIL 1491009 6 14 HOSN3S diN3L LNV1009 8 14 81 14 HOIH HOSN3S HA 62 14 MO1HOSN3S HA 21 14 1 14 9 1d VZ HONU3AOD HOLIMS 3UNSSIYA 1 14 1 9015 1 15 310W3H 92 19 2 9015 1 16 310W3H 92 19 9 14 81 HONH3AOO 5 14 VI HONE3AOO SNNIW Md NANI ONIONIM NANI ONIONIM aNnoHo d 103738 SGOW H3MOd 2 44 ONN 1 24 100 AV13H HSY 1VBA bet 22 14 81 14100 TINI 1d 100 L INVA NOWWOO 1 14 LNO HILUVIS 0012 DOV M sio doi INSNI lu gt TINSNI HOLIMS HIISNVHL NO SLOVINOD 1UVLS 3NION3 HO HOLIMS LEWIS SLOWS STVNINHIL BIMOLSNO OL Z SNONNILNOI lt OL H3dWnr HAMOd MOT Yad WN 24 3aoN SNOILOANNOO Zd QNO 8 pldj NOI vor td 00 d ABILIVE 9 Figure 5 3 8 5 12RES Schematic Diagram Single Phase Sheet 1 ADV 6835A A TP 6195 1 04 22 Section 5 Diagrams and Drawings
11. Inc ind int int ext hex high cylinder head temperature heavy duty high exhaust temperature high engine temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe Appendix A 1 International Organization for Standardization J joule JIS Japanese Industry Standard k kilo 1000 K kelvin kA kiloampere KB kilobyte 210 bytes kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display Id shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG l
12. storing and using fuels 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 with applicable emission standards and to provide the best possible hot and cold starting Note Do not adjust the factory sealed fuel metering adjustments on the fuel block Changing the fuel metering adjustments may violate federal or state laws Use the following procedure to convert from natural gas to LP vapor moving the fuel connection from the natural gas to the LP port plugging the natural gas port and connecting the DSAM leads See Figure 6 10 for the fuel system component locations Fuel Conversion Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect the power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Turn off the fuel supply 5 Remove the hose clamp and fuel hose from the hose fitting in the fuel block See Figure 6 11 6 Remove the hose fitting from the natural gas outlet port in the fuel block See Figure 6 11 TP 6195 1 04
13. 10 5 Battery 3 Clean the battery Refer to Section 3 8 1 for the cleaning procedure Perform battery storage last 4 Place the battery in a warm dry location 1 Place the generator set master switch in the OFF RESET position 5 Connect the battery to a float equalize battery charger or charge the battery monthly using a 2 Disconnect the battery negative lead first trickle charger Follow the battery charger manufacturer s recommendations 18 Section 3 Scheduled Maintenance TP 6195 1 04 Section 4 Troubleshooting 4 1 Introduction dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help Use the following charts to diagnose and correct describe the problem and repairs or adjustments made common problems First check for simple causes such to the equipment as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of 4 2 Generator Set Troubleshooting common problems possible causes of the problem and recommended corrective actions Figure 4 1 contains generator set troubleshooting diagnostic and repair information Check for loose If the procedures in this manual do not explain how to connections before replacing parts correct the problem contact an authorized distributor Problem Possible Cause Corrective Action The generator set Battery weak or dead Check power to the battery charger does not crank Recharge
14. counterclockwise can loosen the hardware TP 6195 1 04 Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6195 1 04 NOTICE Electrostatic discharge damage Elect
15. cover and the paper element with precleaner 6 Remove the precleaner from the paper element Note Do not wash the paper element or clean it with pressurized air as this will damage the element 7 Replace the element if it is dirty bent or damaged 8 Check the air cleaner base Make sure it is secure and not bent or damaged Also check the element cover for damage and fit Replace all damaged air cleaner components Remove any loose dirt or debris from the air cleaner base Wipe the base carefully so that no dirt drops into the intake throat Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary 9 Reinstall the paper element precleaner element cover element cover nut and the air cleaner cover Secure the cover with the cover retaining knob 10 Reconnect the power to the battery charger 11 Reconnect the generator set engine starting battery negative lead last 3 6 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery The alternator fan draws cooling air through openings on the side walls of the enclosure The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet See Figure 3 6 To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times TP 6195 1 04 Note Do not block the generator set cooling air i
16. emission requirements The following table provides the engine compliance period in hours associated with the category descriptor found on the certification label Emission Compliance Period hours Moderate Intermediate Extended Refer to the certification label for engine displacement The exhaust emission control system for the 8 5RES CH20 and 12RES CH740 is EM For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Lookatthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters 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 33 141 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 ii Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6
17. power to the battery charger c Disconnect the generator set engine starting battery negative lead first 2 Remove the controller from the generator set housing a Disconnect the engine wiring harness connector P1 plug 35 pin from the controller Disconnect the J15 and J16 connectors See Figure 6 14 b Remove the controller from the generator set housing in order to access the back of the controller 3 Remove the controller 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 6 14 b Remove the cover screws and remove the controller s back cover See Figure 6 14 32 Section 6 Installation 4 Locate the P7 connector near the top of the controller See Figure 6 14 Remove the jumper from pins 1 and 2 of the P7 connector If the P7 connector has three pins connect the jumper across pins 2 and 3 for storage 5 Replace the controller s back cover and secure the cover screws 6 Reconnect the three pink connectors to the generator set master switch 7 Reconnect the J15 and J16 connectors 8 Reconnect the generator set engine starting battery negative lead last 9 Reconnect power to the battery charger 10 Place the generator set master switch in the AUTO position 1 Engine wiring harness connector plug P1 2 Continuous power mode jumper locat
18. produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power 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 applicabl
19. reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Section 6 Installation 33 Use a 12 volt battery with a minimum rating of 675 cold cranking amps at 0 F The generator set uses a negative ground with a 12 volt engine electrical system See Figure 6 15 for battery connections Make sure that the battery is correctly connected and the terminals are tight Note The generator set will not start and circuit board damage may occur if the battery is connected in reverse Figure 6 16 shows the location of the engine starting battery Standard battery cables provide easy connection to the battery Use the following procedure to install and connect the battery Battery Installation Procedure 1 Ensure that the starting battery is fully charged before placing the battery in service 2 Clean the battery posts and or adapters if necessary 3 Install the battery post adapters if needed 4 Place the battery in the housing 5 Verify that the controller master switch is in t
20. the battery charger is charging at a FLOAT or MAINTENANCE rate of less Green ON than 1 5 amps stage 3 Your battery is now 90 charged and ready for use This float charging current will gradually decrease to as low as 0 1 amps as the battery reaches 100 charge It will now be kept at full charge without overcharging If the green LED stays on when your battery is known to be low refer to Section 4 5 in this manual Figure 2 9 Battery Charger LED Indicator Functions 8 Section 2 Operation TP 6195 1 04 A WARNING J x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe powertothe battery 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 automatic transfer switch remote start stop switch or engine start command from a remote computer WARNING Hot engine and exhaust system Can cause severe injury or de
