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Residential/Commercial Generator Sets

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1. il iil b Ifthe throttle linkage moves erratically or not at all at startup proceed to step 7 to check the stepper motor Figure 5 13 Magnetic Pickup Leads 4 Verify the operation of the magnetic pickup by connecting a voltmeter to the magnetic pickup leads See Figure 5 13 48 Section 5 Component Testing and Adjustment TP 6196 5 04 Ignition module Air gap 0 5 mm 0 020 in A 358000B C Top of flywheel ring gear tooth Lock nut Magnetic pickup Figure 5 14 Magnetic Pickup Air Gap Check that the carburetor throttle linkage is connected to the stepper motor as shown in Figure 5 12 Check for broken or loose wiring or connections and other items in step 2 Check stepper motor operation at startup Does it move to fully open and then move Y to and stay in the fully closed position en See step 3 No Y Check the magnetic pickup See steps 4 6 Disconnect the magnetic pickup and check the stepper motor operation again See steps 7 9 Checkthe magnetic pickup connections to the controller P1 17 P1 18 and P1 29 Check the stepper motor connections to the controller See step 10 Check the stepper motor coils See step 11 Y Troubleshoot the ADC controller See step 12 Figure 5 15 Governor
2. 1 Appendix Common Hardware Application Guidelines A 3 Appendix C General Torque Specifications 4 Appendix D Common Hardware Identification A 5 Appendix Common Hardware List 6 Table of Contents TP 6196 5 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 or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates install
3. TOSSA g Remove the leads connected to the end bracket from the convoluted conduit leading to the controller Set the end bracket assembly aside WA GM29253B P Side View Brush holder Spring Ring collector Brush holder Brush Correctly positioned brush Retainer wire Incorrectly positioned brush Shim Slip ring Figure 6 10 Brush Details GM29253B P Brush cover screws Overbolt and centering washer Brush holder Brush retainer wire hole Thrubolt Alternator mounting plate Figure 6 9 Alternator End Bracket 64 Section 6 Disassembly Reassembly TP 6196 5 04 7 Remove the stator and rotor a Remove the stator from the rotor b Loosen and remove the thrubolt Use a strap wrench on the rotor to keep the rotor from turning during loosening if necessary See Figure 6 11 c Remove the rotor assembly by striking the side of the rotor repeatedly with a soft faced hammer to loosen it from the tapered crankshaft fitting See Figure 6 11 Rotate the rotor and strike it on alternate sides Set the rotor assembly aside 8 Remove the four engine adapter mounting bolts See Figure 6 12 Remove the generator adapter 4 IN k GM29253A P 1 Thrubolt and magnetic actuator 2 Rotor strike surface 3 Generator ad
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6. NOLLINDI 5 NOI 3NION3 ANO 3NION3 ScHO v on BSVHd s85 AQv 33 SNOLLO3NNOO HOLVH3N39 HOS 310N AV1AG 03S 0 038 S LIBIHNI O3S 01 AHO vy 3SN3s OV 93S 0 NMOGLAHS 1 ma i 180 Lito or dann E a v 91d aneo 0 9 1 134 99 y XX 134 99 FR Tm 734 99 di 4 940 99 940 99 6 914 ATH 8 91444 13 4 14 1 z 9id 7IOH1NOO ATH XPIV 130 L v 1d 7IOH1NOO ATH L14 WOO 7IOH1NOO ATH 1HVIS 76 Ld AV 938 NMOGLNHS 39V LTOAH3AO 3OVLIOA OV 1O3NNOOSIQ MO1HOSNAS 1 1009 6 14 NMOGLNHS G3Av 13d 0385 HOIH HOSN3S LNV1009 8 14 2 1 HONH3AOO 81 14 HOSN3S HA 68 14 9 14 MO1HOSN3S HA 21 19 140181 16 82 14 Id VI
7. 50 5 9 Fault Shutdown Tests 51 5 9 1 Controller Fault Shutdown Functions 52 5 9 2 Fault Shutdown 5 53 540 FUG Systems e belts isque 54 5 10 1 pe dade 54 5 10 2 Fuel Solenoid Valve 54 5 10 3 5 54 5 10 4 Fuel Conversion 55 5 10 5 Digital Spark Advance Module DSAM 57 5 10 6 Fuel Metering Valve Adjustment 57 5 11 FUSES perras MGR M eR Rus ME SA I 59 5 12 Continuity Checks 59 Section 6 Disassembly Reassembly 61 6 1 4 rede ues ei det Eden b deerit 61 6 2 Beassembly 8 65 Section 7 Wiring Diagrams eur EI 71 7 1 Specification Numbers 71 7 2 Controller Wiring Diagram Reference 71 Appendix A Abbreviations
8. EMI 21 41 Introduction S ua 21 4 2 Controller Display and Keypad 22 4 3 Sequence of Operation 23 4 3 1 Starting Sequence Master Switch Moved to RUN 23 4 3 2 Starting Sequence Remote Start 23 433 Running Sequence 23 4 3 4 Stopping Sequence Master Switch Moved to OFF RESET 23 4 3 5 Stopping Sequence Remote Stop 23 44 Eaults chet iate Sede desc aR o up e 24 4 4 1 cera 2 ede tbe Set c 24 442 Sh tdOWHs RS ee 24 TP 6196 5 04 Table of Contents Table of Contents continued 4 5 Controller Configuration and Adjustment 26 4 5 1 Controller Time 26 4 5 2 Controller Configuration 26 453 Voltage and Frequency Adjustments 27 4 5 4 Controller Application Program 27 4 6 Continuous Power Mode Jumper 32 4 7 Master Switch YVES RES eni espe PODER t pond 33 4 8 Relay Interface Board RIB 34 4 9 Silicon Con
9. 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 Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service as this may result 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
10. Low coolant level Not used on air cooled models Loss of coolant Not used on air cooled models Low oil pressure Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protective becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Check low oil pressure switch connections and operation Check the oil pump and lubrication system 2 2 2 2 5 9 2 5 9 Engine S M Overcrank Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest Check the fuel supply valves and pressure Check spark plug and battery See Troubleshooting Chart generator set cranks but does not start 5 10 2 3 3 3 The generator set shuts down on an overcrank fault if no engine rotation is sensed Shuts down after 3 seconds of cranking or 1 second after the fault is detected Check mag pickup connections and operation Check for a locked rotor 5 8 4 5 4 Overfrequency Shutdown occurs when the governed frequency exceeds 11096 of the system s frequency setpoint for more than 5 seconds This protective becomes active 10 seconds after en
11. SE89 AQV 33S SNOLLOSNNOO YAdWNS HOS ALON 6L SNOILO3NNOO 14 H3TIOHLINOO 001 6196 5 04 Diagram Single Phase GM29358 D Figure 7 5 8 5 12 5 Point to Point Wiring 74 Section 7 Diagrams and Drawings 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 5 AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min CARB CB CCW CEC cert cfh 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
12. p To raise or lower the engine governor stability gain in smaller increments To enter SAVE mode Go to Figure 4 12 SAVE Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 4 11 Output Voltage and Frequency Adjustments Continued TP 6196 5 04 Section 4 Controller 31 There are 3 options when the display says SAVE Press To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 4 7 To save changes To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET Figure 4 12 Save Mode after generator set and engine adjustments 4 6 Continuous Power Mode Jumper WARNING x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative
13. WARNING 4 Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel supplier provides and maintains manual shut off valves and the primary regulator Verify that the fuel system capacity is adequate to supply the generator set plus all other gas appliances A factory installed secondary regulator and 12 VDC solenoid valve are located in the front inlet air compartment The controler energizes the fuel solenoid valve to open at startup and deenergizes the valve to close at shutdown The secondary fuel regulator reduces fuel pressure for delivery to the fuel block The fuel flows from the fuel block to the carburetor in a gaseous state The carburetor mixes the fuel with intake air for consumption by the engine Use a universal exhaust gas oxygen UEGO sensor to check the fuel mixture after replacing the fuel regulator fuel mixer or silencer The engine should be warm when the fuel mixture is checked See Section 5 10 6 for instructions to check the fuel mixture Refer to the troubleshooting instructions in Section 3 Troubleshooting to identify generator set operation problems that may be caused by an inadequate fuel supply incorrect adjustments or damaged fuel system components Then use the instructions in this section to check fuel system components 5 10 1 Gas Piping Verify that the gas pipe size meets the size specification
14. c Repair or replace the rotor if the reading is less than approximately 500 kOhms A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground d Following the test remove the retainer wire from the brush holder and check the brush positions on the slip rings See Section 5 6 Brushes e Reinstall the brush cover on the end bracket Section 5 Component Testing and Adjustment 48 5 5 Slip Rings Slip rings acquire a glossy brown finish in normal operation Do not attempt to maintain a bright newly machined appearance on the slip rings Cleaning with a dry lint free cloth is usually sufficient Use very fine sandpaper 00 and apply light pressure to remove roughness Do not use emery or carborundum paper or cloth Clean all carbon dust from the generator after sanding the slip rings If the rings are black or pitted remove the rotor and use a lathe to remove some of the slip ring surface material 5 6 Brushes The brushes transfer current from the SCR module to the slip rings The brushes should last the life of the generator Abrasive dust on the slip rings however shortens the life of the brushes Excessive arcing atthe brushes could damage the SCR module and the controller Weak springs damaged slip rings sticking brushes a loose brush holder or poor brush contact causes arcing The brushes must be free to move within the holder and be held in contact w
15. internal engine component storage 2 8 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Remove and replace the oil filter 5 Refill the crankcase with oil suited to the climate 6 Run the generator set for two minutes to distribute the clean oil 7 Stop the generator set 8 Check the oil level and adjust if needed 2 8 2 Fuel System Prepare the fuel system for storage as follows 1 Start the generator set 2 With the generator set running shut off the gas supply TP 6196 5 04 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position 2 8 3 Internal Engine Components Gas Gasoline Fueled Engines If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows 1 While the engine is running spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops 2 Place the generator set master switch in the OFF RESET position If a fogging agent is not available perform the following 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
16. 52 Section 5 Component Testing and Adjustment Increase the engine speed parameter 4P to at least 11596 ofthe rated engine speed 69 Hz on 60 Hz models or 58 Hz on 50 Hz models Verify that the generator set shuts down on an overspeed fault OS If the overspeed shutdown does not operate the generator set should shut down on an overfrequency fault OF after approximately 5 seconds If the controller does not indicate an overspeed fault OS check the wiring to the magnetic pickup red and black leads P1 17 and P1 29 Check the magnetic pickup air gap and voltage output see Section 5 8 4 Low Oil Pressure LOP Shutdown Connect a jumper wire from the LOP switch lead 13 to the generator set ground Startthe generator set Verify that the generator set shuts down after approximately 25 35 seconds of operation Remove the jumper wire from the LOP switch and ground Startthe generator set and run it for at least 25 35 seconds to verify that the generator set does not shut down Overcrank Shutdown Disconnect the starter motor lead the starter solenoid K20 terminal Move the controller master switch to the RUN position Observe that the generator set simulates cranking for 15 seconds and then rests for 15 seconds Check that the generator set shuts down after the third crank rest cycle High Engine Temperature Shutdown Connect a jumper wire across coolant temperature sensor CTS connections P1 8 and P1 9 Start the ge
17. 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 rotorthrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware Notice NOTICE This generator set has been rewired from its nameplate voltage to 246242 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 numer
18. Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See Appendix C General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance 3 1 1 2 of bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6196 5 04 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued whiz nut or spiralock nut See Figure
19. Repair or replace the component causing the blown fuse Section 7 ADV 6835 If fuse continues to blow and the previous step did not identify the cause check the continuity of leads FP and FN and the leads from the P14 connector Replace any bad leads Use a pin pusher part 241918 large or 241919 small to remove leads from the connector if necessary If replacing the leads does not solve the problem replace the RIB Section 7 ADV 6835 Section 4 8 Crank relay on relay interface board RIB Check connections to the RIB Check for 12VDC to the RIB on lead 71N Section 4 8 Section 7 Check for a good ground connection lead 16N Section 7 Check crank relay K2 operation LEDS Replace the RIB if relay does not operate Section 4 8 Generator set master switch Check connections to the master switch on the ADC 2100 Section 4 7 Section 5 12 Test function of switch Section 5 12 Poor ground connection Clean and retighten Starter relay Check connections to the starter relay Section 1 8 Check continuity of circuit Section 5 12 Section 7 Check that the starter relay picks up when 12VDC is applied at lead 71A connection Section 7 Check starter connections Section 1 8 Section 7 Rebuild or replace starter Engine Service Manual S M Controller 16 Section 3 Troubleshooting Check controller connections and operat
20. Section 5 Component Testing and Adjustment 51 Controller Fault Shutdown Functions 5 9 1 Check the operation of the fault functions programmed in the ADC 2100 by performing the following tests If the ADC 2100 does not operate as described check the controller configuration settings see Section 4 5 2 Also check the controller wiring and connections Overspeed Shutdown The overspeed setting is programmed into the ADC controller and is not adjustable Verify that the following controller configuration parameters are set correctly for your unit See Section 4 5 2 and Figure 4 6 for the settings e System voltage frequency parameter UU e Unit configuration parameter UC e Engine type parameter EC e Engine data input type parameter ED WARNING QMS Ea Hot engine and exhaust system Can cause severe injury or death 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 Open the generator set output circuit breaker before beginning the test See Figure 4 1 for the circuit breaker location Connect a DVM to measure the output frequency Start the generator set and manually adjust the engine speed by moving the throttle linkage Note Be carefull not to touch the hot silencer when reaching in to adjust the throttle linkage
21. To raise or lower the voltage in smaller increments approximately 0 5 0 7 volts per step lt N To enter coarse voltage stability gain adjustment mode To raise or lower the voltage stability gain in large increments To enter fine voltage stability gain adjustment mode To raise or lower the voltage stability gain in smaller increments To enter volts Hz adjustment mode To raise or lower the volts Hz 00 low 09 high Continued on Figure 4 11 Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 4 10 Output Voltage and Frequency Adjustments 30 Section 4 Controller TP 6196 5 04 Continued from Figure 4 10 Display Press To enter engine governor speed coarse adjustment mode 2 N E To raise or lower the engine speed in large increments To enter engine governor speed fine adjustment mode 2 N increments To raise or lower the engine speed in smaller To enter engine governor stability gain coarse adjustment mode To raise or lower the engine governor stability gain in large increments To enter engine governor stability gain fine adjustment mode
22. d 1 u30uvHo Figure 7 3 8 5 12RES Schematic Diagram Single Phase Sheet 1 ADV 6835A E TP 6196 5 04 72 Section 7 Diagrams and Drawings pv 8A sir 6A 1 OY LULA 1 OV 1 8 SNOLLO3NNOO 917 99 LNdNI XNY 9 9 4 8 9 4 3 SANIN SAG 91314 9 ONIGNIM XNY 91d 100 2 9 4 5 SAd 1 914 SNOILLOSNNOO 917 6 4 103185 SGOW H3MOd 12 44 1 44 SNOLLO3NNOO 24 O N 6 Sd O N 8 Sd O N 1084 O N 9 Sd 9 84 65654 9 2605 82 84 b Sd SNOLLO3NNOO Sd 65254 86 14 46 14 LYSA 66 14 26 1 TWNDIS HOSN3S 3HflSSdHd 16 14 3Oounos HOSN3S du iS S3Hd 06 14 HOSN3S 62 14 SSOT 3A311NV1OOO 82 14 46 14 24018 1 16 31OW3H 98 14 13S3u 440 dOLS LHVLS 31OWdH 98 14 1V8A v ld aNnOHO 62 14 22 14 QNnOHO 12 14 QNnOHO 02 14 6 71 vin HOSN3S 3H lSSdHHd 6 14 voz 1904 2 914 QNnOHO 81 14 1VS8A 9 bld MOT1HOSN3S HA 21 14 QNnOHO 91 14 AV 13H HSV14 S vld S3ALLVO3N NOILINDI t tld HOLIMS 39055394 10 91 14 AVI3H H3lHVIS vld 110 HOWL LINYA NOWIWOO 2 1nOAvI3H 1903 6