21. x 0p 001 002 TP 6195 1 04 Section 2 Operation 2 2 Exercising the Generator Set Operate the generator set under load once each week for one hour If the generator set does not have a programmed exercise mode or an automatic transfer switch ATS with an exercise option exercise the unit in the presence of an operator During the exercise period apply a minimum of 35 load based on the nameplate standby rating The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks Check the air inlets and outlets and remove any items restricting the air flow 2 3 Generator Set Operation Figure 2 1 illustrates the user interface on the Advanced Digital Control ADC 2100 generator set controller 900 KOHLER ADVANCED DIGITAL CONTROL CODE DEFINITION AF Auxillary Fault Crank Cycle High Battery Voltage r Voltage Under Frequency Under Voltage OFF RESET GM28707A C 1 LED display 2 Select button use for setup and adjustment only 3 Up and down arrow buttons use for setup and adjustment only 4 Generator set master switch Figure 2 1 ADC 2100 Controller User Interface Section 2 Operation 3 2 3 1 Controls and Indicators Fig
22. 01 Charge the battery if the specific gravity is less than 1 215 with the electrolyte at 26 7 C 80 F 16 Section 3 Scheduled Maintenance Correction Example 1 Temperature below 26 7 C 80 F Hydrometer Reading 1 250 Electrolyte Temperature 6 7 C 20 F Subtract 024 Specific Gravity Corrected Specific Gravity is 1 226 Example 2 Temperature above 26 7 C 80 F Hydrometer Reading 1 235 Electrolyte Temperature 37 8 C 100 F Add 008 Specific Gravity Corrected Specific Gravity is 1 243 The temperature correction amounts to about 004 4 points of specific gravity for each 5 5 C 10 F change in electrolyte temperature 5810322 Figure 3 10 Specific Gravity Temperature Correction TP 6195 1 04 3 9 Battery Charger The generator set is equipped with a 6 amp float equalize battery charger to maintain the engine starting battery The chargers DC leads are factory wired Figure 3 11 illustrates the battery charger 4 Fuse 5 AC power cord 1 LED indicators 2 Mounting flanges 3 Battery leads 12 VDC Figure 3 11 6 Amp Float Equalize Battery Charger Periodically tighten all connections No other maintenance on the battery charger is required 3 10 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer Follow the engine manufacturer s reco
23. 04 6 11 Controller Configuration 6 11 1 System Configuration The system configuration is factory set and should not normally require changes in the field However the controller s configuration modes allow setting of the system voltage frequency and adjustment of the output voltage and frequency after reconnection Have reconnection and the related adjustments performed by an authorized distributor dealer or service technician The unit configuration and engine type are factory set for each type of generator set and engine and should not be changed in the field 6 11 2 Advanced Configuration Mode The controller s advanced configuration mode allows a technician to set the data input type for different senders change the battery voltage to 12 or 24 VDC if the battery voltage is changed in the field and change the controller communications setting for field installed meters Have these adjustments performed by an authorized distributor dealer or service technician TP 6195 1 04 6 12 Prestart Installation Check Review the entire installation section Inspect all wiring and connections to verify that the generator set is ready for operation Check that there are no obstructions to the air inlet and outlet Check all items in the Prestart Checklist See Section 2 1 6 13 Warranty Registration Complete the startup procedure and installation checklists supplied with the startup notification form Return the form to the distribu
24. 288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6195 1 04 Section 1 Specifications and Features 1 4 Specifications The generator set specification sheets provide specific generator and engine information Refer to the spec sheet for data not supplied in this manual Consult the generator set service manual engine operation manual and engine service manual for additional specifications Obtain copies of the latest spec sheets manuals diagrams drawings from your local distributor dealer 1 2 Generator The generator uses Kohler s unique PowerBoost voltage regulation system which provides instant response to load changes PowerBoost ensures reliable motor starting and consistent voltage levels PowerBoost utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage 1 3 Engine The generator set has a four cycle twin cylinder air cooled Kohler engine The engine operates on clean burning natural gas or propane LP vapor Engine features include e Efficient overhead valve design and full pressure lubricat
25. F position 13 Reconnect the generator set engine starting battery leads negative lead last 14 Reconnect power to the battery charger 1 DSAM leads connect for natural gas disconnect for LP 15 Startthe generator set by moving the generator set Figure 6 12 Digital Spark Advance Module DSAM master switch to the RUN position Leads located in generator set air intake area 16 Check for leaks using a gas leak detector 30 Section 6 Installation TP 6195 1 04 6 9 Electrical Connections 6 9 1 AC Load Lead Connections A WARNING as Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby normal sources of supply Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power 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 applicable codes and standards Never contact electrical leads or appliances when standing in water oron wet ground because these conditions increase the risk of electrocution Electrical backfeed to the utility Hazardous backfeed voltage can
26. ON uo SNOILOANNOO Std ov Hos 134 99 se Ong SNOLLO3NNOO 9Ld MI j vise vod E uws ss x y 110A 017 071 SNOLLO3NNOO HANOLSNO ivn inv 13538440 11 89 H 217289 H 13 ss ve vi a SNOLLO3NNOO 9d VEN EN DI o GS ae AA d IHM 9 899 N3 SNOILO3NNOO Sd 8 719 NOL Ad 22 1d N 3NION3 NOL voz NOI vee NOL 1 Nid SNOLLO3NNOO tld Co oolzoav NMOHS JOW H3MOd MOT S 89 AQV 33S SNOLLO3NNOO H3dMWff Zd HOS 31ON H3TIOHLNOO 00120QV ZTNSNI ea 612 GALVINSNINN AZLVINSNINN se ve ee ze ila oc e e 92 se ra ez zz z oz e SNOLLO3NNOO Figure 5 5 8 5 12RES Point to Point Wiring Diagram Single Phase GM29358 B TP 6195 1 04 24 Section 5 Diagrams and Drawings 6 1 General Have an authorized distributor dealer install the gener
27. Operation and Installation Residential Commercial Generator Sets Models 8 5RES 12RES Controller Advanced Digital Control NATIONALLY REGISTERED KOHLER POWER SYSTEMS wss on California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily 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 nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information seen Inside front cover Safety Precautions and Instructions
28. SNIS HA 2 1 ONNOY9 9 4 HOLIMS AUNSSIYHA 1 100 vid 1nOAVI3H 1904 1 1 NMOGLNHS 21 1 IVNH3IX3 IVNH3IX3 Ol Ld MOT1HOSN3S dWALINVIOOOD 6 4 HOSN3S dWALINVIOOD 8 4 92 HONHJAOO Z Id Vc HONH3AOO 9 14 VL HONHJAOO S Ld 8L HONHJAOO r ld NOWNOO Ld INdINO AYVdS eld 1nOAVIHH HILlHVIS SNOILOANNOO Hd 56 Oo saa0g O0 gt 000000 I lt H3TIOH INOO 001 IdV Figure 5 4 8 5 12RES Schematic Diagram Single Phase Sheet 2 ADV 6835B 23 Section 5 Diagrams and Drawings TP 6195 1 04 8SE6ZND ame PMOESESAIO Sau MI 21 68 ABONVIS SdH 21 98 ONIHIM AVHOVIO 5 SUV NOLINSANTHO NOISSO 40 SIHDIM TV dit S 89 AQV 335 OLLVINIHOS HOS HOLON H3dd3 S WLS HOLVIS LVLS SINGOW LUVINS HdSSs GION31OS HILUVIS SS HILUVIS US HOLOW H31HVIS WS H3HSVM 15 MIYOS H3ATIS ONILSIXa ISN ILON 993 o Wo Hfini Sovauns 007 300 Y H caen u YSISILOSY Q3T10H1NOO NOOTIIS HOS QHVO8 3OVH31NI AV 3H SI 1O3NNOO YOINO 090 HOLO3NNOO d OLL3NOVIN HOLIMS SYNSSAYd 10 MOT GNLS H3TIOHINOO 07 HOLO3NNOO f IOH1NOO NOILINDI NOI XO8 H3TIOHLNOO GND 3AWA Ad 3SNI 03
29. TRIC PRO E STUB NPT FEM ADV 6823 DIMENSION PRINT qe QUU F RESET AUTO EQUIPMENT GROUND LOCATION UIT BREAKER RC AIR FILTER W O BATTERY FRONT VIEW DIPSTICK A rm ER ET ALTERNATOR AIR INL Note Dimensions in are in inch equivalents Figure 6 1 Generator Set Mounting Details and Dimensions ADV 6823 B 26 Section 6 Installation TP 6195 1 04 Figure 6 2 gives the exhaust flow and temperature at rated load Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials Exhaust System Exhaust flow at rated kW m8 min cfm 8 5RES 12RES Exhaust temperat
30. ace battery charger TP 6195 1 04 5 1 Specification Numbers At the time of print this manual applied to the model numbers and specification spec numbers in Figure 5 1 On occasion the manufacturer may provide this manual with units that are not listed below such as when similar new specs are created prior to the updated reprint or in other cases when the manual is a suitable substitute for a manual under development 8 5RES GM29253 GA1 12RES GM29253 GA2 Figure 5 1 Generator Set Specification Numbers TP 6195 1 04 Section 5 Wiring Diagrams 5 2 Controller Wiring Diagram Reference Figure 5 2 lists the wiring diagram numbers and locations Wiring Diagram Description Schematic Diagram Sheet 1 Sheet 2 Drawing Number ADV 6835A ADV 6835B GM29358 Point to Point Wiring Diagram Figure 5 2 Controller Wiring Diagrams Section 5 Wiring Diagrams 21 L S 89 AQV EA 300 mu ei PROV Vivos on e Sad My e L S 8 amo swiousw OUVWSHOS WVHOVIC 5 EE 00 P ZSO 00 ERE EARUM DUM SERES SES Nn X208 INIONIS HOLON HIdd3LS WLS HOLVIS 115 SINGOW uvas LUVINS 955 GION3 1OS HILUVIS SS H31HVLS US HOLON H31HVLS WS H3lJlLO3H Q3T10H1NOO NOONIS HOS GHVOS AV T3H 1O3NNOO MINO NODO OLLSNOWW HOLIMS 55 IO
31. age within the limits for more than 10 seconds Low battery Fault code is displayed if the engine starting battery voltage falls Check the battery rating and condition voltage warning below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 10 seconds when the engine is not running This fault condition does not inhibit engine starting Charge or replace the battery Check the battery charger operation The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Figure 2 4 ADC Fault Warning Codes TP 6195 1 04 Section 2 Operation 5 2 3 5 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Move the generator set master switch to OFF RESET 2 Disconnect the generator set from the load using the line circuit breaker or ATS See the safety precautions at the beginning of this section before proceeding 3 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this section before proceeding Refer to Section 4 Troubleshooting 4 Startthe generator set by moving the generator set master switch to RUN Test operate the generator set to verify that the cause of the shutdown has been corrected 5 Move the gener
32. an cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Installthe heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place A WARNING 2 Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator setengine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt
33. ath Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 6195 1 04 Section 3 Scheduled Maintenance A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set 3 1 Routine Maintenance Refer to the service schedule following and the runtime hours displayed on the ADC 2100 display to schedule routine maintenance Have an authorized distributor dealer perform all generator set service Perform maintenance on each item in the service schedule at the designated interval for the life of the generator set Service units subjectto extreme weather long operating hours or dusty or dirty conditions more frequently 3 2 Service Schedule Perform the tasks listed in the following service schedule at the designated intervals for the life of the generator set For example an item serviced every 100 hours of operation or 3 months must also be serviced aft
34. ating gas that can cause death if inhaled for even a short time Avoid breathing exhaustfumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas present exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately andremain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air TP 6195 1 04 Fuel System A WARNING v 4 Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handl
35. ator set Figure 6 6 lists Section 6 Installation 27 the recommended fuel ratings for natural gas and LP vapor fuels Contact the natural gas utility for flow rate information or a gas meter upgrade Fuel System Fuel types Natural Gas or LP Vapor 1 2 NPT Fuel supply pressure kPa in H2O 1 7 2 7 7 11 Natural gas 1000 37 LP vapor 2500 93 Fuel supply inlet Figure 6 6 Fuel Supply Fuel Consumption m3 hr cfh Natural Gas at 96 load 10096 8 7 132 7596 3 2 113 50 2 6 99 25 2 2 77 LP Vapor at load 100 2 0 72 1 7 61 75 13 45 11 88 50 10 36 0 9 31 25 0 8 29 0 7 25 LP vapor conversion factors 8 58 ft 1 Ib 36 39 ft 1 gal 3 3 118 2 9 101 23 83 1 9 69 5 9 209 4 8 168 3 6 127 2 4 85 4 9 175 4 0 141 8 0 106 20 71 3 1 108 2 5 89 2 5 87 2 0 72 1 9 65 1 5 53 12 44 1 0 36 Figure 6 7 Fuel Consumption Gas Flow Rate Btu hr MJ hr Generator Set Model 8 5RES 132 000 139 12RES 202 000 2138 Figure 6 8 Natural Gas Flow Rate 28 Section 6 Installation 6 8 2 Fuel Pipe Size Ensure that the natural gas pipe size and length meet the specifications in Figure 6 9 Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet Add 2 4 m 8 ft to the measured length for each 90 degree elbow Compare the pipe size and
36. ator set master switch to OFF RESET 6 Reconnect the generator set to the load using the line circuit breaker or ATS 6 Section 2 Operation 7 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Note The controllers LED display remains off until an engine start command is received Opening and closing a remote start stop contact also resets the controller 2 3 6 Continuous Power Mode The controller is powered by the generator set engine starting battery A jumper on the back of the controller maintains power to the controller at all times Controllers are shipped with the jumper connected Note The 8 5 and 12 RES generator sets are equipped with factory installed battery chargers to prevent battery discharge Disconnecting the jumper allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position A remote start signal from a transfer switch or a remote start stop switch connected to controller leads 3 and 4 or moving the generator set master switch to the RUN position turns the controller back on See Section 6 9 3 for instructions to disconnect the jumper TP 6195 1 04 2 4 Circuit Protection Ifthe generator set circuit breaker trips or the fuses blow repeatedly see Section 4 Troubleshooting for possible causes 2 4 4 Line Circuit Breaker A li
37. ator set outdoors according to the instructions in this section Do not install this generator set indoors The generator set installation must comply with state and local code requirements Use the specifications provided here only in the initial planning Use the generator set and transfer switch spec sheets dimension drawings and wiring diagrams for installation Contact an authorized service distributor dealer for the most current information 6 2 Weight A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid The generator set weighs approximately 186 kg 410 Ib Use lifting bars inserted through the holes in the skid to lift the unit See Figure 6 1 for lifting hole locations 6 3 Generator Set Inspection Complete a thorough inspection of the generator set Check for the following 1 Inspect the generator set for loose or damaged parts or wires Repair or tighten any loose parts before installation 2 Check the engine oil Fill if necessary with the recommended make and grade of oil See Section 3 3 3 for engine oil recommendations TP 6195 1 04 Section 6 Installation 6 4 Mounting Install the generator set outdoors Maintain a minimum clearance of 0 9 m 3 ft from any building as shown in Figure 6 1 Do not install the generator set whe
38. cause severe injury or death Install a transfer switch in standby powerinstallations to preventthe connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 Have an authorized distributor dealer or a licensed electrician make the following load connections Verify that the electrical installation complies with the National Electrical Code NEC and all applicable local and state codes Connect the AC output leads in the controller compartment to the AC circuit breaker Route AC leads through flexible conduit directly to the AC circuit breaker box See Figure 6 1 for the recommended electrical inlet location Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas TP 6195 1 04 See Figure 6 13 and Section 5 Wiring Diagrams for the generator set electrical connections Make the following AC connections 1 Connect the output leads going to the transfer switch L1 L2 black leads to the AC circuit breaker load side 2 Connect the LO white leads from the ATS and the main panel to the neutral terminal 3 Connect the green lead to the equipment ground terminal lab
39. ch startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Exhaust System Check for exhaust leaks and blockages Check the muffler and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps muffler and outlet pipe for cracks leaks and corrosion e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set