23. FLASH GM29779 A K1 common fault relay optional K2 crank relay standard K8 flash relay standard K4 auxiliary run relay optional K5 run relay standard P14 engine harness connection standard P13 connection to optional relay harness optional Figure 4 14 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 closed Figure 4 15 Optional Common Fault and Run Relay Board Harness Connections TP 6196 5 04 4 9 Silicon Controlled Rectifier SCR Module The silicon controlled rectifier SCR module works with the ADC 2100 to regulate the output voltage The ADC 2100 monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module The SCR module location is shown in Figure 4 1 The SCR module is powered through stator leads 55 and 66 connected to SCR terminals AC1 and AC2 Leads G connected to terminals G1 and G2 provide the controller signal Leads FP and FN connected to the positive and negative SCR terminals provide excitation current to the rotor See Figure 4 16 and the wiring diagrams in Section 7 The SCR module is protected by a 20 amp fuse F1 in lead 55 in the wiring harness Check the fuse and replace it if blown In the case of output voltage prob
24. 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 material 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 cubic feet per hour TP 6196 5 04 CG CID CL cm CMOS cogen com 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 DVR E emer EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc 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
25. for further information 5 this test shows that the rotor and stator are in good condition check the wiring and fuses Check the SCR module See Section 4 9 Silicon Controlled Rectifier SCR Module Check the controller settings and connections See Section 4 Controller TP563274 SCR module FN lead disconnected from SCR FP lead disconnected from SCR 10 amp fuse DC ammeter 12V battery Brushes Slip rings Main field rotor Figure 5 3 Separate Excitation Connections TP 6196 5 04 5 3 Stator The stator contains a series of coils of wire laid in a laminated steel frame The stator leads supply voltage to the load and voltage regulator Before testing the stator inspect it for heat discoloration and visible damage to housing lead wires exposed coil windings and exposed areas of frame laminations Be sure the stator is securely fastened to the stator housing Note Disconnect all stator leads before performing all stator tests 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 High voltage test Hazardous voltage can cause severe injury or death Follow the instructions ofthe test equipment manufacturer when performing high voltage
26. 14 15 16 Follow the instructions in Section 4 5 2 to change the new controller s configuration settings to match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings Use a voltmeter to check the output voltage Follow the instructions in Sections 4 5 3 Voltage and Frequency Adjustments and 5 7 2 Voltage Adjustment to adjust the output voltage and stability Check the output frequency Follow the instructions in Sections 4 5 3 Voltage and Frequency Adjustments and 5 8 5 Frequency Adjustment to adjust the output frequency and stability Place the generator set master switch the AUTO position if an ATS or remote start stop switch is used Replace the enclosure door TP 6196 5 04 Section 5 Component Testing and Adjustment 5 1 Theory of Operation 1 Phase Generator Sets Single phase 8 5 12RES generator sets utilize rotating field alternator to produce AC voltage Upon activation of the generator master switch DC current from the battery magnetizes the rotor field When the magnetized rotor rotates within the stator windings an electrical voltage develops within the stator As engine speed and generator output increase the SCR module feeds rectified stator output current to the rotor through the brushes slip rings to increase the strength of the rotor field the rotor field increases in strength
27. 2 11 55 or 66 4 and 1 2 11 55 or 66 Any stator lead and ground on stator housing or frame laminations Figure 5 6 Continuity Test Results on a Good Stator 42 Section 5 Component Testing and Adjustment 5 4 Field Rotor The two pole rotor creates the magnetic field needed to produce alternating current in the stator windings Before testing inspect the rotor for visible damage to pole shoes insulation exposed coil windings and slip ring surfaces Rotate the bearing to check for wear heat discoloration or noise 5 4 4 Rotor Continuity and Resistance Tests 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 High voltage test Hazardous voltage can cause severe injury or death Follow the instructions ofthe test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure 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 cod
28. 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 WARNING QM Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation 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 TP 6196 5 04 Section 2 Scheduled Maintenance See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized distributor dealer perform generator set service Alternator Service Under normal operating conditions the generator set alternator does not require scheduled service Refer to the service schedule for items that require maintenance Engine Service Perform generator set engine service atthe intervals specified by the engine service literature Contact an authorized Kohler servic
29. Description High battery Fault code is displayed if the engine starting battery Check the battery rating and condition voltage warning voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than one minute 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 voltage within the limits for more than 10 seconds Low battery Fault code is displayed if the engine starting battery Check the battery rating and condition voltage warning voltage falls below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than one minute when the engine is not running This Charge or replace the battery fault condition does not inhibit engine starting 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 4 4 Fault Warning Codes 24 Section 4 Controller TP 6196 5 04 Auxiliary fault Description Not used on the model 8 5 12RES Check Refer to Section High engine temperature Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protective becomes active after the engine reaches the crank disconnect speed Check for blocked air inlets and exhaust outlets
30. Elastic Stop Elastic Stop Spiralock Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Standard Elastic Stop Standard Bolt Thick Screw M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 o 3 03 0 CO TO NN as Os oooooo0ooooo This metric hex bolt s hardness is grade 10 9 This metric hex nut s hardness is grade 8 Appendix A 7 6196 5 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 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
31. M933 12040 82 M961 14025 60 M933 14025 60 M961 16025 60 M933 16025 60 M961 16030 82 M933 16030 82 M933 16035 60 M961 16040 60 M933 16040 60 M933 16050 60 M933 16050 82 M933 16060 60 M933 18035 60 M933 18050 60 M933 18060 60 M933 20050 60 M933 20055 60 M4 0 70 x 6 5 0 80 x 35 5 0 80 50 6 1 00 10 6 1 00 14 6 1 00 16 6 1 00 20 6 1 00 25 6 1 00 40 6 1 00 50 M8 1 25 x 12 M8 1 25 x 16 M8 1 25 x 20 M8 1 25 x 25 M8 1 25 x 30 M8 1 25 x 30 M10 1 50 x 12 M10 1 25 x 20 M10 1 50 x 20 M10 1 50 x 25 M10 1 25 x 30 M10 1 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M12 1 75 x 16 M12 1 75 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 25 x 30 M12 1 75 x 30 M12 1 75 x 35 M12 1 25 x 40 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M16 1 50 x 25 M16 2 00 x 25 M16 1 50 x 30 M16 2 00 x 30 M16 2 00 x 35 M16 1 50 x 40 M16 2 00 x 40 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M18 2 50 x 35 18 2 50 x 50 M18 2 50 x 60 M20 2 50 x 50 M20 2 50 x 55 Pan Head Machine Screws M7985A 03010 20 7985 03012 20 M7985A 04010 20 M7985A 04020 20 M7985A 04100 20 M7985A 05010 20 M7985A 0501 2 20 M7985A 05016 20 M7985A 05100 20 M7985A 06100 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 10 M4 0 70 x 20 M4 0 70 x 100 5 0 80 x 10 5 0 80 x 12 5 0 80 16 5 0 80 100 6 1 00 100 Flat Head Machine Screws M965A 04012 SS
32. M965A 05012 SS M965A 05016 20 M4 0 70 x 12 5 0 80 12 5 0 80 16 Part No Hex Nuts M934 03 50 M934 035 50 M934 04 50 M934 05 50 982 05 80 934 06 60 934 06 64 6923 06 80 982 06 80 934 08 60 6923 08 80 982 08 80 934 10 60 M934 10 60F M6923 10 80 M6923 10 62 M982 10 80 M934 12 60 M934 12 60F M6923 12 80 M982 12 80 M982 14 80 M6923 16 80 M982 16 80 M934 18 80 M982 18 80 M934 20 80 M982 20 80 M934 22 60 M934 24 80 M982 24 80 M934 30 80 Washers Part No M125A 03 80 M125A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80 M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions M3 0 50 M3 5 0 50 M4 0 70 5 0 80 5 0 80 6 1 00 6 1 00 6 1 00 6 1 00 8 1 25 8 1 25 8 1 25 10 1 50 10 1 25 10 1 50 10 1 50 10 1 50 12 1 75 12 1 25 12 1 75 12 1 75 14 2 00 16 2 00 16 2 00 18 2 5 18 2 50 M20 2 50 M20 2 50 M22 2 50 M24 3 00 M24 3 00 M30 3 50 OD 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Standard Standard Standard Standard Elastic Stop Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop Standard Standard Spiralock Spiralockt Elastic Stop Standard Standard Spiralock
33. connection P15 1 and P15 3 stator leads 11 and 44 OFF RESET Zero ohms continuity If no continuity check wiring P16 3 and P16 6 stator leads 55 and 66 OFF RESET Zero ohms continuity If no continuity check fuse F1 and wiring Controller fuse and wiring P1 24 and battery positive OFF RESET Zero ohms continuity If no continuity is found check fuse F3 and wiring Auxiliary winding fuse 20 amp fuse P16 3 and stator lead 55 OFF RESET Zero ohms continuity If no continuity is found check for an open circuit and or a blown fuse Low oil pressure LOP switch Lead 13 and ground engine block R x 100 OFF RESET Zero ohms continuity No continuity indicates a bad switch and or wiring Temperature sensor CTS P1 8 and P1 9 R x 1000 OFF RESET 180 2500 ohms depending on engine temperature Zero ohms or an open circuit indicates bad wiring or a bad switch Starter relay See illustration below CIRCUIT DIAGRAM NORMALLY OPEN CASE GROUND Starter relay terminal and relay base ground OFF RESET 5 7 ohms Lower resistance indicates a shorted relay coil and or wiring High resistance indicates an open relay coil and or wiring See Section 5 9 2 Fault Shutdown Switches Figure 5 29 Continuity Checks 60 Section 5 Component Testing and Adjustment TP 6196 5
34. d Loosen and remove four controller mounting screws at the front of the controller See Figure 4 24 Remove the controller from the compartment 1 P1 35 pin connector e Placethe new controller into position and install 2 P15 connector the four mounting screws Pil Connecter f Attach connectors P1 P15 and P16 to the new controller g Replace the cover on the controller compartment h Replace the front panel on the air intake end of the enclosure 1 Controller mounting screws 4 ea Figure 4 21 Controller Mounting Screws inside mounted controller shown 1 Cover screws Figure 4 19 Controller Compartment Cover TP 6196 5 04 Section 4 Controller 37 7 10 11 For front mounted controllers a Remove four mounting screws from the front of the controller b Carefully pull the controller forward angling it sothatthe P1 connector on the right side clears the opening in the mounting plate c Disconnect plugs P1 P15 and P16 from the ADC controller See Figure 4 20 d Attach plugs P1 P15 and P16 to the new controller e Placethe new controller into position and install the four mounting screws Verify that the generator set master switch is in the OFF position Reconnectthe engine starting battery negative lead last Reconnect power to the battery charger Replace the roof and tighten the four roof screws 38 Section 4 Controller 12 13
35. then a problem in the load circuits is causing the line circuit breaker to trip Check for and correct short circuits or overloading on the load side before resetting the circuit breaker Alternator or control system Perform separate excitation procedure to isolate the problem to the alternator or the control system Then troubleshoot the alternator or control system components as follows Section 5 2 Aux winding fuse blown lead 55 Replace blown fuse If fuse blows again check stator Section 5 3 SCR module Check auxiliary winding fuse F1 lead 55 Replace SCR module and test voltage Section 5 11 Section 4 9 Controller Check controller settings Check wiring and connections Before replacing controller replace SCR module and check voltage Section 4 5 Section 4 10 Open wiring terminal or pin in buildup circuit or SCR module circuit Check continuity Sections 5 11 Section 7 Brushes Inspect brushes and replace if worn Section 5 6 Check for brushes sticking in brush holder or broken brush spring Section 5 6 Rotor connections Check for open circuit in rotor connection circuit leads FN and FP to SCR and RIB Section 7 Rotor slip rings dirty or corroded Check slip ring condition Section 5 4 Rotor open grounded or shorted windings Check voltage and continuity Section 5 4 Stator open grounded or shorted windings Check vo
36. 0 05 2 60 0 05 2 60 0 05 Figure 5 26 Acceptable Oxygen Sensor Readings TP 6196 5 04 5 11 Fuses The engine harness contains three inline fuses See Figure 5 27 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 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts Part Number 292937 Location Auxiliary Winding Lead 55 20 amps Relay Interface Board 10 amps Controller 10 amps Battery Charger 10 amps 223316 Lead PF2 223316 AGS 10 Lead PF1 Battery charger DC lead Figure 5 27 Fuses 5 12 Continuity Checks 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 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 or repairs Remove all jewelry before servicing the equipment TP 6196 5 04 To further check generator set components disconnect the battery and remove wiring harness plugs from the controller circuit board Use an ohmmeter to check the continuity of the components listed in Figure 5 29
37. 04 Section 6 Disassembly Reassembly This section provides instructions for the disassembly and reassembly of the generator set alternator Before beginning the generator disassembly or reassembly procedure carefully read all safety precautions at the beginning of this manual 6 1 Disassembly The disassembly procedure provides important information to minimize disassembly time and indicates where special configurations exist which may require taking notes 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 1 Remove the generator set from service and remove the generator set enclosure a Remove the enclosure service side door See Figure 6 1 b Place the generator set master switch in the OFF position c Remove 4 roof screws Lift the roof up and off See Figure 6 1 d Remove 5 screws to remove the front panel Remove the plastic caps to access the 2 side screws See Figure 6 2 e Disconnect power to the battery charger f Disconnect the generator set engine starting battery negative lead first g Turn off the fuel supply to the generator set h From the inside of the enclosure remove 5 screws to remove the rear exhaust end panel See Figure 6 3 i From the inside of the enclosure remove the remaining screws to remove the non service side housing panel TP 61
38. 2 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware and a slot b Always use a washer under a nut see 2 above for exception Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities E Cap screw Entry hole types Standard nut and SAE washer 4 Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types Figure 2 Acceptable Hardware Combinations Appendix A 3 Appendix C General Torque Specifications Use the following torque specifications when service literature instructions give no specific torque values The charts list values for new plated zinc phosphate or oiled threads Increase values by 1596 for nonplated threads All torque values are 0 10 American Standard Fasteners Torque Specifications Torque Assembled into Cast Iron or Steel Assembled into Aluminum Measurement Grade 2 1 8 Grade 5 Grade 8 Grade 2 or 5 1 8 2 9 2 9 2 9 6 8 6 8 8 1 8 1 13 6 13 6 14 9 14 9 24 0 24 0 27 0 39 0 43 0 60 0 66 0 81 0 91 0 113 0 128 0 199 0 147 222 0 164 259 0 191 283 0 209 Metric Fasteners Torque Specifications Measured in N
39. 4 20 x 62 1 4 20 x 75 1 4 20 x 88 1 4 20 x 1 00 1 4 20 x 1 25 1 4 20 x 1 50 1 4 20 x 1 75 1 4 20 x 2 00 1 4 20 x 2 25 1 4 20 x 2 75 1 4 20 x 5 00 1 4 28 x 38 1 4 28 x 1 00 5 16 18 x 50 5 16 18 x 62 5 16 18 x 75 5 16 18 x 88 5 16 18 x 1 00 5 16 18 x 1 25 5 16 18 x 1 50 5 16 18 x 1 75 5 16 18 x 2 00 5 16 18 x 2 25 5 16 18 x 2 50 5 16 18 x 2 75 5 16 18 x 3 00 5 16 18 x 4 50 5 16 18 x 5 00 5 16 18 x 5 50 5 16 18 x 6 00 5 16 18 x 6 50 5 16 24 x 1 75 5 16 24 x 2 50 5 16 24 x 75 5 16 24 x 2 00 5 16 24 x 2 75 3 8 16 x 62 3 8 16 x 75 3 8 16 x 88 3 8 16 x 1 00 3 8 16 x 1 25 3 8 16 x 1 50 3 8 16 x 1 75 3 8 16 x 2 00 3 8 16 x 2 25 3 8 16 x 2 50 3 8 16 x 2 75 3 8 16 x 3 00 3 8 16 x 3 25 3 8 16 x 3 50 3 8 16 x 3 75 3 8 16 x 4 50 3 8 16 x 5 50 3 8 16 x 6 50 3 8 24 x 75 3 8 24 1 25 3 8 24 4 00 3 8 24 4 50 6 Appendix Part No Dimensions Hex Head Bolts cont X 6024 5 X 6024 2 X 6024 8 X 6024 3 X 6024 4 X 6024 11 X 6024 12 X 129 15 X 129 17 X 129 18 X 129 19 X 129 20 X 129 21 X 129 22 X 129 23 X 129 24 X 129 25 X 129 27 X 129 29 X 129 30 463 9 129 44 129 51 129 45 129 52 6021 3 6021 4 6021 2 X 6021 1 273049 X 6021 5 6021 6 6021 7 6021 12 6021 11 6021 10 6021 9 6239 1 6239 8 6239 2 6239 3 6239 4 6239 5 6239 6 X 792 1 X 792 5 X 792 8 7 16 14 x 75 7 16 14 x 1