40. chedule x n ep quoc glean towels aei eg 9 3 3 Lubrication System ccc 11 3 3 1 Low Oil Pressure Shutdown 11 q 3 2 Oll Gheck ss senses te ete mie demas 11 3 3 3 Engine Oil Recommendation 11 3 3 4 Oil Change Procedure 11 3 4 Spark Plugs iie e RE XR AIR WV e etme bere 12 3 5 Air Cleaner Element and Precleaner 12 3 5 1 Precl aner Service 2 1 Lola bia eee 12 3 5 2 Paper Element Service 12 3 6 Gooling System v ia dela era br bbs bu Ei Ri 13 3 7 Exhaust System salire oliena iS 14 3 8 Battery oos cr olo EU E lele ia aa 14 3 8 1 Cleaning the Battery sees 15 3 8 2 Checking Battery Electrolyte Level 15 3 8 8 Checking Electrolyte Specific Gravity 16 3 9 Battery Charger i c e re e e 17 3 10 Storage Proced ra gt b EXFL I Rb p Re atei 17 3 10 1 Lubricating System eee 17 3 10 2 Fuel System ceno uper bbb bri reni aud 17 3 10 3 Cylinder Lubrication o 17 3 10 4 Exterior Preparation 17 3 10 57 Battery ae Lal e Li 18 TP 6195 1 04 Table of Contents Table of Contents continued Section 4 Troubleshooting bonum tere Ie EE Rx Ra 19 4T
41. d electronics e Sealed connections e Digital isochronous governor to maintain steady state speed at all loads e Digital voltage regulation 1 5 RMS no load to full load e Automatic start for programmed cranking cycle Section 1 Specifications and Features 1 1 5 Service Views N N a oa al ol cl ol ol cl ll lt N N ADV 6823 A Enclosure Oil drain valve Muffler Oil filter Oil check Alternator cooling air intake Oil fill Exhaust Air cleaner Spark arrestor Spark plug locations both sides DSAM leads Controller Multi fuel block Generator set master switch RUN OFF RESET AUTO Gas regulator assembly Nameplate Fuel solenoid valve Line circuit breaker Air intake Engine starting battery location Battery charger Oil drain hose Relay board OMANDARWON Figure 1 1 Generator Set Service View 2 Section1 Specifications and Features TP 6195 1 04 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at ea
42. damage to the battery charger and battery ies Have a qualified electrician install the battery ies 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 connections with tools or jewelry while making adjustments repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines IV Safety Precautions and Instructions Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Hot Parts WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the generator Hot parts can cause severe injury or death Avoid touching the generator set field or exciter armature When shorted the generator set field and exciter armature become hot enough to cause severe burns Servicing the exhaust system Hot parts c
43. e The fuse is located in the battery lead See Figure 2 7 1 LED indicators 2 Battery leads 12 VDC 3 Fuse 4 AC power cord Figure 2 7 6 Amp Float Equalize Battery Charger Section 2 Operation 7 2 5 4 Battery Charger Operation Figure 2 8 illustrates the three stage charging method Red and green LEDs indicate charger operation The chart in Figure 2 9 describes the LED indicator operation during each stage of the charging process a gt E 5 5 a gs amp 8 5 Pei 5 B 2 o Figure 2 8 Charging Method Display Operating Condition Red ON When the red LED is on it indicates the battery is discharged and the battery charger is recharging at the Green OFF BULK rate stage 1 This charging rate is 6 amps While the red LED is on the voltage measured with the battery charger on will be 11 8 14 volts If the red LED stays on for more than 24 hours refer to Section 4 5 in this manual Red ON When both the green and the red LEDs are on the battery charger is charging at an ABSORPTION rate Green ON of between 1 5 and 5 amps stage 2 This mode of charging gradually tops off your battery and reduces harmful sulfating While both LEDs are on the voltage measured with the battery charger on should be approximately 14 0 14 5 VDC If both LEDs stay on longer than 24 hours refer to Section 4 5 in this manual Red OFF When the green LED is on
44. e codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Safety Precautions and Instructions 111 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 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment 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 the battery correctly positive to positive and negative to negative to avoid electrical shock and
45. eled GRD Verify that the electrical installation complies with the National Electrical Code NEC and all applicable local and state codes VIEW B B Bottom of Junction Box GM29253A F 1 Line circuit breaker 2 Ground terminal GRD 3 Neutral terminal LO Figure 6 13 Field Installed Wiring Connections Section 6 Installation 31 6 9 2 Remote Start Connection optional Connect leads 3 and 4 from the ADC 2100 controller to the automatic transfer switch s engine start terminals or to an optional remote start stop switch 6 9 3 Continuous Power Mode Jumper A jumper on connector P7 on the back of the controller causes the controller to remain powered at all times See the wiring diagram and schematic drawing in Section 5 Controllers are shipped from the factory with the jumper connected Disconnecting the jumper allows the controller to power down 48 hours after the generator set shuts down See Section 2 3 6 Note For most applications it is not necessary to disconnect the continuous power mode jumper Use the following procedure to disconnect the jumper if desired Procedure to disconnect the continuous power mode jumper optional 1 Prevent the generator set from starting a Move the generator set master switch to the OFF RESET position b Disconnect
46. er 200 hours or 6 months 300 hours or 9 months and so on Rough operation lack of power and excessive oil use indicate serious generator set problems Have an authorized distributor dealer perform all generator set service Section 3 Scheduled Maintenance 9 System Component or Procedure Fuel See Section Procedure Visually Inspect Check Change Frequency Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather Yearly or 500 hours Change oil Yearly or 100 hours Replace filter Yearly or 200 hours Cooling Air ducts louvers Yearly Exhaust Line Leakage Weekly Insulation fire hazards Yearly Hangers and supports Yearly DC Electrical System Battery charger operation charge rate if equipped Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals Yearly Battery electrolyte level and specific gravity Yearly AC Electrical System Visible wear or damage Quarterly Wire abrasions where subject to motion Six Months Tighten control and power wiring connections Yearly Wire cable insulation breakdown 3 Years or 500 hours Engine and Mounting Visible wear or damage Weekly Air cleaner service Year
47. esistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital spark advance module digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ibs ft min 9 gal gen genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W xD height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC in H20 in Hg in Ibs
48. fere with the operation of the generator set or obstruct the service areas Verify that the electrical installation complies with the National Electrical Code NEC and all applicable local and state codes See Section 5 Wiring Diagrams for more information regarding generator set electrical connections 6 10 1 Common Fault and Run Relay Board The optional relay board provides two additional relays to control customer provided equipment e Common fault relay e Auxiliary run relay The optional relay board replaces the standard relay board Therelay board location is shown in Figure 6 17 Connect customer equipment to the relay board harness Figure 6 18 lists the customer connections The common fault relay is energized on a fault The auxiliary run relay is energized when the generator set is running Connect to each relay s normally open or normally closed contacts depending on the application TP 6195 1 04 OT VAVAAVARARAARAARARARARAVAR 1 Relay board 2 Relay board harness Figure 6 17 Common Fault and Run Relay Board Harness Lead Connector Number Pin Number Connection Common fault normally open Common fault common Common fault normally closed Run relay normally open Run relay common Run relay normally c
49. he OFF position EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 6 15 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection 34 Section 6 Installation 6 Connect the positive lead to the engine starting battery 7 Connectthe negative lead to the engine starting battery Refer to Section 3 8 for battery maintenance instructions 6 9 5 Battery Charger The generator set requires an external battery charger to keep the starting battery fully charged A 6 amp battery charger is factory installed in the battery compartment The battery charger s DC leads are factory connected Plug the battery charger s power cord into a 120 VAC outlet on the load side of the system Refer to Section 2 5 for battery charger operation information 1 Engine starting battery location Figure 6 16 Battery Location Air Intake End TP 6195 1 04 6 10 Accessories Have accessories installed by an authorized distributor dealer or a licensed electrician Follow the installation instructions provided with each kit Use separate conduit for AC and DC leads to reduce the possibility of electrical interference Verify thatthe leads and conduit do not inter
50. hecking Battery Electrolyte Level Check the battery electrolyte level before each startup Remove the filler caps and verify that the electrolyte level reaches the bottoms of the filer holes see Figure 3 8 Refill as necessary with distilled water or clean tap water Do not add electrolyte Install and tighten filler caps After adding water to the battery in freezing temperatures run the generator set 20 30 minutes to mix the added water and the battery electrolyte Mixing the water and the electrolyte prevents the added water from freezing and damaging the battery 1 Filler caps 2 Electrolyte level Figure 3 8 Checking Electrolyte Level Section 3 Scheduled Maintenance 15 3 8 3 Checking Electrolyte Specific Gravity Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell Use the hydrometer s test instructions if available or Figure 3 9 for bead type testers Number of Beads Floating Battery Condition Overcharged Full Charge Adequate Charge Low Charge Battery Dead Figure 3 9 Electrolyte Testing Chart Temperature affects specific gravity correct the indicated hydrometer readings for temperature If the hydrometer does not have a correction table use Figure 3 10 A fully charged battery should have a specific gravity of 1 260 with the electrolyte at 26 7 C 80 F Charge the battery if the specific gravity from cell to cell varies by more than 0
51. hing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery 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 Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions Battery gases Exp
52. ial battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified TP 6195 1 04 cfh cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DSAM DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD cubic feet per hour cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current r
53. if the engine speed exceeds 115 of the Contact an authorized distributor dealer for shutdown normal running speed for more than 1 second service if problem continues Overvoltage Shutdown occurs if the voltage exceeds 120 of the voltage Contact an authorized distributor dealer for shutdown regulator setpoint for more than 1 second service if problem continues Underfrequency Shutdown occurs when the governed frequency falls 1 Hz Reduce the load and restart the generator shutdown below the system s frequency setpoint for more than 1 second set Contact an authorized distributor dealer for service if problem continues Undervoltage Shutdown occurs if the voltage falls below 80 of the voltage Reduce the load and restart the generator shutdown regulator setpoint for more than 1 second This protective set becomes active 30 seconds after engine start Contact an authorized distributor dealer for service if problem continues Figure 2 3 ADC Fault Shutdown Codes Fault Description Check High battery Fault code is displayed if the engine starting battery voltage rises Check the battery rating and condition voltage warning above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running This fault condition does not inhibit engine starting Check the battery charger operation The fault condition clears when the battery voltage returns to a volt
54. ing and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble TP 6195 1 04 Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can
55. ion P7 3 J15 connector 4 J16 connector 5 Generator set master switch connectors Figure 6 14 Advanced Digital Control Connections TP 6195 1 04 6 9 4 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn 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 battery in service as this may result in hazardous spattering of battery acid TP 6195 1 04 Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neut
56. ion for maximum power torque and reliability under all operating conditions e Dependable maintenance free electronic ignition e Precision formulated cast iron construction of parts subjected to the most wear and tear e Field convertible multi fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintaining CARB emission certification e Digital spark advance module DSAM optimizes ignition timing for the selected fuel 12RES TP 6195 1 04 1 4 Advanced Digital Control The generator set is equipped with the Kohler Advanced Digital Control ADC 2100 Controller features include the following e Compact controller e Integrally mounted to the generator set e LED display e Runtime hours e Crank cycle status e Diagnostics e LED display communicates faults Auxiliary fault High battery voltage High engine temperature Low battery voltage Low oil pressure e e e e e e Overcrank safety e Overspeed e Overfrequency e Overvoltage e Underfrequency e Undervoltage e Membrane keypad for configuration and adjustment e Password protected user access to menus e Voltage gain and speed adjustment e System configuration system voltage phase and frequency settings battery voltage and generator set model e Master control switch Run Off Reset Auto e Remote two wire start stop capability e Superior electronics protection from corrosion and vibration e Potte
57. ipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference RH round head RHM round head machine screw rly relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S Sec second SI Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole doub
58. iquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 229 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour A 2 Appendix MS m sec MTBF MTBO mig MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns oc OD OEM OF opt 0 OV OZ pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI military standard meters per second mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National P
59. ith tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together TP 6195 1 04 Refer to this section for general battery information and maintenance All generator set models use a negative ground with a12 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator spec sheet for battery capacity recommendations for replacement purposes Wiring diagrams provide bat
60. le throw SPST single pole single throw spec specs specification s Sq square sq cm square centimeter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6195 1 04 TP 6195 1 04 2004 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler 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 Jur
61. length with the chart in Figure 6 9 If the piping is longer than the maximum length shown for that size replace it with the specified size before proceeding Contact the local LP provider for LP installation information Maximum Pipe Length m ft 8 5RES 12RES 3 4 in NPT 18 3 60 9 2 30 1 in NPT 61 200 30 100 11 4 in NPT 91 5 300 68 6 225 Pipe Size Figure 6 9 Maximum Natural Gas Pipe Length 6 8 3 Fuel Conversion WARNING J ass x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe powerto the battery 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 automatic transfer switch remote start stop switch or engine start command from a remote computer TP 6195 1 04 WARNING ee LI b Explosive fuel vapors Can cause severe injury or death Use extreme care when handling
62. losed Figure 6 18 Common Fault and Run Relay Board Harness Connections Section 6 Installation 35 6 10 2 Carburetor Heater An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 C 32 F The carburetor heater prevents condensation and carburetor icing The heater turns on when the temperature at the thermostat falls below approximately 4 C 40 F and turns off when the temperature rises above approximately 16 C 60 F The heater requires a continuous source of 120 VAC power The heater power cord and thermostat are located in the generator set housing air intake area battery compartment See Figure 6 16 Plug the carburetor heater into an outlet that supplies continuous 120 VAC power The heater thermostat is installed in the cord Figure 6 20 shows the location of the thermostat on the power cord 1 Carburetor heater air cleaner removed to show heater Note Do not place the heater thermostat inside the 2 Carburetor heater power cord generator set engine compartment The thermostat must be exposed to the ambient air The thermostat will shut off power to the heater when the ambient temperature reaches approximately 60 F 16 C Figure 6 19 Carburetor Heater 1 Thermostat 2 Connector 3 Heater Figure 6 20 Carburetor Heater with Thermostat 36 Section 6 Installation TP 6195 1