40. Low Oil Pressure Shutdown 7 2 222 discere E 7 2 2 8 Engine Oil Recommendation 7 224 Change Procedure 8 2 37 SparkiElugs ae ee 9 24 Air Cleaner Element and Precleaner 9 2 5 Cooling System Docteur tete date vo PRU Rie VE 11 2 6 Exhaust i tse dd ERE RP Rb beue brit 11 2 7 BRAD etr RE 11 2 7 1 Cleaning the Battery 12 27 2 soie come ok ile Rar 12 2 8 Storage Procedure esee Ree x 12 2 8 1 Lubricating System 12 28 2 Fuel System iore VES eren RU eee 12 2 8 8 Internal Engine Components Gas Gasoline Fueled Engines 13 2 8 4 Exterior 2 eed E us 13 2 8 5 Battery AT EE 13 Section 3 Troubleshooting 15 3 Introduction 2 Med riui 15 3922 Ghecks s ise 15 3 3 Troubleshooting Chart 15 Section 4 Controller ure a
41. Refer to Section Action Inspect Check Change Interval Oil level 8 hrs or before use Crankcase breather hose Yearly or 500 Hrs Change oil Yearly or 100 Hrs Replace filter s Yearly or 200 Hrs Fuel Flexible lines and connections t Quarterly Main tank supply level Weekly Fuel piping Yearly Cooling Air ducts and louvers in enclosure Yearly Exhaust System Leakage Weekly Obstructions or combustible materials near exhaust outlet Weekly DC Electrical System Battery charger operation Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals Yearly Inspect battery boots and replace if necessary Yearly Tighten DC electrical connections Yearly AC Electrical System General inspection Quarterly Wire abrasions where subject to motion Six Months Tighten control and power wiring connections Yearly Wire cable insulation breakdown 3 Years or 500 Hrs Engine and Mounting General inspection Weekly Air cleaner and precleaner service Yearly or 100 Hrs Spark plugs Yearly Replace spark plugs 500 Hrs Stepper motor coupling and bushing 3 Years or 500 Hrs Generator Compartment condition Weekly Inspect brushes and collector ring Yearly Measure and record
42. fuse 20 amp Battery charger fuse 10 amp Figure 1 1 Mode Circuit Breaker Part Number GM24928 358384 Recommended Spare Parts 8 5RES 12RES Figure 1 2 Circuit Breakers Introduction i Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler Power KohlerPowerSystems com Systems website at Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 21 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 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 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 803
43. generator output also increases The ADC 2100 controller monitors the generator output voltage through leads 11 and 44 and adjusts the DC current from the SCR module to the rotor to meet load requirements See Figure 5 1 5 2 Separate Excitation To determine the cause of no or low AC output refer to the troubleshooting flow chart in Figure 5 2 Before beginning the test procedures read all safety precautions atthe beginning of this manual Many ofthe test procedures include additional safety precautions Check the condition of the alternator fuse before performing the separate excitation procedure The inline fuse is located in lead 55 of the wiring harness See Figure 5 1 f the fuse is not blown use the following procedure to separately excite the generator using an external voltage source a 12 volt automotive battery Separately exciting the generator can identify faulty voltage regulation by the ADC controller or reveal a running fault in the rotor and or stator An external power source duplicates the role of the voltage regulator and excites the generator field rotor A generator component that appears to be in good condition while stationary may exhibit a running open or short circuit while moving Centrifugal forces acting on the windings during rotation cause a broken circuit to open or increasing temperatures cause the insulation to break down resulting in a running fault If this test shows that the rotor and stator a
44. 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 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 32 Section 4 Controller 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 or repairs Remove all jewelry before servicing the equipment A jumper across controller pins P7 1 and P7 2 maintains power to the controller at all times Controllers are shipped with the jumper connected for continuous power See Figure 4 13 Note The controller is powered by the generator set engine starting battery The 8 5 and 12 RES generator sets are equipped with factory installed battery chargers to prevent battery discharge The P7 connector has either 2 or 3 pins Disconnecting the jumper or
45. 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 284 Exterior Prepare the exterior for storage as follows TP 6196 5 04 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electrical connections 5 Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion 2 8 5 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to 2 7 Battery for the battery cleaning procedure 4 Place the battery in a cool dry location 5 Connect the battery to a float equalize battery charger or charge it monthly with a trickle battery charger Refer to the battery charger manufacturer s recommendations Maintain a full charge to extend battery life Section 2 Scheduled Maintenance 13 5 14 Section 2 Scheduled Maintenance TP 6196 5 04 3 1 Introduction Corrective action and testing in many cases requires knowledge of electrical systems and electronic circuits Have an autho
46. measured voltage and frequency see Section 4 5 3 Figure 4 10 and Figure 4 11 Unit configuration Uc This parameter sets the generator set type marine standby or mobile The setting for the 8 5 12RES is UcO1 standby Engine configuration Ec The engine configuration must match the generator set engine type The engine configuration setting for the 8 5 12RES is Single phase 60 Hz 120 VAC and frequency Uu01 Single phase 60 Hz 120 240 VAC Uu05 Single phase 50 Hz 115 VAC UuO6 Single phase 50 Hz 115 230 VAC Unit configuration UcO1 8 5 12 RES standby Engine type 00 8 5 12 RES Engine data input types Ed05 Digital low coolant level digital pressure analog temp with mag pickup Btl2 Battery voltage 12 VDC Communications No CAN communications Factory settings for 8 5 12RES Choose 50 or 60 hz setting for Uu as required for generator set frequency Figure 4 6 8 5 12RES Controller Configuration Parameters 26 Section 4 Controller TP 6196 5 04 Advanced configuration mode Adnc The data input types battery voltage and communications setting can be changed in the advanced configuration mode Press the up arrow button when Adnc is displayed to enter the advanced configuration mode Engine data input types Ed This setting defines the type of senders used on the generator set engine Use Ed05 for the 8 5
47. moving the jumper to pins P7 2 and P7 3 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 TP 6196 5 04 Engine wiring harness connector plug P1 Continuous power mode jumper location P7 415 connector J16 connector Generator set master switch AUTO VBAT RUN 1 2 3 4 5 6 T 8 Figure 4 13 ADC 2100 back cover removed Use the following procedure to disconnect the jumper if desired Procedure to disconnect the continuous power mode jumper optional Note For most applications it is not necessary to disconnect the continuous power mode jumper 1 Prevent the generator set from starting a Move the generator set master switch to the OFF RESET position b Disconnect 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 TP 6196 5 04 a Disconnect the engine wiring harness connector P1 plug 35 pin from the controller Disconnect the J15 and J16 connectors See Figure 4 13 b Remove the controller from the generator set housing in order to access the back of the
48. need to be checked or changed during generator set service or controller replacement Definition Parameter Setting Unit s system voltage Uu00 The controller s configuration mode allows adjustment of the system parameters listed in this section The system voltage and frequency and unit configuration and engine type are factory set for each type of generator set and engine and should not require changes unless the controller is replaced The controller s advanced configuration mode allows the user to set the data input type for engine senders toggle the battery voltage between 12 and 24 volts and change the controller communications setting for optional meters not offered for standby models Check these settings after controller replacement and change them if necessary to match the settings shown in Figure 4 6 Follow the instructions in Figure 4 7 to enter the configuration mode while the engine is not running and then step through the following parameters Use the up and down V arrow buttons to select the appropriate setting for the application Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Voltage frequency setting Uu Select the system voltage and frequency from the table in Figure 4 6 Note This parameter sets the nominal system voltage and frequency To adjust the output
49. relays Three LEDs indicate relay operation See Figure 4 14 Refer to the schematic diagram in Section 7 for the standard relay board connections The RIB is protected by a 10 amp fuse F2 located in the wiring harness Ifthe fuse blows repeatedly disconnect the board loads one at a time to identify the cause of the blown fuse e Lead 70A at the fuel valve e Lead IGN at the ignition module e Lead 71A atthe starter relay e Leads FP and FN at the rotor Repair or replace the component causing the blown fuse Iffuse continues to blow and disconnecting components did not identify the cause remove the leads from the P14 connector using a pin pusher part 241918 large or 241919 small If replacing the leads does not solve the problem replace the RIB The individual relays are not replaceable If one or more relays are faulty replace the entire RIB To replace the RIB 1 Disconnect P14 and the brush leads FP and FN 2 Pull the board straight off the mounting stand offs 3 Snap the new board onto the stand offs and reconnect P14 and the brush leads The generator set may be equipped with an optional RIB which contains the K4 auxiliary run relay and K1 common fault relay in addition to the standard relays The optional relay board kit includes a wiring harness for 34 Section 4 Controller connection of customer equipment to the K1 and 4 relays See Figure 4 15 for optional relay connections
50. reset the controller Section 3 Troubleshooting Section 4 4 Section 5 9 17 Troubleshooting Chart continued Problem Stops suddenly Possible Cause Fault shutdown Corrective Action Check for a fault shutdown code on the controller s LED display Correct the fault and then move the generator set master switch to OFF RESET to reset the controller Reference Section 4 4 Section 5 9 No fuel Turn on fuel supply Fuel line restriction Inspect fuel lines Fuel lines too long Check fuel line length Section 5 10 1 Air cleaner clogged Replace element Section 2 4 Blown controller fuse F3 Replace fuse Section 5 11 Blown auxiliary winding fuse F1 Replace fuse If fuse blows again test generator components Section 5 11 Blown relay interface board RIB fuse F2 Replace fuse Section 5 11 Spark plug s Replace and regap plug s Engine S M Engine overheated hot engine only Check air intake fuel adjustment oil level air inlet outlet Section 2 5 Section 2 2 Section 5 10 Low oil pressure LOP switch Attempt startup If unit shuts down remove lead from LOP switch and reset controller A successful restart attempt indicates a faulty LOP shutdown switch Note Check engine oil pressure before performing test and or replacing LOP shutdown switch Section 2 2 1 Section 5 9 2 Fuel valve fuel regulator C
51. tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure 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 or repairs Remove all jewelry before servicing the equipment Stator Continuity and Resistance Tests 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Disconnect all stator leads before performing all stator tests 5 To check for stator continuity set the ohmmeter on Rx1 scale First setthe ohmmeter zero by holding the red and black meter leads together and setting the ohmmeter reading to zero Then check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 5 4 Note Leads 1 2 and 4 are the generator output leads Leads 11 44 55 and 66 are the controller and SCR module sensing and TP 6196 5 04 supply leads Refer to the schematic in Figure 5 5 when performing the following steps 6 Contact the ohmmeter leads and readjust the ohmmeter to read zero ohms 14807 14 Figure 5 5 Alternator Stator Leads 7 Check the cold resistance of the stator windings by connecting the meter leads to stator l
52. the generator set speed frequency If the frequency has changed repeat step 4 Note Speed adjustments have no effect on gain adjustments It is not necessary to repeat the gain adjustments steps 5 and 8 after adjusting the engine speed Check the overspeed shutdown operation when investigating a shutdown problem See Section 5 9 1 for the overspeed shutdown test procedure TP 6196 5 04 5 9 Fault Shutdown Tests Verify the operation of the generator set overspeed overcrank and low oil pressure shutdowns by performing the following tests If these tests are inconclusive test individual shutdown circuit components wiring harness switch etc as described elsewhere in this section 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 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 or repairs Remove all jewelry before servicing the equipment
53. 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 resistance 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 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 estimated emergency stop et cetera and so forth exh ext F fglass FHM fl oz flex freq FS ft ft Ibs ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt 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 gal
54. 00 7 16 14 x 1 25 7 16 14 x 1 50 7 16 14 x 2 00 7 16 14 x 2 75 7 16 14 x 6 50 1 2 13 x 75 1 2 13 x 1 00 1 2 13 x 1 25 1 2 13 x 1 50 1 2 13 x 1 75 1 2 13 x 2 00 1 2 13 x 2 25 1 2 13 x 2 50 1 2 13 x 2 75 1 2 13 x 3 00 1 2 13 x 8 50 1 2 13 x 4 00 1 2 13 x 4 50 1 2 13 x 5 50 1 2 13 x 6 00 1 2 20 x 75 1 2 20 x 1 25 1 2 20 x 1 50 5 8 11 x 1 00 5 8 11 x 1 25 5 8 11 x 1 50 5 8 11 x 1 75 5 8 11 x 2 00 5 8 11 x 2 25 5 8 11 x 2 50 5 8 11 x 2 75 5 8 11 x 3 75 5 8 11 x 4 50 5 8 11 x 6 00 5 8 18 x 2 50 3 4 10 x 1 00 3 4 10 x 1 25 3 4 10 1 50 3 4 10 2 00 3 4 10 2 50 3 4 10 3 00 3 4 10 3 50 1 8 2 25 1 8 3 00 1 8 x 5 00 Part No Hex Nuts X 6009 1 X 6210 3 X 6210 4 X 6210 5 X 6210 1 X 6210 2 X 6210 6 X 6210 7 X 6210 8 X 6210 9 X 6210 10 X 6210 11 X 6210 12 X 6210 15 X 6210 14 X 85 3 X 88 12 X 89 2 Washers Part No X 25 46 X 25 9 X 25 48 X 25 36 X 25 40 X 25 85 X 25 37 X 25 34 X 25 26 X 25 15 X 25 29 Dimensions ID 125 156 188 219 281 344 406 469 531 656 812 X 25 127 1 062 1 8 6 32 8 32 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 1 2 13 7 16 20 1 2 20 5 8 11 3 4 10 1 2 20 1 062 1 312 1 469 Type Standard Whiz Whiz Whiz Whiz Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Spiralock Standard Standard Standard Bolt OD
55. 00 x 150 M8 1 25 x 35 M8 1 25 x 40 M8 1 25 x 40 M8 1 25 x 45 M8 1 25 x 50 M8 1 25 x 55 M8 1 25 x 55 M8 1 25 x 60 M8 1 25 x 70 M8 1 25 x 70 M8 1 25 x 75 M8 1 25 x 80 M8 1 25 x 90 M8 1 25 x 95 M8 1 25 x 100 M8 1 25 x 120 M8 1 25 x 130 M8 1 25 x 140 M10 1 25 x 40 M10 1 50 x 40 M10 1 50 x 45 M10 1 50 x 50 M10 1 50 x 55 M10 1 50 x 60 M10 1 50 x 65 M10 1 50 x 70 M10 1 50 x 80 M10 1 50 x 90 M10 1 50 x 90 M10 1 50 x 100 M10 1 50 x 110 M10 1 50 x 120 M10 1 50 x 130 M10 1 50 x 140 M10 1 50 x 180 M12 1 75 x 45 M12 1 25 x 50 M12 1 25 x 50 M12 1 75 x 50 M12 1 75 x 55 M12 1 75 x 60 M12 1 75 x 65 M12 1 75 x 75 M12 1 75 x 80 M12 1 75 x 90 M12 1 75 x 100 M12 1 75 x 110 M16 1 50 x 90 M16 2 00 x 90 M16 2 00 x 100 M20 2 50 x 65 M20 2 50 x 120 M20 2 50 x 160 M22 2 50 x 90 M22 2 50 x 120 M22 2 50 x 160 M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 Part No Dimensions Hex Head Bolts full thread M933 04006 60 M933 05035 60 M933 05050 60 M933 06010 60 M933 0601 4 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06040 60 M933 06050 60 M933 08012 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 08030 82 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M961 10030 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035 60 M933 12016 60 M933 12020 60 M933 12025 60 M933 12025 82 M961 12030 60 M933 12030 60 933 12035 60 961 12040 82 M933 12040 60
56. 1 14 E NMOGLNHS XNV 21 14 IOHINOO AV T3H NOE ee zid 7 NYO VNHJIX3 11 14 NYO 1 8 01 14 MO1HOSN3S LNY1009 6 14 HOSN3S dWILLNY1009 8 14 ES gZ HONH3AOO 42 14 ON LINV4NOWNOD 9 ld 9 14 8 614 VLHONH3JAOO 6 4 ONAVISHN H 614 8LHONH3JAOO d ON LINYA 6 614 1 4 NOWWOO 6 14 0012907 NONWWOO NONNOO 2 ld 104100 2 1 NOWNWOO 1 614 1nOAVvI3H 1 15 5 1 14 SNOLLO3NNOO 614 14 597 M IA H 3 S 2 UN u 22 gt gt BY 8 er QHVO8 1 AV THH H3TIOHLNOO 0016 OOV 73 Section 7 Diagrams Drawings Figure 7 4 8 5 12RES Schematic Diagram Single Phase Sheet 2 ADV 6835B E TP 6196 5 04 dSVHd STONIS 98 33S SNOLLO3NNOO HOLVH3N39 HOS 310N S 89 AQV 33S OLLVW3HOS HOS 8 7 5 9NLLSIX3 ISN WoL 3 12 91 woe H3HSVM HVIS 8 MANOS E z983 1983 7 5993 MENS u3ouvHo dac AH31Lv8 aunoas Lb NOI
57. 1 2RES Battery voltage Bt This setting toggles between 12 and 24 VDC for the engine starting battery voltage The 8 5 12RES uses a 12 volt battery Bt12 Communications setting Cn This setting allows the user to set the controller for communication with optional meters which are available for marine and mobile units only The 8 5 12RES is factory set for no CAN communications CnOO 4 5 3 Voltage and Frequency Adjustments The flowchart in Figure 4 11 outlines the procedures for using the ADC controller to adjust the output voltage and engine speed frequency Voltage and or frequency TP 6196 5 04 adjustments may required after controller replacement or other service procedures The generator set must be running during these adjustments Use a multimeter to measure the generator set output voltage and frequency during adjustments Refer to Sections 5 7 2 Voltage Adjustment and 5 8 5 Frequency Adjustment for instructions to measure the output voltage and frequency Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position 4 5 4 Controller Application Program The ADC 2100 s application program version number is displayed on the LED screen during the key sequence to enter the configuration mode Hold the Select button and move the generator set master switch to the RUN position Aft
58. 315972 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 6196 5 04 Section 1 Specifications 1 1 The spec sheets for each generator set provide specific generator and engine information Refer to the generator set spec sheet for data not supplied in this manual Consult the generator set installation manual engine operation manual and engine service manual for additional specifications Introduction 1 2 Generator Set Ratings See the generator set ratings table below Consult the generator set nameplate for specific generator set ratings 1 3 Controller Specifications The generator set is equipped with the Advanced Digital Control For a specific description of the controller see Section 2 Operation in the operation manual Environmental Specification 8 5 12 5 Operating temperature 20 to 70 C 60 to 70 C 0 95 condensing Storage temperature Humidity Power requirements Voltage Current 12 or 24 VDC 250 mA 12 VDC 125 mA 24 VDC Generator Set Ratings Model Series 8 5RES 8 5RES 12RES 12RES Generator Model 2F4 2F4 2F4 2F4 Hz 60 50 60 50 Voltage Phase 120 240 115 230 120 240 115 230 Standby Amps Natural Gas 29 27 43 40 1 4 Engine Features The 8 5 12RES gener
59. 96 5 04 KOHLER POWER SYSTEMS Roof Roof locating pin Roof screws 4 ea Service side door Front panel air intake end Rear panel exhaust end Figure 6 1 Generator Set Weather Housing Section 6 Disassembly Reassembly 61 1 Screws 2 ea 2 Plastic caps 2 ea remove to access screws 3 Screw 1 ea access from inside the enclosure Figure 6 2 Front Panel Mounting Screw Locations 1 Screws 5 ea Figure 6 3 Rear Panel Mounting Screw Locations viewed from inside the enclosure 62 Section 6 Disassembly Reassembly 2 Disconnect the alternator leads inside the controller box Note the locations of the alternator lead connections for reconnection later See Figure 6 4 a Disconnect alternator leads 1 and 4 from the line circuit breaker b Disconnect alternator leads 2 and 3 from the load connection terminal LO c Disconnect brush leads FP and FN and stator leads 55 and 66 from the SCR module d Disconnect the 3 pin plug P15 from the mating connector on the ADC con
60. Also see Section 7 Wiring Diagrams Figure 5 29 gives resistance readings for functional components A zero reading on the ohmmeter indicates continuity No ohmmeter reading indicates very high resistance or an open circuit A measurement that varies significantly from the value shown in the table indicates a faulty component replace faulty components Note Disconnect the generator set battery before performing continuity checks to prevent damage to the ohmmeter Zero ohms continuity across RUN and COM terminals Master Switch in RUN Position Zero ohms continuity across COM and AUTO terminals Master Switch in AUTO Position Figure 5 28 Generator Set Master Switch Continuity Checks Section 5 Component Testing and Adjustment 59 Generator set master switch Ohmmeter Connections RUN and COM See Figure 5 28 Ohmmeter Scale Generator Set Master Switch Position RUN Ohmmeter Readings for Operative Components Zero ohms continuity Any other reading indicates a bad switch OFF RESET No reading open circuit Any other reading indicates a bad switch AUTO and COM See Figure 5 28 AUTO Zero ohms continuity Any other reading indicates a bad switch OFF RESET No reading open circuit Any other reading indicates a bad switch P1 wiring harness P1 27 and ground OFF RESET Zero ohms continuity Any other reading indicates a poor ground
61. Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20x 1 L Length In Inches Screws and Bolts 9 32 x 58 128 Thickness Threads Per Inch External Dimension Major Thread Diameter In Fractional Inches Or Screw Number Size L Internal Dimension Metric Screws Bolts Studs and Nuts M8 1 25 x 20 Lock Washers Length In Millimeters Screws and Bolts 5 8 Distance Between Threads In Millimeters NEN Internal Dimension Major Thread Diameter In Millimeters TP 6196 5 04 Appendix 5 Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Hex Head Bolts Grade 5 X 465 17 X 465 6 X 465 2 X 465 16 X 465 18 X 465 7 X 465 8 X 465 9 X 465 10 X 465 11 X 465 12 X 465 14 X 465 21 X 465 25 X 465 20 X 125 33 X 125 23 125 3 125 31 125 5 125 24 125 34 125 25 125 26 230578 125 29 125 27 125 28 125 22 125 32 125 35 125 36 125 40 125 43 125 44 125 30 125 39 125 38 6238 2 6238 10 6238 3 6238 11 6238 4 6238 5 6238 1 6238 6 6238 17 6238 7 6238 8 6238 9 6238 19 6238 12 6238 20 6238 13 6238 18 6238 25 6238 14 6238 16 6238 21 6238 22 Dimensions 1 4 20 x 38 1 4 20 x 50 1
62. See Figure 5 12 If the engine runs ata steady speed with no hunting or surging when the throttle is held steady then the hunting surging problems during operation are probably caused by the governor Proceed to Section 5 8 4 4 If the engine speed hunts or surges while the throttle is held steady check the carburetor position and engine operation a Check the carburetor position Slotted mounting holes in the base of the carburetor determine the carburetor position which affects the throttle operation Verify that the carburetor is mounted as close to the governor Section 5 Component Testing and Adjustment 47 actuator stepper motor as the mounting holes If the air gap is correct the voltage should be allow 1 75 volts AC minimum during engine cranking b Refer to the Engine Service Manual for other 5 If the voltmeter displays less than 1 75 volts AC engine diagnostic and service information check the air gap as described in the following steps before replacing the sensor Verify that the magnetic pickup air gap is 0 5 mm 0 020 in Measure the air gap at 3 or 4 places to get an accurate reading See Figure 5 14 a Stop the generator set Remove housing panels as required to gain access to the front of the engine b Remove the engine blower housing c Use a feeler gauge to check the gap The gap 1 Electronic governor stepper motor should be 0 5 mm 0 020 in 2 Carburetor throttle linkage TP5632721 3 Carbur
63. Service Residential Commercial Generator Sets Models 8 5RES 12RES Controller Advanced Digital Control NATIONALLY REGISTERED KOHLER POWER SYSTEMS sss Table of Contents Safety Precautions and Instructions Introduction eee eee EYE List of Related Materials i Service Assistance y GI ue rm eere NER aa aise E CUI rers ii Section 1 Specifications esas ee eil Ru alee ee px EI 1 TM Introduction xor her REDE eme eeu tems ette his 1 1 2 Generator Set Ratings 1 1 3 Controller Specifications 1 1 4 Engine Features See Gad 1 1 5 Engine Specifications 2 1 6 Alternator Specifications 3 1 7 Torque Specifications 3 18 Service View 4 Section 2 Scheduled 5 2 1 Service Schedule 5 22 Lubrication System unis oe d er Rs 7 2 2 1
64. System Operation Test Procedure Summary Section 5 8 4 TP 6196 5 04 Section 5 Component Testing and Adjustment 49 10 11 12 After adjusting the air gap check the voltage again as described in step 4 If the voltage does not measure 1 75 VAC minimum replace the magnetic pickup To test the controllers governing function disconnect the magnetic pickup leads and open the generator set circuit breaker Manually move the throttle shaft governor stepper motor fully counterclockwise closed throttle Start the generator set The stepper motor should step clockwise to the wide open throttle position The stepper motor should remain in the clockwise throttle fully open position If the stepper motor does not operate as described here proceed to the next steps to check the governor and stepper motor Place the generator set master switch in the STOP position Check the stepper motor connections to the controller Leads 1A 1B 2A and 2B to pins P1 4 P1 5 P1 6 and P1 7 Check the pins and connections at plugs J6 and P6 See the wiring diagrams in Section 7 Check the stepper motor coil resistance across pins 2 and 3 and across pins 1 and 4 Only two stepper motor leads of each coil group are used BLK YEL and RED WHT See Figure 5 16 The resistance per half coil is 38 5 ohms If one of the coils has a significantly higher resistance or is shorted replace the stepper motor If there is power and a goo
65. Thick Screw 022 4 049 6 049 8 049 10 065 1 4 065 5 16 065 3 8 065 7 16 095 1 2 095 5 8 134 3 4 134 1 2 000 6196 5 04 Metric Hex head bolts are hardness grade 8 8 unless noted Part No Hex Head Bolts partial thread M931 05055 60 M931 06040 60 M931 06055 60 M931 06060 60 M931 06070 60 M931 06070 SS M931 06075 60 M931 06090 60 M931 06150 60 M931 08035 60 M931 08040 60 M931 08040 82 M931 08045 60 M931 08050 60 M931 08055 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 08070 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60 M931 08100 60 M931 08120 60 931 08130 60 931 08140 60 931 10040 82 931 10040 60 931 10045 60 931 10050 60 931 10055 60 931 10060 60 931 10065 60 931 10070 60 931 10080 60 931 10090 60 931 10090 82 931 10100 60 931 10110 60 931 10120 60 931 10130 60 931 10140 60 931 10180 60 931 12045 60 960 12050 60 960 12050 82 931 12050 60 931 12055 60 931 12060 60 931 12065 60 931 12075 60 931 12080 60 931 12090 60 931 12100 60 931 12110 60 960 16090 60 931 16090 60 931 16100 60 931 20065 60 931 20120 60 931 20160 60 931 22090 60 931 22120 60 931 22160 60 931 24090 60 931 24120 60 931 24160 60 6196 5 04 Dimensions 5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M6 1
66. Tighten the four alternator assembly overbolts to 7 Nm 60 in Ib 6 Reinstall the end bracket components a Install the brush holder onto the end bracket Verify that the brushes are not sticking in the holder GM29253B P 1 OBROUND holes for overbolts 4 Figure 6 15 End Bracket TP 6196 5 04 b Verify that the brushes are centered on the slip rings If required insert spacers between the mounting surface and brush holder to center the brushes on the slip rings See Figure 6 17 See Section 5 6 Brushes for more information c Reinstall the brush cover onto the alternator end bracket Verify that the brush leads are not pinched between the brush cover and end bracket 7 Reinstall the alternator air inlet duct Orient the duct as shown in Figure 6 18 8 Install the exhaust shield See Figure 6 18 tp6196 1 Alternator assembly overbolts 2 Rotor thrubolt 3 Vibromount plate Figure 6 16 Generator Set Right Side 1 Brush holder 2 Brushes 3 Slip rings Figure 6 17 Brush Positioning Section 6 Disassembly Reassembly 67 ALTERNATOR AIR INLET DUCT DETAIL VIEWED FROM REAR OF UNIT 1 Alternator air inlet duct 2 Mou
67. and down arrow buttons use for setup and adjustment only 4 Generator set master switch Figure 4 2 ADC Controller 22 Section 4 Controller Controller Display Item Description 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 Crank indication Runtime hours Displays total generator set runtime hours when no other code is displayed Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 4 4 Fault codes System parameters Displays 2 letter codes or 4 digit alphanumeric codes during system configuration or adjustment See Section 4 5 Application program version number Displays the version number of the controller s application program before entering the configuration or adjustment mode See Section 4 5 4 Figure 4 3 ADC controller LED Display TP 6196 5 04 4 3 Sequence of Operation The following sections describe the controller sequence of operation during generator start run stop and fault shutdown modes Use this as a starting point for controller and relay board fault identification Refer to the wiring diagrams in Section 7 to assist in the troubleshooting procedure 4 3 4 Starting Sequence Master Switch Moved to RUN When the master switch is moved to the RUN position there is a delay of about 2 seconds before the controller at
68. aner components could allow unfiltered air into the engine causing premature wear and failure 1 Cover knob 2 Air cleaner cover 3 Element cover nut 4 Element cover 5 Foam precleaner 6 Air cleaner element 7 Air cleaner base Figure 2 7 Air Cleaner Components Section 2 Scheduled Maintenance 9 Air Cleaner Service Procedure 1 Disable the generator set a a a b Place the generator set master switch in the OFF RESET position Disconnect the power to the battery charger Disconnect the generator set engine starting battery negative lead first Remove the foam precleaner and paper element Loosen the air cleaner cover retaining knob and remove the cover Remove the element cover nut element cover and paper element with precleaner Remove the precleaner from the paper element Wash and oil the foam precleaner Wash the precleaner in warm soapy water Rinse the precleaner with warm water until the water runs clear Squeeze out excess water and allow the precleaner to air dry Note Do not wring twist the precleaner or dry it with compressed air Saturate the precleaner with new engine oil Squeeze out the excess oil Replace the paper element if it is dirty bent or damaged Note Do not wash the paper element or clean it with compressed air as both will damage the element 10 Section 2 Scheduled Maintenance 5 Reinstall the air cleaner Install th
69. ank LED 3 turns off When the output voltage on leads 11 and 44 reaches about 30 VAC the flash relay deenergizes and the flash LED 2 turns off 4 3 4 Stopping Sequence Master Switch Moved to OFF RESET Place the generator master switch in the OFF RESET position The run relay deenergizes and the run LED 1 turns off The generator set stops 4 3 5 Stopping Sequence Remote Stop When the remote start contacts open the run relay deenergizes and the run LED 1 turns off but the controller does not power down The controller remains powered and displays the engine runtime hours Note Disconnecting the P7 jumper inside the controller will allow the controller to power down 48 hours after generator set shutdown See Section 4 6 Continuous Power Mode Section 4 Controller 23 4 4 Faults Always identify and correct the cause of a fault shutdown before restarting the generator set Refer to Section 3 Troubleshooting for instructions to identify 4 4 1 Warnings and correct the cause of the fault The fault conditions listed in Figure 4 4 will cause the controller to display a fault code but will not shut down the generator set Move the generator set master switch to the OFF RESET position to reset the controller after a fault shutdown Then move the switch to the AUTO or RUN position 442 Shutdowns Under the fault conditions listed in Figure 4 5 the controller displays a fault code and the generator set shuts down
70. aptor Figure 6 11 Rotor and Thrubolt A 358000A B 1 Generator adapter 2 Generator fan guard 3 Engine adapter mounting holes 4 Alternator adapter guard Figure 6 12 Generator Adapter TP 6196 5 04 6 2 Reassembly 1 Reinstall the generator adapter onto the engine a b Attach the generator adapter and alternator adapter guard to the engine using four 7 16 14 x 1 0 hex cap bolts and washers See Figure 6 12 Torque the bolts to 40 Nm 28 ft 2 Install the rotor See Figure 6 11 a b Apply a small amount of antisieze compound to the end of the engine crankshaft for rotor assembly installation Install the rotor onto the engine crankshaft c Thread the thrubolt through the actuator and rotor into the crankshaft Do not tighten the thrubolt 3 Install the stator and end bracket a Align the stator so that the alternator frame vibromount points down toward the generator base See Figure 6 13 Install the stator assembly around the rotor Align the alignment mark on the top of the stator slightly off center of the slot in the generator adaptor See Figure 6 14 The small offset is necessary in order to connect the muffler bracketto the muffler later without interference GM29253A F 1 End bracket 2 Alternator 3 Alternator frame vibromount 4 Overbolts Figure 6 13 Generator Set Right Side Section 6 Disassembly Reassembly 65 c Route the
71. ation 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 6196 5 04 Accidental Starting WARNING aS 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 WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin
72. ator sets are equipped with four cycle twin cylinder air cooled Kohler engines Some of the engine features include e One side serviceability of air cleaner carburetor oil fill dipstick and oil drain e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions e Electronic governor to ensure AC power output is maintained at desired frequency e Overspeed shutdown to prevent governed frequency from exceeding 70 Hz on 60 Hz models 60 Hz on 50 Hz models e Low oil pressure cutout to prevent failure e Dependable maintenance free electronic ignition e Digital Spark Advance Module DSAM optimizes engine timing for natural gas or LP fuel 12RES only e Parts subject to the most wear and tear made from precision formulated cast iron e Hydraulic valve adjusters to eliminate the need for valve adjustments Field convertible fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintaining CARB certification For engine service information and specifications not covered in this manual see the Engine Service Manual See the List of Related Materials in the Introduction Section Standby Ratings kW kVA Natural Gas LP Gas 7 0 7 0 8 5 8 5 6 3 6 3 7 5 7 5 10 4 10 4 12 0 12 0 9 3 9 3 10 5 10 5 LP Gas 35 33 50 46 RATINGS Standby ratings apply to installations served by a reliable utility s