63. losion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permitflames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away fromthe battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Il Safety Precautions and Instructi
64. ly or 100 hours Spark plugs Yearly or 300 hours Replace stepper motor coupling and bushing 500 hours Compartment condition Weekly Remote Control System Remote control Monthly Run generator set Weekly Generator Visible wear or damage Quarterly Exercise generator set Weekly Rotor and stator Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier disconnected 3 Years General Condition of Equipment Evidence of vibration leakage excessive noise temperature or deterioration X Weekly Interior of sound enclosure X Quarterly Contact your local distributor dealer for parts or service Not necessary for maintenance free batteries Figure 3 1 Service Schedule 10 Section 3 Scheduled Maintenance Action Replace as necessary TP 6195 1 04 3 3 Lubrication System See Section 3 2 Service Schedule for oil change and oil filter replacement intervals See Section 1 5 Service Views for the oil drain oil check oil fill and oil filter locations For extended operation check the oil level every 8 hours Maintain the oil level at or near not over the full mark on the dipstick 3 3 4 Low Oil Pressure Shutdown The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below 24 1 kPa
65. mmendations for storage if available Note Run the generator set monthly whenever possible 3 10 1 Lubricating System 1 Operate the generator set until it reaches operating temperature or about 15 minutes TP 6195 1 04 2 Stop the generator set 3 While the engine is still warm drain the engine lubrication oil from the engine crankcase 4 Refill the engine crankcase with oil See Section 3 3 3 for oil recommendations 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the generator set 3 10 2 Fuel System 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position 3 10 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the plugs 3 Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders 3 10 4 Exterior Preparation 1 Clean the exterior surface of the generator set 2 Seal all openings in the engine with nonabsorbent adhesive tape 3 Mask all areas to be used for electrical contact 4 Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion Section 3 Scheduled Maintenance 17 3
66. ne circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown in Figure 1 1 See Figure 2 5 for the circuit breaker ratings If the circuit breaker trips reduce the load and switch the breaker back to the ON position With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load Circuit Breaker Rating Amps 8 5RES 12RES Figure 2 5 Line Circuit Breakers 2 4 2 Fuses The engine harness contains two 10 amp and one 20 amp inline fuses See Figure 2 6 Another 10 amp fuse protects the battery charger Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 4 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts Location Lead 55 Lead PF2 292937 223316 Auxiliary Winding Relay Interface Board Controller 358337 AGS 10 Lead PF1 Battery charger DC lead See Section 2 5 Battery Charger Figure 2 6 Fuses TP 6195 1 04 2 5 Battery Charger The generator set is equipped with a 6 amp float equalize battery charger to maintain the engine starting battery The charger s power cord must be connected to a 120 VAC power source Figure 2 7 illustrates the battery charger The battery charger uses an AGS 10 inline fus
67. nlets or mount other equipment above them Overheating and severe generator damage may occur Cover knob Air cleaner cover Element cover nut Element cover Foam precleaner Air cleaner element Air cleaner base Figure 3 5 Air Cleaner Components 1 Exhaust outlet 2 Alternator air intake both sides 3 Engine air intake Figure 3 6 Cooling Air Intake and Exhaust Section 3 Scheduled Maintenance 13 3 7 Exhaust System Remove all combustible materials from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 0 3 m 1 ft from the exhaust outlet Periodically inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks leaks and corrosion e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace clamps and or hangers as needed e Check for and remove loose insulation in the exhaust duct e Check that the exhaust outlet is clear 3 8 Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulf
68. o the controller longer Controller fuse F3 is blown Low or no battery voltage Continuous power mode jumper is disconnected and the generator set has not run for 48 hours or 4 5 Battery Charger Troubleshooting Use the battery charger s LED indicators and the table in Figure 4 3 to troubleshoot battery charger operation problems Corrective Action Controller display will automatically activate when a remote start command is received or the generator set master switch is moved to the RUN position Connect the jumper to maintain continuous power to the controller if desired See Sections 2 3 6 and 6 9 3 Replace the fuse If the fuse blows again contact the distributor dealer Check connections Check generator set battery and battery charger See Figure 4 1 position Generator set master switch is in the OFF RESET Move generator set master switch to the AUTO or RUN position reset Figure 4 2 Controller Troubleshooting Chart Problem Red LED stays on for more than 24 hours One or more defective or damaged cells Generator set master switch in AUTO but no start command has been received since last controller No action required see Section 2 3 1 Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position Use the remote switch to start generator set and activate the controller display if desired S
69. olution Load test the battery and replace if necessary Battery charger has reduced its output voltage below the normal level due to a DC overload or a DC short Remove the source of the overload or short Disconnect the battery charger s black NEGATIVE ring terminal from the battery Reapply AC power and the green LED only should now light Onboard DC systems are drawing more current than the battery charger can replace Turn off all DC equipment while charging Red and green LEDs stay on for more than 24 hours Onboard DC systems are drawing between 1 5 and 5 amps Turn off all DC equipment while charging One or more defective or damaged cells Load test the battery and replace if necessary Extremely low AC voltage at the battery charger Apply a higher AC voltage source or reduce the length of the extension cord Green LED stays on when the battery is known to be low Open DC output fuse Replace AGS 10 fuse Faulty or contaminated terminal connections Clean and tighten or repair all terminal connections One or more defective or damaged cells Load test the battery and replace if necessary Neither of the LEDs turn on when the AC power is applied No AC power available at the battery charger Connect AC power or reset the AC breaker on the main panel Component failure Figure 4 3 Battery Charger Troubleshooting 20 Section 4 Troubleshooting Repl
70. ong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
71. ons Engine Backfire Flash Fire A WARNING 7 di 4 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirrit
72. or replace the battery Battery charger fuse blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Battery connections reversed or poor Check the connections Controller fuse F3 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Relay interface board fuse F2 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Generator set master switch in the OFF position Move the master switch to the RUN position The generator set Air cleaner clogged Clean and or replace the air cleaner cranks but does not start starts hard lacks power or operates erratically Battery connection poor Clean and tighten the battery connections Battery weak or dead Check power to the battery charger Recharge or replace the battery Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check the oil level Fuel pressure insufficient Check the fuel supply and valves Engine malfunction Contact the distributor dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC circuit breaker tripping because of overload Reduce the load on the generator set AC circuit breaker tripping because of short circuit Contact an authorized distributor dealer for service Low output or Generator set overloaded Reduce the load exces
73. output Figure 6 5 Battery Charger Power Requirements 6 8 Fuel System The generator set operates using natural gas or LP vapor fuel 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 Generator sets with multi fuel systems are CARB and EPA certified for both natural gas and LP vapor fuels 6 8 1 Fuel Supply Comply with local state and federal codes regarding the correct storage of fuel Because of variable climates and geographical considerations contact an authorized service distributor dealer for fuel system planning and installation Figure 6 1 shows the location of the fuel inlet connection Bring the fuel supply lines through the rear access opening Use flexible sections to prevent fuel line breakage caused by vibration Remove the housing end panel and hold the fuel solenoid valve with a wrench when tightening the fuel connections Protect all fuel lines from machinery or equipment contact adverse weather conditions and environmental damage Verify that the output pressure from the primary gas utility or LP tank pressure regulator is 1 7 2 7 kPa 7 11 in water column and that the utility gas meter flow rate is sufficient to supply the generator set plus all other gas consuming appliances Figure 6 8 shows the flow rate required for the gener
74. r property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6195 1 04 Accidental Starting WARNING Pa Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery 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 automatic transfer switch remote start stop Switch or engine start command from a remote computer Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clot
75. r to the battery charger c Disconnect the generator set engine starting battery negative lead first d Remove the housing side panel e Remove the oil drain hose from its retaining clip Remove the cap from the oil drain hose and lower the hose into an oil collection container f Open the oil drain valve on the engine g Allow time for the engine oil to drain completely h Close the oil drain valve i Replace the cap on the oil drain hose Replace the oil drain 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 Clean the gasket sealing surface of the oil filter adapter c Apply a light coat of clean oil to the rubber seal of the new oil filter d 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 oil a Remove the oil fill cap and fill the engine to the F mark on the dipstick The engine oil capacity is 1 9 L 2 0 qt See Section 3 3 3 Engine Oil Recommendation for oil selection b Reinstall the dipstick and the oil fill cap c Checkthatthe generator set master switch is in the OFF position Section 3 Scheduled Maintenance 11 d Reconnect the generator set engine starting battery negative lead last e Reconnect the power to the battery charger
76. rEngines com KOHLER ENGINES KOHIER CO KOHLER WISCONSIN USA Figure 1 Emissions Label 8 5RES Engine CH20 IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH1 AND CALIFORNIA 2006 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY KHXS 7252NA DISPL CC 725 MODEL NO SPEC NO SERIAL NO EMISSION COMPLIANCE PERIOD EPA CARB EXTENDED THIS ENGINE IS CERTIFIED TO OPERATE ON LPG NATURAL GAS REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS SALES AND SERVICE IN US CANADA Qv 1 800 544 2444 KohlerEngines com KOHLER ENGINES KOHIER CO KOHLER WISCONSIN USA Figure2 Emissions Label 12 RES Engine CH740 Introduction i ENGINE AIR INDEX California Only 2 4 6 0 10 MOST CLEAN LEAST CLEAN Q NOTE THE LOWER THE AIR INDEX THE LESS POLLUTION THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT FOR THE FOLLOWING USE MODERATE D INTERMEDIATE CHECK OWNER S MANUAL FOR FURTHER DETAILS THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY CAUTION CHECK OIL LEVEL BEFORE STARTING ENGINE V EXTENDED 1 6195 Figure 3 Air Index Label 8 5 12RES This engine generator is certified to operate using natural gas or propane fuel The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number Service Assistance of operating hours for which the engine has been shown to meet CARB
77. ralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid 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 time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when
78. re exhaust gas could accumulate and seep inside or be drawn into a potentially occupied building Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials See Figure 6 1 for the generator set dimensions and fuel and electric inlet locations The drawing dimensions are shown in millimeters with inches in brackets The generator set is shipped on a plastic mounting pad Prepare a flat level mounting area covered with gravel or compacted soil Setthe plastic mounting pad directly on the gravel or compacted soil Do not install the mounting pad directly on the grass 6 5 Exhaust Requirements A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a shorttime Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied buildingthrough windows air intake vents or other openings The exhaust system is complete for generator sets installed outdoors Do not install this generator set indoors Section 6 Installation 25 LE UP ME
79. rostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground Safety Precautions and Instructions V Notes VI Safety Precautions and Instructions TP 6195 1 04 This manual provides operation and installation instructions for model 8 5RES and 12RES generator sets equipped with the Kohler Advanced Digital Control ADC 2100 Information in this publication represents data available at the time of print The manufacturer may provide this manual for models not listed on the front cover Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The generator set is approved for use in stationary applications in locations served by a reliable utility power source The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required se
80. rvice atthe prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition Nameplate The following illustration shows a typical generator set nameplate Copy the model serial and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual See Section 1 5 Service Views for the nameplate location KOHLER KOHLER CO KOHLER WI USA MODEL SERIAL SPEC SERVICE DUTY HZ RPM VOLTAGE AMPS PHASE kw GEN MODEL INSULATION NEMA CLASS KW VARIES WITH BTU CONTENT OF FUEL BATT V TP 6195 1 04 Introduction EPA and California Emission Certification An engine or generator set with the following identification labels is certified to meet Small Off Road Engine emission standards for EPA CARB All model 8 5RES and 12RES generator sets with multi fuel systems are emission certified IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH1 AND CALIFORNIA 2006 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY _ 7252 DISPL CC 624 MODEL NO SPEC NO SERIAL NO EMISSION COMPLIANCE PERIOD EPA CARB EXTENDED THIS ENGINE IS CERTIFIED TO OPERATE ON LPG NATURAL GAS REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS Cu SALES AND SERVICE IN US CANADA Qv 1 800 544 2444 Kohle
81. sive drop in voltage Generator set stops Low oil pressure shutdown Check the oil level suddenly Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact the distributor dealer Controller fuse F3 blown Replace the fuse If the fuse blows again contact the distributor dealer Overspeed shutdown Reset the controller If the overspeed fault occurs again contact the distributor dealer Generator set master switch in the OFF RESET Move the switch to the correct position RUN or AUTO position Remote stop command received from a remote switch Check the remote switch position or ATS Engine malfunction Contact the distributor dealer Auxiliary winding fuse F1 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Figure 4 1 General Troubleshooting Chart TP 6195 1 04 Section 4 Troubleshooting 19 4 3 Fault Codes The Advanced Digital Control displays fault codes to aid in troubleshooting Fault codes descriptions and recommended actions are listed in Figure 2 3 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 3 5 4 4 Controller Troubleshooting Figure 4 2 contains troubleshooting diagnostic and repair information for the Advanced Digital Control Problem Controller LED display is off Possible Cause No power t