73. ay occur KOFLER POWER SYSTEMS 196 1 Exhaust outlet 2 Alternator air intake both sides 3 Engine air intake Figure 2 8 Cooling Air Intake and Exhaust 2 6 Exhaust System Remove 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 safe distance from the exhaust outlet Check the area periodically for accumulated debris and seasonal grass or foliage Inspect exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks and corrosion e Checkfor corroded or broken metal parts and replace them as needed e Check that exhaust outlet is clear TP 6196 5 04 2 7 Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin 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 quantitie
74. ck for the cause using the procedure Section 5 83 before proceeding 5 Check stability with the generator set running and with no load applied If the generator set speed is unstable hunts or surges use the ADC controller to decrease the gain parameter 5P until the generator set becomes stable with no hunting or surging Observe the frequency reading 6 Repeat steps 4 and 5 to obtain the rated frequency and stable operation 7 Save the settings Refer to Section 4 5 for instructions Note The controller will revert to the previous settings at the next startup if the changes are not saved within one minute after the last change 8 Apply rated load to the generator set and observe the frequency reading The no load and full load frequencies should be within 0 4 Hz of the rated generator frequency if not check that the TP 6196 5 04 carburetor throttle plate opens completely without sticking and check the carburetor adjustment If these procedures do not correct the problem replace the controller 9 Check for hunting and surging at full load Use the controller to increase the gain parameter 5P until the engine hunts and surges Then decrease the gain in small steps using the governor gain fine adjust parameter until the engine operation stabilizes Save the controller changes 10 Remove the load and observe the frequency The frequency should return to the value stated in step 4 Gain adjustment may affect
75. controller 3 Remove the controller s back cover to access the jumper a Notethe labels on the three leads connected to the generator set master switch reconnection later Disconnect the leads at the pink connectors See Figure 4 13 b Remove the cover screws and remove the controller s back cover See Figure 4 13 4 Locate the P7 connector near the top of the controller See Figure 4 13 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 as shown in Figure 4 13 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 4 7 Master Switch The generator set master switch is a three position RUN OFF RESET AUTO rocker switch The leads connecting to the master switch are labeled RUN VBAT and AUTO Check that the three pink connectors are connected to the terminals on the back of the switch as shown in Figure 4 13 Be careful not to reverse the RUN and AUTO leads Section 4 Controller 33 4 8 Relay Interface Board The standard relay interface board RIB contains the K2 crank K3 flash and K5 run
76. ctile iron Main bearings number type 2 parent material Governor Electronic Lubrication system Full pressure Oil capacity w filter L qt 1 9 2 0 2 2 1 Oil pressure kPa psi 172 241 25 35 Fuel system LP gas or natural gas LP natural gas minimum supply pressure 2 02 2 7 11 4 6 Battery voltage 12 VDC Battery ground Negative Spark plug gap mm in 0 76 0 030 Ignition system Capacitor Discharge Smart Spark Capacitor Discharge Starter motor Electric solenoid shift Cooling system 2 Section 1 Specifications Air cooled TP 6196 5 04 1 6 Alternator Specifications Alternator Specification 8 5 12 5 Frequency Hz 50 60 Alternator overbolts 1 7 Torque Specifications Torque Specifications Nm ft Ib 8 5 12RES 7 5 Phase Single Phase Alternator thrubolt 40 28 Number of leads 4 Oylinder head nuts 30 40 7 Excitation method Static Excited Generator adapter screws 40 28 Voltage regulator type Digital Muffler flange bolts 24 17 7 Coupling type Direct Cil filter 5 7 9 0 4 2 6 7 Thrubolt torque Nm ft Ib 40 28 Overbolt torque Nm in Ib 7 60 Insulation rotor and stator Epoxy varnish vacuum impregnated Class 180 H Winding material Cop
77. cumulation 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 6196 5 04 LP liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi 621 kPa Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Electrical Shock 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 TP 6196 5 04 A WARNING Hazardous volta
78. d ground connection to the ADC 2100 and the stepper motor coil resistances are good but the stepper motor does not operate as described in step 9 the problem is with the ADC controller Check controller connections fuses wiring and settings Refer to the troubleshooting procedures in Section 3 PIN 3 BLK PIN 2 YEL 0 0 PIN 5 GRN not used PIN 4 PIN 1 PIN 6 BLUE RED WHT not used SB555 Figure 5 16 Actuator Coil Group 50 Section 5 Component Testing and Adjustment 5 8 5 Frequency Adjustment The engine speed determines the generator output frequency 60 Hz units operate at 3600 rpm and 50 Hz units run at 3000 rpm Adjust the engine governor to change the output frequency using the following procedure Note Engine governor speed frequency and gain adjustments are made using the ADC controller See Section 4 5 3 for instructions Frequency Adjustment Procedure 1 Open the generator set line circuit breaker 2 Attach a frequency meter to the AC output leads 3 Start and run the generator set until it reaches normal operating temperature at least 10 minutes 4 Use the ADC controller to adjust the electronic governor speed parameter 4P to obtain a frequency reading of 60 Hz or 50 Hz on 50 Hz models Note Often hunting surging problems thought to be caused by the governor are actually caused by engine or carburetor problems If the generator set speed is unstable hunts or surges che
79. e alternator end of the generator set enough to place a thin block of wood beneath the rear of the engine See Figure 6 8 GM29253A F 1 Alternator end vibromount Figure 6 7 Generator Set Right Side Engine exhaust muffler Muffler bolts Heat shield Flange connection Heat shield bolts GM29253A F Figure 6 5 Muffler and Heat Shield 1 Engine support block Figure 6 8 Generator Set Right Side TP 6196 5 04 Section 6 Disassembly Reassembly 63 c Remove 4 screws securing the brush cover to 6 Check the brushes the alternator end bracket See Figure 6 9 a Removethe brush holder from the end bracket d Raise the brushes in the brush holder and See Figure 6 9 insert a small piece of wire into the brush holder retainer wire hole See Figure 6 9 and b Inspect the brushes Replace brushes when Figure 6 10 they are worn to half of their original size See Figure 6 10 and Section 5 6 Brushes e Remove the alternator overbolts and centering washers See Figure 6 9 f Using a soft faced hammer strike the side of the end bracket with medium force blows to remove the end bracket from the stator or remove the end bracket from the stator using a puller SS 26 gt 2
80. e distributor dealer to obtain engine service literature All generator sets have emission certified engines The carburetors on emission certified engines are not adjustable Generator Set Service See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized Kohler service distributor dealer perform all generator service Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the runtime hours displayed on the generator set controller to determine when to schedule routine maintenance Service the generator set more frequently if it is subject to extreme weather long operating hours or dusty or dirty conditions Service Schedule Perform maintenance on each item in the service schedule at the designated interval for the life of the generator set Tools Tools and instruments used to perform some maintenance items are not generally available to the generator set owner Therefore have service performed by an authorized distributor dealer 2 1 Service Schedule Perform the items listed in the service schedule at the designated intervals for the life of the generator set For example an item serviced every 100 hours or 3 months must also be serviced after 200 hours or 6 months 300 hours or 9 months etc Section 2 Scheduled Maintenance 5 System Component Lubrication
81. e following Light headedness dizziness e Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain 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 Fuel System A WARNING 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 handling 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 Donot operate the generator set in the presence of fuel leaks fuel ac
82. e precleaner over the paper element Check the air cleaner base Make sure it is secure and not bent or damaged Remove any dirt or debris from the air cleaner base Wipe the base carefully so that no dirt falls into the intake throat Check the element cover for damage and fit Replace all damaged air cleaner components Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary Install the paper element precleaner element cover element cover nut and air cleaner cover Secure the cover with the cover retaining knob finger tighten only Check the element cover for damage and fit Replace all damaged air cleaner components Check the condition of the rubber seals and replace them if necessary 6 Enable the generator set a Reconnect the generator set engine starting battery negative lead last b Reconnect the power to the battery charger TP 6196 5 04 2 5 Cooling System Fans in the engine and generator draw cooling air through the louvered openings in the sides and end of the sound enclosure The cooling air mixes with the engine exhaust and is discharged through the outlet end To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times See Figure 2 8 Note Do not block the generator set cooling air inlet or mount other equipment above it Overheating and severe generator damage m
83. e 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 orexciter armature When shorted the generator setfield and exciter armature become hot enough to cause severe burns 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 Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the 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 IV Safety Precautions and Instructions Moving Parts 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 WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place WARNING 2
84. eads 1 2 3 4 and 55 66 See Section 1 6 Alternator for stator winding resistances Most ohmmeters do not provide accurate readings below 1 ohm Low resistance readings continuity and no evidence of shorted windings heat discoloration indicate a stator in good condition See Figure 5 6 8 If the resistance test proves inconclusive use a megohmmeter to test the stator as described in the next step Note Because ohmmeter accuracy varies resistance readings approximate readings Take readings of the rotor and stator at room temperature Note Make sure that all stator leads are disconnected before running the megohmmeter test Section 5 Component Testing and Adjustment 41 9 Use megohmmeter to determine whether the stator is shorted to ground Apply 500 volts DC to any stator lead and the stator frame Perform the megohmmeter test following the instructions of the megohmmeter manufacturer b Repeat the test on the other stator leads until each coil is tested Note A reading of approximately 500 kOhms 1 2 megohm and higher indicates a good stator c Repair or replace the stator if any reading is less than approximately 500 kOhms A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground Continuity 1and2 1 and 11 2 and 11 4 3 and 44 4 and 44 55 and 66 1 and 3 4 44 55 or 66 2 and 3 4 44 55 or 66 3 and 1
85. eep the electrical connections dry and tight Consult the battery manufacturer s instructions for battery care and maintenance 2 7 4 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 remove corrosion from battery terminals disconnect the cables 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 12 Section 2 Scheduled Maintenance After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease 2 7 2 Battery Charger Generator sets are equipped with a factory installed battery charger to keep the starting battery fully charged Observe the battery polarity when connecting the battery charger Check the battery charger fuse and power supply See the Generator Set Operation Manual for information about battery charger operation and troubleshooting 2 8 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system
86. ents containing batteries to prevent accumulation of explosive gases Section 2 Scheduled Maintenance 11 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 Use a 12 volt battery with a minimum rating of 675 cold cranking amps at 18 C 0 F The generator set uses a negative ground with a 12 volt engine electrical system Make sure that the battery is correctly connected and the terminals are tight See Figure 2 9 Note The generator set will not start and circuit board damage may result if the battery is connected in reverse EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 2 9 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Clean the battery and cables and tighten battery terminals using the service schedule recommendations Clean the battery by wiping it with a damp cloth K
87. er about 5 seconds the application program version number will be displayed on the controller display For example 01 04 will be displayed for program version 1 04 Section 4 Controller 27 Controller Configuration Mode Hold the Select button Display Move the generator set master switch to the RUN 0 position The generator set engine will not start Wait about 5 seconds until the display shows the program version number The number may be different than the one shown here Press the down arrow key and then the up arrow key 3 times to enter the configuration mode This is the controller password Now release the Select button 2 N 27 To set the voltage frequency setting Uu01 for 60 Hz or Uu06 for 50 Hz models To step to the next parameter unit configuration Uc or To set the unit configuration setting to UcO1 if necessary To step to the next parameter engine type Ec or To set the engine type to 05 if necessary To step to the next parameter advanced configuration mode or save mode selection N e N Press Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communications Press J To enter advanced configura
88. eration Inspect the parts often and perform required service atthe prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service For engine service procedures not covered in this manual refer to the Engine Service Manual TP 2428 List of Related Materials Separate manuals contain operation installation and parts information not provided in this manual separate engine Operation and Service manuals are also available The following table lists the available manual part numbers Part Number TP 6195 TP 6331 TP 6328 TP 5868 TP 2428 Document Description Operation Installation Manual 8 5 12RES Operation Manual 8 5 12RES Installation Manual 8 5 12RES Parts Catalog 8 5 1 2RES Engine Service Manual Replaced by TP 6328 and TP 6331 May 2004 TP 6196 5 04 Introduction Routine Service Parts The following tables contain part numbers for recommended spare parts Contact your Kohler generator distributor dealer for a complete list of service parts for your generator set or for models or spec numbers not listed here Part Description Part Number Air cleaner element 24 083 08 24 083 02 12 050 01 12 132 02 S 223316 223316 292937 AGS 10 Precleaner element Oil filter Spark plug Relay interface board fuse 10 amp Controller fuse 10 amp Alternator
89. es and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution TP 6196 5 04 Rotor Test Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Remove the brush cover from the alternator end bracket 5 Check the rotor for continuity and resistance Raise the brushes from the slip rings while performing ohmmeter tests Measure the rotor resistance ohms between the two slip rings see Figure 5 7 See Section 1 6 Generator for rotor resistance readings If the resistance readings are low perform a megohmmeter test on rotor as described in the next step Note Because ohmmeter accuracy varies resistance readings are approximate Take readings at room temperature Figure 5 7 Rotor Resistance Check TP 6196 5 04 6 Perform a megohmmeter test to determine whether the rotor is shorted to ground a Raise and secure the brushes away from the slip rings by inserting a retaining wire in the brush holder hole b Using a megohmmeter apply 500 volts DC to one rotor slip ring and the rotor poles or shaft Follow the instructions of the megohmmeter manufacturer when performing this test Note A reading of approximately 500 kOhms 1 2 megohm or higher indicates a good rotor
90. est and or replace components Engine S M Digital spark advance module DSAM connections 12RES only Connect for natural gas Disconnect for LP Check for loose connections Section 5 10 5 No engine rotation sensed check for an overcrank fault shutdown Check mag pickup connections mag pickup gap and operation Section 5 8 4 Check for locked rotor Section 5 4 Starts hard Low battery voltage Check battery voltage and battery charger connections power supply and operation Generator Set Operation Manual Air cleaner clogged Replace element Section 2 4 Fuel mixture adjustment incorrect Adjust fuel valve Section 5 10 DSAM leads incorrectly connected or disconnected 12RES only Connect for natural gas Disconnect for LP Section 5 10 5 Spark plug s Replace or regap spark plug s Section 2 3 Spark plug wire s Check spark plug wires and connections Replace spark plug wires Engine S M Ignition components spark control or ignition module Test replace ignition components Engine S M Insufficient fuel pressure Check fuel pressure Section 5 10 3 Worn piston rings valves Check compression Engine S M Starts but shuts down TP 6196 5 04 Fault shutdown Check for a fault shutdown code on the controller s LED display Correct the fault and then move the generator set master switch to OFF RESET to
91. etor mounting holes d Adjust the air gap if necessary by loosening the locknut and turning the pickup See Figure 5 12 Stepper Motor and Carburetor Figure 5 14 5 8 4 Governor System Magnetic e Hold the pickup in position and retighten the Pickup Operation Test locknut If the engine continues to operate erratically after the f Verify the magnetic pickup air gap after previous checks test the governor system operation tightening the locknut using the following procedure The procedure is 1 summarized in the flowchart in Figure 5 15 MOURINO h Reinstall the junction box and housing panels Governor System Operation Test Procedure removed to gain access to the front of the engine 1 Verify that the carburetor throttle linkage is 9 connected to the stepper motor as shown Figure 5 12 2 Look for broken or loose wiring or plug connections if the stepper motor moves erratically Check the condition of the throttle linkage and verify that the throttle plate closes completely 3 Check the operation of the stepper motor at RED P1 29 BLK P1 17 startup QCON1 a If the throttle moves to the fully open throttle position and then steps to and remains in the fully closed position the engine speed input is probably missing The engine starts and then shuts down on an overspeed fault Proceed to step 4 to check the magnetic pickup
92. frequency Uu and engine type Ec parameters Adjust engine governor speed Troubleshoot engine Section 4 5 2 Section 4 5 3 Engine S M Light flicker TP 6196 5 04 Voltage stability gain setting Check and adjust the voltage stability gain setting using the ADC 2100 Section 3 Troubleshooting Section 4 5 3 19 Troubleshooting Chart continued Problem High output voltage Possible Cause Incorrect controller configuration Corrective Action Check and adjust the controller configuration parameters Reference Section 4 5 2 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 4 5 3 Engine speed too high Check engine speed using tachometer or frequency meter Adjust governor as necessary Section 5 8 Loose voltage sensing connections Check connections stator leads 11 and 44 and P15 controller connection Section 7 SCR module Check wiring and connections to the SCR module Check auxiliary winding fuse F1 lead 55 Replace SCR module and recheck voltage Section 4 9 Section 5 11 Section 4 9 Controller Check fuses wiring and connections Before replacing controller replace SCR module and test voltage Section 4 10 No output voltage AC output circuit breaker open Check for AC voltage on the generator side of circuit breaker If there is AC voltage on the generator side of the breaker
93. g correctly 18 Section Troubleshooting Check cylinder pressures with leakdown test Inspect valves and valve seats Engine S M TP 6196 5 04 Troubleshooting Chart continued Problem Possible Cause Air intake restriction inadequate cooling Corrective Action Inspect air intakes and exhaust for obstructions Check air cleaner Reference Section 2 5 Section 2 4 Generator overloaded Reduce load Section 1 2 Spark plug s Replace and regap plug s Section 2 3 Spark plug wire s Replace spark plug wires Engine S M DSAM leads incorrectly connected or disconnected 12RES only Connect for natural gas Disconnect for LP Section 5 10 5 Insufficient fuel pressure Check fuel pressure at carburetor outlet Section 5 10 Fuel line restriction Check fuel pipe size Section 5 10 Fuel regulator Check function of fuel regulator Section 5 10 Engine not running at rated rpm Check controller settings for unit configuration UC and engine type EC Adjust governor speed Section 4 5 Engine power loss Refer to the Engine Service Manual for troubleshooting and repair instructions Engine S M Governor malfunction or misadjustment Test readjust governor Section 5 8 Ignition system Test and or replace Engine S M Overheats Inadequate cooling Inspect cooling system for air intake obstruction
94. gaseous fuel system uses two regulators The primary regulator reduces the line pressure to an allowable inlet pressure for the secondary regulator The fuel supplier provides and maintains the primary regulator The secondary regulator is factory installed on the generator set and is designed for maximum inlet pressure of 2 7 kPa 6 oz in 2 or 280 mm 11 in water column Note Do notattemptto adjustthe fuel mixture or engine speed by adjusting the regulators TP 6196 5 04 The fuel lock off prevents fuel flow when the engine is not operating See Figure 5 21 Do not try to adjust the fuel pressure fuel mixture or engine speed using the fuel lock off Checking the Fuel Pressure Use a gauge or manometer to check the fuel pressure at the secondary regulator inlet See Figure 5 21 Measure the fuel pressure with the generator set running at rated load The fuel pressure should be 178 280 mm 7 11 in water column or 1 7 2 7 kPa 4 6 oz in 2 Contact the fuel supplier if the inlet pressure is not within the specified range Hose fitting Plug Fuel block Fuel metering valves factory sealed do not adjust Secondary regulator 5 10 4 Fuel Conversion 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 b
95. ge 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 electrical circuits to comply with applicable 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 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 bat
96. generator set by moving the generator set master switch to the RUN position 16 Check for leaks using a gas leak detector 17 Move the generator set master switch to the AUTO position To convert from LP vapor to natural gas follow the same fuel conversion procedure moving the hose fitting to the natural gas port and plugging the LP port For the 12RES model disconnect the DSAM leads for LP vapor See Figure 5 23 1 DSAM connector location 2 Fuel block 3 Fuel inlet 1 2 in NPT female 4 DSAM Figure 5 22 Generator Set Fuel System Location Air Inlet Side TP 6196 5 04 5 10 5 Digital Spark Advance Module DSAM The digital spark advance module DSAM on the Model 12RES optimizes the engine timing for the selected fuel natural gas or LP The location of the DSAM is shown in Figure 5 22 Connect the DSAM leads in the air intake compartment together for natural gas fuel Disconnect the leads if LP is used See Figure 5 23 See the engine Service Manual for DSAM service information 1 DSAM leads connect for natural gas disconnect for LP Figure 5 23 Digital Spark Advance Module DSAM Leads located in generator set air intake area 5 10 6 Fuel Metering Valve Adjustment The fuel system is factory adjusted to comply with applicable emission standards and to provide the best possib
97. gine start 10 second inhibit Check system frequency setting parameter UU on controller Measure output frequency and ajdust if necessary Check governor system condition and operation Overspeed Shutdown occurs if the engine speed exceeds 11596 of the normal running speed for more than 0 3 seconds Check governor settings and operation Overvoltage Shutdown occurs if the voltage exceeds 12096 of the system nominal voltage for more than 2 seconds Check AC voltage Check wiring and connections Underfrequency Shutdown occurs when the governed frequency falls blow 90 6 of the nominal system frequency for more than 5 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Undervoltage Shutdown occurs if the voltage falls below 8096 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Check wiring and connections Check controller configuration system voltage and frequency parameter UU Check AC voltage and adjust if necessary Replace the SCR module and test voltage again Separately excite unit Check stator continuity Software Communication Fault 0 TP 6196 5 04 Indicates a software or communication problem within the ADC 2100 Figure 4 5 Fault Shutdown Codes Replace the controller Section 4 C
98. gth by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied 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 cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 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 milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second A 2 Appendix MTBF MTBO mtg 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 PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH mean time between failure mean time between overhauls mounting mega
99. heck regulator valve operation Section 2 Section 6 Engine overloaded Reduce electrical load Section 1 2 Loss of generator output voltage to controller Check connections at P15 plug Check continuity of AC sensing leads 11 and 44 Section 7 Magnetic pickup connections Check for loose connections to the mag pickup Section 5 8 Ignition module Test and or replace Engine S M flash relay Check for Flash LED illumination Check RIB fuse Replace relay board Section 4 8 Operates erratically Air cleaner clogged Replace element Section 2 4 Spark plug s Replace and regap plugs Section 2 3 Spark plug wire s Replace spark plug wires Engine S M DSAM leads incorrectly connected or disconnected 12RES only Connect for natural gas Disconnect for LP Section 5 10 5 Fuel line restriction Check fuel lines Section 5 10 1 Fuel mixture adjustment incorrect Check and or adjust Section 5 10 Magnetic pickup connections Check for loose connections to the mag pickup Section 5 8 Governor adjustment incorrect Adjust governor stability Section 5 8 Section 4 5 Ignition system Test and or replace components Engine S M Inadequate cooling hot engine only Inspect air inlet and outlet Section 2 5 Carbon buildup in engine Clean cylinder head Engine S M Engine valves not seatin
100. hm resister Figure 4 17 SCR Test Section 4 Controller 35 9 Connect the positive lead from the DC power Source with the lamp in series to terminal AC1 on the SCR module The lamp should not glow 10 Connectthe jumper with the resistor in series from the positive lead ofthe DC power source to terminal G1 on the SCR module The lamp should glow 11 Repeat steps 9 and 10 with the positive lead and lamp connected to terminal AC2 on the SCR module and connecting the jumper with resister to terminal G2 12 If any of the above checks indicates a bad SCR module replace the module 4 10 Controller Replacement If the troubleshooting procedures in Section 3 identify a bad controller use the procedure in this section for controller replacement Always check the controller configuration fuse wiring and connections before replacing the controller For output voltage problems replace the SCR module and check the operation again before replacing the controller After replacing the controller verify that the new controller s configuration settings match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings Refer to Section 4 5 for instructions to check the controller configuration and to change the settings if necessary After the controller configuration has been checked and set to match the generator set use a voltmete
101. ic 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 NOTICE Electrostatic discharge damage Electrostatic 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 TP 6196 5 04 This manual provides troubleshooting and repair instructions for the generator set models listed on the front cover This manual may also be supplied for similar models not listed on the front cover Information in this publication represents data available at the time of print 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 equipment service requirements are very important to safe and efficient op
102. ide RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier 5 sec second Sl Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw Spec specs specification s Sq square 4 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 6196 5 04 Appendix
103. ides Controller Generator set master switch RUN OFF RESET AUTO Nameplate Line circuit breaker Battery charger Air intake Engine starting battery location Oil drain hose High engine temperature HET sensor located on non service side Oil drain valve Figure 1 2 Generator Set Service View 4 Section 1 Specifications Fuel System Detail Oil filter Air intake alternator Exhaust Spark arrestor not visible in this view Relay interface board RIB SCR module Digital spark advance module leads DSAM leads ignition timing Multi fuel block Secondary fuel regulator assembly Fuel solenoid valve Starter solenoid Positive battery connection Starter relay Negative battery connection DSAM ground screw TP 6196 5 04 WARNING 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 set as follows 1 Move the generator set master switch to the OFF position
104. ion Check for power to the controller Move generator set master switch to OFF RESET and then to RUN Section 4 Section 7 TP 6196 5 04 Troubleshooting Chart continued Problem Cranks but does not start Possible Cause No fuel Corrective Action Open turn on manual fuel valve Check fuel supply tank LP Reference Insufficient fuel pressure Check fuel pressure to the generator set Verify adequate fuel pressure and pipe size for the generator set plus all other gas appliances Section 5 10 3 Fuel regulator valve Check regulator valve operation Section 5 10 Section 4 Spark plugs or spark plug connections Check spark plug wires and connections Replace or clean and regap spark plugs Section 2 3 Loose connection or open circuit Check for loose or open connection at the fuel valve lead 70A and at the engine spark control module leads IGN and 70A Check controller engine wiring continuity Section 7 Air cleaner clogged Clean or replace Section 2 4 Magnetic pickup Check for 1 75 volts or higher from the magnetic pickup during cranking A lower signal will cause the stepper motor to open and close during cranking Section 5 8 4 Incorrect controller configuration Check for correct controller configuration parameters unit configuration UC and engine configuration EC Section 4 5 Ignition system spark control or ignition coil T
105. ion 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 GM29253 GA1 GM29253 GA3 GM29253 GA2 GM29253 GA4 Figure 7 1 Generator Set Specification Numbers TP 6196 5 04 7 2 Controller Wiring Diagram Reference Figure 7 2 lists the wiring diagram numbers and locations Drawing Number Wiring Diagram Description Schematic Diagram Sheet 1 Sheet 2 ADV 6835A ADV 6835B GM29358 Figure 7 3 Figure 7 4 Point to Point Wiring Diagram Figure 7 5 Figure 7 2 Controller Wiring Diagrams Section 7 Wiring Diagrams 71 0018 HOLOW H3dd31S WLS HOLVIS 1918 1HVWS 458 GION31OS H31HVIS SS H31HVIS HS H31HVLS WS 31411934 Q3T10H1NOO NOOTIIS HOS GHVOG 3OVJH31NI AV 13H ld 1O3NNOO NOOO ona OLL3NOVIN di HOLIMS 668 10 MOT 401 O1XO8 H3TIOHL1NOO O1 71051409 NOI H3TIOHINOO INWA Taf Ad 3end 4 H3aNas auniveadWa LNV1009 SLO 3aola 1Inoulo 99 ON3931 LOANNOO LON OG 193NNOO LON OG 5 941 LOANNOO 10 04 NOIL S9 LO3NNOO SVD TWHNLVN 1303
106. ith the slip rings by the springs When correctly positioned spring pressure on the brush surface causes the brush to wear evenly The entire brush must ride on the ring or arcing occurs and causes burned rings or voltage regulator failure Figure 5 8 shows the correct positioning of the brushes Add or remove shims as necessary to center the brushes on the slip rings Replace the brushes if they show uneven wear or are worn to one half their original length 44 Section 5 Component Testing and Adjustment Check the resistance through the brushes Resistance through the brushes should be low 0 1 0 2 ohms without meter lead resistance GM29253B P Side View 11 Brush holder Spring Ring collector Brush holder Brushes Correctly positioned brush Brush Incorrectly positioned brush Retainer wire Slip ring Shim Figure 5 8 Brush Assembly TP 6196 5 04 5 7 5 7 1 Voltage Regulation Voltage regulation is performed by the Advanced Digital Control ADC and the SCR module The ADC monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module 5 7 2 Voltage Adjustment The factory sets the voltage for correct generator operation under a variety of load conditions Usually the voltage needs no further adjustment Adjust the voltage when necessary according to the following procedure The adju