82. tart when the fault is active input is grounded High engine Shutdown occurs if the engine coolant temperature exceeds Check for blocked air inlets and exhaust temperature the maximum temperature for more than 5 seconds This outlets shutdown protective becomes active after the engine reaches the crank disconnect speed Low oil pressure Shutdown occurs if a low oil pressure condition exists 7 Check for leaks in the lubrication system shutdown seconds after the engine has reached crank disconnect speed Check the oil level and add oil if the level Note The low oil pressure shutdown does not protect against is low low oil level Check the oil level at the engine Overcrank Shutdown occurs after 3 unsuccessful starting attempts The Check the fuel supply spark plug and shutdown crank cycle is set for three starting attempts of 15 seconds battery cranking and TS segonds rest Check for loose connections The generator set also shuts down after 1 crank attempt if Contact an authorized distributor dealer for speed signal is sensed Shuts down 1 second after the fault is service if problem continues detected Overfrequency Shutdown occurs when the governed frequency exceeds 110 Contact an authorized distributor dealer for shutdown of the system s frequency setpoint for more than 1 second service if problem continues This protective becomes active 30 seconds after engine start Overspeed Shutdown occurs
83. tart stop switch can be connected to controller leads 3 and 4 See the wiring diagrams in Section 5 2 3 3 Stopping the Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Automatic Stopping With the generator set master switch in the AUTO position and an automatic transfer switch ATS or other automatic device connected to controller leads 3 and 4 1 The ATS or other device disconnects the load from the generator set 2 If the ATS is equipped with an engine cooldown time delay the generator set continues to run for a preset engine cooldown time Note There is no engine cooldown time delay on the ADC controller 3 The ATS or other device opens the connection between controller leads 3 and 4 The generator set shuts down LED display Runtime hours Displays total generator set runtime hours while the generator set is running 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 Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 2 3 4 Software version number See TP 6196 Generator Set Ser
84. tery connection information See Figure 3 7 for typical battery connections Check the electrolyte level and specific gravity of batteries with filler caps Maintenance free batteries do not require electrolyte level checking or specific gravity testing Clean the battery and cables and tighten battery terminals using the service schedule recommendations Clean the battery by wiping it with a damp cloth Clean both battery terminals with baking soda Keep the electrical connections dry and tight EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 7 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection 3 8 1 Cleaning the Battery To prevent dirt and grime buildup occasionally wipe the battery with a damp cloth To prevent corrosion maintain tight dry electrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables TP 6195 1 04 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 with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease 3 8 2 C
85. tor dealer or mail it directly to Kohler Power Systems Generator Warranty Administrator M S 072 Kohler Wisconsin 53044 Section 6 Installation 37 Notes 38 Section 6 Installation TP 6195 1 04 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt AI ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux AN avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA CCW CEC cert ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring mater
86. ule Wash and reoil the precleaner more often under extremely dusty or dirty conditions 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the power to the battery charger 3 Disconnect the battery negative lead first 4 Loosen the cover retaining knob and remove the cover Remove the precleaner from the paper element Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 5 Saturate the precleaner with new engine oil Squeeze out all of the excess oil 6 Reinstall the precleaner over the paper element 7 Reinstall the air cleaner cover Secure the cover with the cover retaining knob 8 Reconnect the power to the battery charger 9 Reconnect the generator set engine starting battery negative lead last 3 5 2 Paper Element Service Use the following procedure to replace the paper element at the intervals specified in the service schedule Replace the paper element more often under extremely dusty or dirty conditions TP 6195 1 04 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Loosen the cover retaining knob and remove the cover 5 Remove the element cover nut element
87. ure 2 2 describes the controls and indicators located on the generator set controller The LED display indicates generator set status as shown in Figure 2 2 The display is activated by a start or run command and remains active until the generator set master switch is moved to the OFF RESET position or power to the controller is removed If the factory installed continuous power mode jumper has been disconnected the LED display turns off 48 hours after generator set shutdown See Section 2 3 6 The buttons on the controller keypad are used only for system configuration and adjustment The controller is factory set and should not require configuration or adjustment under normal operating conditions Contact an authorized distributor dealer or service technician if adjustments are required 2 3 2 Starting the Generator Set The following procedures describe the actions required to start the generator set The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault Local Starting Move the generator set master switch to the RUN position to immediately start the generator set Auto Automatic Starting Move the generator set master switch to the AUTO position to allow startup by the ATS or the remote Control or Indicator Item Description start stop switch A remote s
88. ure at rated kW dry exhaust C F 3 3 115 3 8 135 2 7 96 3 2 113 816 1500 Figure 6 2 Exhaust Flow and Temperature 6 6 Air Requirements The generator set requires correct air flow for cooling and combustion The inlet and outlet openings in the sound enclosure provide the cooling and combustion air Figure 6 3 shows the locations of the cooling air intake and exhaust vents Inspect the air inlet and outlet openings inside and outside the housing to ensure that the air flow is not blocked 1 Exhaust outlet 2 Alternator air intake both sides 3 Engine air intake Figure 6 3 Cooling Air Intake and Exhaust 3 8 5RES 12RES Cooling Air Requirements 60 Hz 50 Hz 60 Hz 50 Hz Cooling air m3 min cfm 26 9 950 22 4 790 26 9 950 22 4 790 Total inlet air requirement m min cfm 27 8 980 23 2 820 28 0 990 23 4 825 Combustion air m3 min cfm 0 94 33 4 0 8 28 0 1 1 39 2 0 9 32 6 Figure 6 4 Cooling Air Requirements TP 6195 1 04 6 7 Power Supply Utility power must be supplied to the generator set location Provide a 110 or 120 volt outlet connected to the utility power supply for the battery charger standard and carburetor heater optional Figure 6 5 lists the battery charger power requirements Rated AC voltage 90 135 VAC 50 60 Hz Current draw 1 6 amp at full
89. uric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety 14 Section 3 Scheduled Maintenance 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 battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid 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 time particularly when itis charging Do not dispose ofa battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals w
90. vice Manual Select and arrow buttons Generator set master Three position switch switch Figure 2 2 ADC 2100 Controls and Indicators 4 Section 2 Operation The keypad is used for controller setup and adjustment only Have setup and adjustments performed only by an authorized distributor dealer The setup and adjustment functions are password protected Switch functions as the generator set operation and controller reset switch TP 6195 1 04 2 3 4 Fault Shutdowns The shutdown switches on the generator set automatically reset when the problem is corrected The The generator set shuts down automatically under the high engine temperature switch automatically resets fault conditions listed in Figure 2 3 and the controller when the generator set cools However the fault does displays a fault code The generator set cannot be not clear until the controller is reset restarted until the fault condition is corrected and the controller is reset See Section 2 3 5 to reset the The controller displays a fault code but the generator set controller after a fault shutdown The controller resets does not shut down under the conditions shown in automatically after a battery voltage fault condition is Figure 2 4 corrected Fault Description Check Auxiliary fault Input from a customer supplied switch that closes when the Check the cause of the auxiliary fault input shutdown fault is active The generator set shuts down and will not s

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