107. le hot and cold starting Note Adjusting the fuel metering valves on emissions certified generator sets may void the emission certification Use a universal exhaust gas oxygen UEGO sensor to check the fuel mixture after replacing the fuel regulator carburetor or silencer Use the following procedure to check the fuel mixture after the engine has reached normal operating temperature The UEGO sensor readings must fall within the range shown Figure 5 26 The fuel metering valves are sealed to prevent field adjustments If the fuel metering valve requires adjustment do not break the seals on the fuel adjustment block Obtain a new fuel adjustment block from the manufacturer and replace the sealed block with TP 6196 5 04 the new part Refer to the generator set Parts Catalog for the fuel block part number Only trained authorized service technicians may adjust the fuel metering valves The adjustment procedure requires a digital volt meter DVM UEGO oxygen sensor service kit GM29385 and a load bank capable of the rated kW for the fuel being used Always use an oxygen sensor when adjusting the fuel metering valves Observe the following safety precautions while performing the procedure WARNING QMS Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system parts can cause severe injury or death Do not
108. leads connected to the alternator end bracket through the opening in the base of the alternator frame Place the end bracket onto the stator assembly lining up the alignment marks on the top of the stator and end bracket Offset the end bracket slightly to compensate for the alternator offset in step 3a See Figure 6 14 e Thread the four overbolts with locating washers through the end bracket and into the generator adapter Position the locating tab of each washer to the outer edge of the oblong OBROUND hole on the end bracket See Figure 6 15 The overbolts should be parallel to the outside of the alternator If the overbolts are slanted rotate the locating washer 1 2 turn Do not final tighten the overbolts 1 Alignment slot on generator adapter 2 Alignment marks showing small offset Figure 6 14 Stator and End Bracket Alignment 66 Section 6 Disassembly Reassembly TP 6196 5 04 4 Secure the generator set to the skid a Raise the alternator end of the generator set and remove the block of wood from beneath the rear of the engine b Lowerthe end ofthe generator set and reinstall the screws and washers that secure the vibromount mounting plate to the generator set skid See Figure 6 16 5 Tighten the hardware to the following torques See Figure 6 16 Tighten the rotor thrubolt to 40 Nm 28 ft Ib It may be necessary to keep the engine flywheel from turning while torquing the rotor thrubolt b
109. lems check the controller configuration and settings Thentestthe SCR module using the following procedure SCR Module Test Procedure Required equipment e Ohmmeter e 12 volt test lamp or voltmeter 12 volt DC power source 100 500 ohm resistor e Jumper 1 Set the ohmmeter to the RX1 scale 2 Connect the ohmmeter from to on the SCR module You should read high resistance in one direction and low resistance in the other reverse the leads Figure 4 16 Silicon Controlled Rectifier SCR Module TP 6196 5 04 3 Connect the ohmmeter from to on the SCR module You should read high resistance in both directions 4 Connect the ohmmeter from AC1 to on the SCR module You should read high resistance in one direction and low resistance in the other 5 Repeat steps 3 and 4 for AC2 6 Connect the ohmmeter from G1 to on the SCR module You should read low resistance in both directions 7 Repeat step 6 for G2 You should read low resistance in both directions 8 See Figure 4 17 Connect the negative lead from the DC power source to the positive terminal on the SCR module Note The SCR module may be damaged if the power supply is connected incorrectly Be sure to connect the negative lead from the battery to the positive terminal on the SCR module 12VDC power source 12 VDC test lamp SCR module Jumper 100 500 o
110. lock 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 Regulator side view TP 6196 6 Fuel solenoid valve 7 Fuel inlet 1 2 in NPT 8 Fuel lockoff do not adjust 9 Inlet pressure check location Figure 5 21 Fuel Regulator Fuel Block and Fuel Solenoid Valve TP 6196 5 04 Section 5 Component Testing and Adjustment 55 Fuel Conversion Procedure Use the following procedure to convert from natural gas to LP vapor See Figure 5 22 for the fuel system component locations WARNING 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 genera
111. lons per minute grade gross equipment ground gross weight HxW xD height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext ISO J JIS hex cap 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 International Organization for Standardization joule Japanese Industry Standard Appendix 1 kilo 1000 K kelvin kA kiloampere KB kilobyte 219 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 len
112. ltage and continuity Section 5 3 Flash relay K3 on relay interface board RIB Check flash LED on RIB Check fuse F2 and troubleshoot RIB as described in Section 4 8 Section 4 8 Noisy operation Exhaust system leaks Check and replace as necessary Section 2 6 Engine not running smoothly See Generator set operates erratically this table Broken or damaged vibromount s Check and replace as necessary Section 6 Loose or vibrating sheet metal housing Retighten screws replace rivets Exhaust piping or air inlets outlets not securely installed Inspect for loose parts and secure if necessary Section 2 6 Excessive engine generator vibration 20 Section 3 Troubleshooting Check rotor crankshaft bearing etc disassembly of engine and or alternator may be required Section 6 Engine S M TP 6196 5 04 4 1 Introduction This section covers operation configuration adjustment and replacement of the ADC 2100 controller See Section 3 for troubleshooting procedures See Figure 4 1 for the locations of the controller and related components Section 4 2 describes the controller keypad and display Section 4 3 describes the sequence of operation and faults are described in Section 4 4 Controller Section 4 Controller configuration and adjustment are covered in Section 4 5 A silicon controlled rectifier SCR module works with the controller
113. m ft Ib Assembled into Cast Iron or Steel Size mm M6 x 1 00 Grade 5 8 5 6 Grade 8 8 Grade 10 9 Assembled into Aluminum Grade 5 8 or 8 8 M8 x 1 25 13 6 M8 x 1 00 21 0 M10 x 1 50 27 0 M10 x 1 25 39 0 M12 x 1 75 47 0 M12 x 1 50 65 0 M14 x 2 00 74 0 M14 x 1 50 100 0 103 M16 x 2 00 115 0 200 0 148 M16 x 1 50 141 0 104 M18 x 2 50 155 0 114 275 0 203 M18 x 1 50 A 4 Appendix 196 0 145 210 0 155 305 0 225 TP 6196 5 04 Appendix D Common Hardware Identification Screw Bolts Studs Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head i Y with Washer Lock or Elastic Grade 5 Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Head Metric Round Head RHM Cap or Acorn Pan Head Wing Number stamped on Hex Socket Head Cap or Washers hardware 5 8 shown Allen Head Cap Washer Styles Hex Socket Head or Allen Head Shoulder Bolt Plain Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles External Tooth Lock Hex Internal Tooth Lock Hex and Slotted Internal External Tooth Lock Phillips Slotted Hex Socket Allen head screw is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw
114. nal or an overspeed condition An erratic signal causes the generator set to govern poorly but not shut down 6196 5 04 e Verify thatthe battery connections are clean and tight e Check for dirt buildup on the magnetic pickup Metal filings or caked on dirt or grease decreases the output signal of the magnetic pickup e Check for a loose or worn stepper motor throttle shaft coupling Replace the shaft and bushing every 500 hours of engine operation e Check the carburetor for dirt grime misadjustment Check for a loose mixer assembly e Check the idle adjustment screw The screw should not prevent the throttle plate from closing completely e Check the throttle linkage for any binding dirt damage or other visible problems Check for electronic governor faults The fuel shutoff solenoid deenergizes and the generator set shuts down under the following conditions e Closed throttle e Engine overspeed e Broken fuel shutoff solenoid lead e Broken stepper motor leads erratic performance e Failed actuator linkage erratic performance 5 8 8 Hunting Surging Often hunting surging problems thought to be caused by the governor are actually caused by engine or carburetor problems Check engine speed stability using the following procedure before testing the governor 1 Open the generator set line circuit breaker 2 Start the generator set 3 Hold the throttle linkage steady while the engine is running
115. nerator set Verify that the generator set shuts down approximately 5 seconds after the generator set comes up to speed Remove the jumper wire Start the generator set and run it for at least 30 seconds to verify that the generator set does not shut down TP 6196 5 04 5 9 2 Fault Shutdown Switches Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests If the sensor does not function as described replace it 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 itis 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 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 or repairs Remove all jewelry before servicing the equipment Temperature Sensor CTS The coolant temperature sensor CTS is used to monitor engine temperature for the high engine temperature fault shutdown HE See Section 1 8 Service Views for the coolant temperature sens
116. ntact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Separate Excitation Procedure Perform the following procedure to use an external voltage source to excite the main field rotor 1 Disconnect the black FN and FP leads from the alternator at the SCR module and terminals 2 Connect a DC ammeter 20 amp fuse and a 12 volt automotive battery to the positive FP and negative FN brush leads as shown in Figure 5 3 Note and record the ammeter reading Note The approximate ammeter reading should be the battery voltage divided by the specified rotor resistance See Section 1 Specifications for specified rotor resistance values Example 12 volts battery voltage S8amps 4 ohms rotor resistance X rotor current 3 Start the engine and check that the ammeter reading remains stable increasing meter reading indicates a shorted rotor A meter reading decreasing to zero or an unstable reading suggests a running open Refer to Section 5 5 40 Section 5 Component Testing and Adjustment Main Field Rotor to test the rotor If the ammeter reading is stable proceed to step 4 4 Check for AC output across the stator leads see Section 5 3 Stator Compare the readings to the AC output values shown Section 1 Specifications If the readings vary considerably a faulty stator is likely Refer to Section 5 3 Stator
117. ntained by an electronic governor system that consists of a magnetic pickup and electric actuator stepper motor The ADC 2100 controls the governor system The magnetic pick up which monitors the speed of the flywheel ring gear provides the speed reference signal to the ADC 2100 The controller provides regulated power to the bidirectional stepper motor actuator which is linked to the carburetor throttle arm At cranking speed a properly adjusted pick up should produce a minimum of 1 75 VAC The magnetic pick up air gap is factory set to 0 5 mm 0 020 in Failure or loss of the input speed signal from the magnetic pick up will result in erratic speed A setting on the ADC 2100 allows adjustment of the engine speed within the 50 60Hz range See Section 5 8 3 A gain adjustment may be required if an unstable hunting surging condition occurs Adjusting the gain may require readjustment of the engine speed See Section 5 8 3 5 8 2 Initial Checks and Operation Test The factory sets the electronic governor Under normal circumstances the electronic governor requires no further adjustment Verify that the governor stepper motor moves smoothly and steadily during operation If the engine operates erratically check the following connections and conditions before adjusting the governor e Verify that the electrical connections are clean and tight e Check the magnetic pickup connections Poor connections may cause an erratic sig
118. nterface Harness GM28981 Electrical Connections 10 11 12 13 14 15 16 17 18 19 20 58 Adjust the fuel metering valve as required to obtain the output from the oxygen sensor specified in Figure 5 26 The output of the oxygen sensor reads high when the mixture is fuel rich and close to zero volts when the mixture is lean Remove the load and allow the generator set to run unloaded to cool for at least 5 10 minutes Place the generator set master switch in the OFF position Disconnect the generator set engine starting battery negative lead first Allow the generator set exhaust system to cool Disconnect the DVM leads from the oxygen sensor Remove the oxygen sensor from the exhaust manifold Apply a small amount of antiseize compound to exhaust plug and reinstall the plug into the exhaust manifold Check that the generator set master switch is in the OFF position Reconnect the generator set engine starting battery negative lead last Reconnect power to the battery charger Section 5 Component Testing and Adjustment GM29253 1 Oxygen sensor mounting location Figure 5 25 Oxygen Sensor Mounting Location Oxygen Sensor Reading VDC Natural Gas LP 2 40 0 05 2 25
119. nting screws 3 ea 3 Exhaust shield Figure 6 18 Alternator Air Inlet Duct 9 Install the exhaust system See Figure 6 19 a Install the heat shield onto the alternator exhaust support using M8 hardware b Using new gaskets connect the engine exhaust muffler to the engine atthe flanges Do not final tighten the mounting hardware c Secure the muffler mounting tab to the heat shield with M8 hardware d Torque the nuts securing the engine muffler flange to the engine to 24 Nm 216 in 68 Section 6 Disassembly Reassembly GM29253C U Engine exhaust muffler Muffler bolts Heat shield Flange connection Heat shield bolts Figure 6 19 Exhaust System TP 6196 5 04 10 Connect the alternator leads inside the controller 11 Reinstall the enclosure panels in reverse order of box See Figure 6 20 removal See Figure 6 21 andreferto Step 1 ofthe disassembly instrructions a Connect alternator leads 1 and 4 to the line circuit breaker Install the non service side housing panel b Connect alternator leads 2 and 3 to the load b Install the alternator end housing panel connection stud LO c Install the generator set housing roof c Connect brush leads FP and FN and stator leads 55 and 66 to the SCR module See 12 Return the generator set to operation Figure 6 20 ria a Checkthatthe generator set master s
120. ontroller 25 4 5 Controller Configuration and Adjustment The first step in troubleshooting the controller is to verify that the controller is correctly configured for the generator set The controller s configuration modes allow setting of the engine type generator set configuration marine mobile or standby data input types and other parameters The controller configuration for each generator model is set at the factory Changes in the controller configuration be required after controller replacement or other service Use the instructions in the following section to check the controller settings and change them if necessary 4 5 1 Controller Time Out The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure again from the beginning ifthe controller exits the configuration mode before the settings have been saved Changes in voltage and speed adjustments are also lost if they are not saved before the generator set shuts down The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup Be sure to save your changes immediately after making adjustments 4 5 2 Controller Configuration The controller configuration is factory set and should not normally require changes in the field However the controller configuration may
121. or location Setthe generator set master switch to the OFF position and allow the generator set to cool Disconnect the CTS and use an ohmmeter to measure the resistance across the sensor The sensor resistance varies with temperature and should be within the values shown in Figure 5 17 If the resistance is very low indicated a short circuit or very high indicating an open circuit replace the CTS Note The HET switch is located in the engine oil pan Drain the engine oil before removing the switch Temperature C F Resistance Ohms 30 86 2100 2500 180 200 100 212 Figure 5 17 Coolant Temperature Sensor Resistance Readings TP 6196 5 04 Low Oil Pressure LOP Switch The low oil pressure LOP switch is located under the engine air cleaner See Figure 5 18 Remove the LOP switch and install an oil pressure gauge to verify that the engine oil pressure is within the range specified in Section 1 Specifications before testing or replacing the LOP switch To test the LOP switch reinstall the switch and startthe generator set If the unit shuts down disconnect lead 13 from the LOP switch and reset the controller Restart the generator set and verify that it does not shut down A successful restart indicates a bad LOP switch Replace the switch 1 Oil pressure switch Figure 5 18 Oil Pressure Switch Location under the air cleaner Section 5 Component Testing and Adjustment 53 5 10 Fuel Systems
122. or permit flames 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 Safety Precautions and Instructions 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 Engine Backfire Flash Fire WARNING 7 d 4 Fire Can cause severe injur
123. ource All single phase units are rated at 1 0 power factor The standby rating is applicable to variable loads with an average load factor of 80 for the duration of the power outage No overload capacity is specified at this rating Ratings are in accordance with ISO 3046 1 BS5514 AS2789 and DIN 6271 GENERAL GUIDELINES FOR DERATING ALTITUDE Derate 4 per 305 m 1000 ft elevation above 153 m 500 TEMPERATURE Derate 1 5 per 5 5 C 10 F temperature increase above 16 C 60 F Availability is subject to change without notice Kohler Co reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever Contact your local Kohler Co generator distributor for availability Figure 1 1 Generator Set Ratings TP 6196 5 04 Section 1 Specifications 1 1 5 Engine Specifications Engine Specification Manufacturer 8 5RES 60 Hz 12RES 60 Hz Model Cycle Number of cylinders Compression ratio 8 5 9 0 1 Displacement cc cu in 624 88 0 725 44 0 Rated power propane fuel kw hp 11 5 15 4 17 6 23 6 Rpm 3600 Bore x stroke mm in 77 x 67 3 03 x 2 64 83 x 67 3 27 x 2 64 Valve material Steel Stellite Cylinder block material Aluminum w cast iron liners Cylinder head material Aluminum Piston rings 2 compression 1 oil Crankshaft material Heat treated du
124. per Bearing number and type 1 replaceable ball Circuit protection Controller 10 amps Aux winding 20 amps Generator AC output Dependent on voltage configuration Rotor resistance ohms cold 4 0 Stator resistance ohms cold Leads 1 2 3 4 11 44 55 66 0 07 0 14 0 70 Stator output voltage with separately excited rotor using 12 volt battery minimum Leads 1 2 3 4 11 44 55 66 Rotor field voltage current readings at rated output voltage hot No load Full load 12V 2 0 amps 47V 7 4 amps Brush length new 19 05 mm 0 75 in Most ohmmeters do not give accurate readings when measuring less than 1 ohm The stator can be considered good if a low resistance reading continuity is obtained and there is no evidence of shorted windings discoloration Do not confuse a low resistance reading with a reading indicating a shorted winding TP 6196 5 04 Spark plug 24 4 29 8 18 22 Section 1 Specifications 1 8 Service View Starter non service side Enclosure Muffler Oil check Oil fill Air cleaner Spark plug locations both s
125. pressure to the generator set See Section 5 10 Fuel Systems 3 3 Troubleshooting Chart Use the following table as a reference in troubleshooting individual problems Generator set faults are listed in groups and include likely causes and remedies The simplest and most likely causes of the problem are listed first follow the recommendations in the order shown The reference column provides additional sources of information in this and related manuals regarding the problem and solution Section 3 Troubleshooting 15 Troubleshooting Chart Problem Generator set does not crank Possible Cause Weak or dead battery Corrective Action Recharge or replace battery If battery is weak or dead check battery charger fuse power supply and operation Reference Generator Set O M Battery connections Check for reversed or poor battery connections Open circuit in engine controller connections Check for loose connections Check the wire harness continuity Section 5 12 Section 7 Blown fuse F3 controller Replace fuse if fuse blows again check circuit and components Section 5 11 Section 7 Blown fuse F2 relay interface board RIB Replace fuse Section 5 11 If fuse blows again disconnect the board leads one at a time to identify the cause of the blown fuse Lead 70A at the fuel valve Lead IGN at the ignition module Lead 71 at the starter relay Leads FP and FN at the rotor
126. put reaches the desired voltage 4 Follow the controller instructions to step to the voltage gain adjustment menu Adjust the voltage gain parameter 2P until the light flicker minimizes Save the settings Section 5 Component Testing and Adjustment 45 E y FN Se N RAS lit N Controller Box Top View GM29253A F 1 Controller box location 2 Line circuit breaker 3 Load connection terminal LO Figure 5 9 Circuit Breaker and LO Terminal Location 5 Check and readjust the voltage if necessary 6 Set the voltmeter to measure frequency Adjust the engine speed to the cut in frequency shown in Figure 5 10 by adjusting the engine governor speed parameter 4P through the ADC controller See Section 4 5 7 Set the voltmeter to measure voltage Adjust the volts Hz parameter 3P until the voltage level measured by the voltmeter begins to drop When set the generator as load is applied attempts to maintain normal output until the engine speed drops below the cut in frequency set in step 6 8 Set the voltmeter to measure frequency Adjust the engine speed to the operating frequency 50 or 46 Section 5 Component Testing and Adjustment 60 Hz by adjusting the engine governor speed parameter 4P through the ADC controller 9 Readju
127. r to check the generator set output voltage and frequency If the output voltage or frequency needs adjustment use the Voltage and Frequency Adjustment Procedure in Section 5 7 2 and the controller voltage and speed adjustment instructions in Section 4 5 3 Also see the Frequency Adjustment Procedure in Section 5 8 5 36 Section 4 Controller ADC 2100 Controller Replacement Procedure 1 Remove the enclosure service side door See Figure 4 18 2 Place the generator set master switch in the OFF position 3 Remove 4 roof screws Liftthe roof up and off See Figure 4 18 4 Disconnect power to the battery charger 5 Disconnect the generator set engine starting battery negative lead first Ot POWER SYSTEMS VVVVVVVVVVVVVVVV Roof Roof locating pin Roof screws 4 ea Service side door Front panel Figure 4 18 Enclosure Roof and Door TP 6196 5 04 Note Some versions of the controller mount from inside the controller compartment Others are front mounted 6 For inside mounted controllers a Remove 5 screws to remove the front panel on the air intake end ofthe enclosure Remove the plastic caps to access the 2 side screws See Figure 4 18 b Remove two screws to remove the cover from the controller compartment See Figure 4 19 c Disconnect wiring harness plugs P1 P15 and P16 from the ADC controller See Figure 4 20
128. rcuits 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 or repairs Remove all jewelry before servicing the equipment 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 or on wet ground because these conditions increase the risk of electrocution Voltage Adjustment Procedure 1 Connect a digital voltmeter from one side of the circuit breaker to the LO terminal inside the controller assembly See Figure 5 9 Set the meter to measure voltage Note For 120 or 240 volt systems the voltage measured from one side of the breaker to LO should be approximately 120 VAC For 240 volt systems the voltage measured from one side of the circuit breaker to the other should be approximately 240 VAC 2 Start the generator set 3 Follow the controller instructions in Section 4 5 to enter the adjustment mode and increase voltage or decrease voltage parameter 1P until the out
129. re in good condition test the voltage regulation using the tests in Section 5 11 TP 6196 5 04 ADC 2100 1 Fuse 2 Power lead 55 3 Excitation to rotor 4 Brushes 5 Slip rings 6 Main field rotor 7 Stator windings 8 Sensing leads 11 44 Figure 5 1 Single Phase Generator Schematic No Generator Output Separate Excitation Output within Specifications Check Wiring Fuses SCR Module and Controller Erratic or No Output Check Rotor Check Stator TP563273 Figure 5 2 Generator Troubleshooting Section 5 Component Testing and Adjustment 39 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 wetground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not co
130. resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads dis connected 3 years Run exercise generator set Weekly Remote control operation Monthly General Condition Of Equipment Any condition of vibration leakage excessive noise high temperature or deterioration Weekly Interior of enclosure Quarterly Follow procedures and frequencies indicated in the engine manufacturer s maintenance manual If not indicated follow this service schedule Some items may not apply to all generator sets R Replace X Action O M Generator Set Operation Manual Service more frequently if operated in dusty areas Replace fuel lines and connections as necessary Figure 2 1 Service Schedule 6 Section 2 Scheduled Maintenance TP 6196 5 04 2 2 Lubrication System See Section 2 1 Scheduled Maintenance for oil change and oil filter replacement intervals See Figure 2 2 for the oil drain oil check oil fill and oil filter locations The engine has a positive pressure lubrication system and low oil pressure shutdown 2 2 1 Low Oil Pressure Shutdown The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below preset limits because of oil pump failure or other malfunction It does not protect against damage caused by operating with the oil level below the safe range it is no
131. rized distributor dealer or trained service technician perform testing and service Refer to the Engine Service Manual TP 2428 for engine service information If the troubleshooting procedures in this section identify a bad part refer to the parts catalog for replacement part numbers See the List of Related Materials in the Introduction for the parts catalog number 3 2 Inital Checks When troubleshooting always check for simple problems first Check for the following common problems before replacing parts e Loose connections or damaged wiring e Dead battery e Fault shutdown Check for a fault code on the controller display Section 4 4 describes the warning and shutdown fault codes e Blown fuses Fuses in the wiring harness protect the controller SCR module and relay interface board A TP 6196 5 04 Section 3 Troubleshooting battery charger fuse is located in the positive battery lead Always check and replace the fuses before replacing other components e Incorrect controller settings Always check the controller configuration settings before replacing the controller Section 4 5 contains the instructions for checking and changing the controller configuration e Inadequate fuel supply Check for damaged primary or secondary fuel regulators loose connections to the fuel solenoid valve a damaged or closed fuel shutoff valve an empty LP fuel tank or other problems with the fuel supply Check the fuel supply
132. s Section 2 5 Fuel mixture adjustment incorrect Readjust fuel mixture Note Adjusting the fuel mixture may void the emission certification Section 5 10 Low output or excessive drop in voltage Generator overloaded Reduce load Section 1 2 Incorrect controller configuration Check and adjust the controller configuration parameters Section 4 5 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 4 5 3 Alternator or control system Perform separate excitation procedure to isolate problem to the alternator or the control system Section 5 2 SCR module Check wiring and connections to the SCR module Check auxiliary winding fuse F1 lead 55 Replace SCR module and test voltage Section 5 11 Section 4 9 Controller Check controller settings Check controller fuse wiring and connections Before replacing controller replace SCR module and test voltage Section 4 5 Section 4 10 Rotor open grounded or shorted windings Test and or replace Section 5 4 Stator open grounded or shorted windings Test and or replace Section 5 3 Brush connection Check for loose brush connections Check the resistance through the brushes Resistance through the brushes should be low 0 1 0 2 ohms without meter lead resistance Section Low engine speed causing voltage roll off Check system voltage
133. s in Figure 5 19 Measure the pipe length from the gas utility pressure regulator to the end of the pipe where it connects to the fuel inlet of the generator set Add 2 4m 8ft for each bend in the pipe Compare the total length with the chart in Figure 5 19 If the piping is longer than the maximum length shown in the chart replace it with a larger pipe size Bleed the air from the gas lines after installation 54 Section 5 Component Testing and Adjustment Figure 5 20 lists the maximum gas flow rates for each model 8 5RES 12RES Pipe Length Natural Natural m ft Gas Gas 8 25 15 50 30 100 46 150 61 200 Figure 5 19 Maximum Gas Pipe Length Gas Flow Rate Ec Natural Gas Generator Set Model 8 5RES 132 000 180 000 12RES 202 000 270 000 Figure 5 20 Maximum Natural Gas Flow Rate 5 10 2 Fuel Solenoid Valve A solenoid valve upstream of the regulator and the flexible fuel connector provides automatic fuel on off control The engine starting battery powers the solenoid valve and the engine starting controls open the valve when the engine cranks or runs Gas Valve Operation Test Procedure 1 Disconnect the positive battery lead from the gas valve terminal 2 Apply 12 VDC to the gas valve terminal and listen for an audible click indicating that the valve actuates 3 Replace the gas valve if it does not actuate in step 2 5 10 3 Fuel Regulators The typical
134. s 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 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 compartm
135. set and tighten the oil filter to stop any leaks Reinstall the housing side panel TP 6196 5 04 2 3 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary Spark Plug Maintenance Procedure 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 2 5 and Figure 2 6 4 Install the spark plug and tighten it according to the torque specification in Section 1 7 Figure 2 6 Adjusting the Spark Plug Gap TP 6196 5 04 2 4 Air Cleaner Element and Precleaner The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 2 7 Refer to Section 1 8 Service View for the air cleaner location Wash and oil the precleaner and replace the paper element at the intervals shown in the service schedule Figure 2 1 Service the air cleaner more often if the generator set operates under dusty or dirty conditions Refer to Maintenance and Service Parts in the Introduction section of this manual for replacement part numbers Keep the area around the air cleaner housing free of dirt and debris Note Operating the engine with loose or damaged air cle
136. st the voltage gain parameter 2P until the light flicker minimizes if necessary 10 Check the voltage Readjust the voltage parameter 1P if necessary 11 Save the settings Refer to Section 4 5 for instructions Note The controller will revert to the previous settings at the next startup if the changes are not saved 12 Stop the generator set Cut In Frequency 60 Hz 57 5 Hz 50 Hz 47 5 Hz Figure 5 10 Cut In Frequencies 5 7 3 Voltage Connections Generator sets are available from the factory connected for 110 220 Volt 50 Hz or 120 240 Volt 60 Hz See Figure 5 11 for the factory connections Model 8 5 12RES generator sets are not reconnectable LO Neutral LO ue dU G GRD round 12 Factory two pole circuit breaker 4 3 Stator Leads 60 Hz 50 Hz 120 volt 110 volt 120 volt 110 volt 240 volt 220 volt Figure 5 11 110 220 and 120 240 Volt 3 Wire Configurations TP 6196 5 04 5 8 Governor System The governor system consists an electromechanical stepper motor actuator and a magnetic pickup The ADC 2100 controls the governor system operation See Section 7 Wiring Diagrams for the governor connections 5 8 4 Operation The frequency of the alternator output is determined by the speed of the engine A two pole alternator must be driven at 3600 RPM to provide 60 Hertz A 50 Hz model must be driven at 3000 RPM The engine speed is mai
137. stment procedure requires a meter that can measure voltage and frequency Use the ADC controller to adjust the voltage gain and volts Hz Refer to Section 4 5 for instructions to adjust each parameter and save the changes using the controller keypad Note The ADC controller will time out and exit the adjustment mode after approximately 1 minute if no buttons are pressed Any unsaved changes are discarded if the controller times out before the settings are saved Refer to Section 4 5 for instructions to save your settings Voltage Adjustment Adjusts generator output between 100 and 130 volts Gain Stability Adjustment circuitry to reduce light flicker Fine tunes regulator Volis Hz Adjustment Determines frequency Hz at which generator output voltage begins to drop The controller maintains generator output at the specified voltage under load until the generator engine speed drops to a preset level factory setting 57 5 Hz on 60 Hz models and 47 5 Hz on 50 Hz models Then the controller allows the generator voltage and current to drop The voltage current drop enables the engine to pick up the load When the generator speed returns to normal 60 Hz or 50 Hz as load is accepted the generator output also returns to normal TP 6196 5 04 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 Short ci
138. t a low oil level shutdown 2 2 2 Oil Level Check Check the oil level regularly and add oil as needed to protect against running out of oil See Figure 2 2 for the dipstick and oil fill locations 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 2 2 3 Engine Oil Recommendation Use synthetic oil of API American Petroleum Institute Service Class SG or higher Synthetic oil causes fewer deposits on the engine intake valves and pistons because it oxidizes and thickens less than other oils See Figure 2 3 and Figure 2 4 TP 6196 5 04 1 drain hose 2 Oil drain valve 3 Oil fill 4 Oil filter Figure 2 2 Lubrication System ro 8 5RES 1 9 2 0 12RES 2 0 2 1 Figure 2 3 Oil Capacity with Filter 5W 20 5W 30 30 20 10 0 10 20 30 40 F 20 0 20 32 40 60 80 100 Temperature Range Expected Before Next Oil Change Figure 2 4 Engine Oil Selection Section 2 Scheduled Maintenance 7 224 Oil Change Procedure Whenever possible drain the oil while it is still warm 8 1 Drain the oil a Place the generator set mas
139. tempts to start the engine The electronic governor moves to its start position The run relay energizes and the run LED 1 turns on The crank and flash relays energize and the corresponding LEDs 2 and 3 turn on 0 5 seconds later The controller display indicates the crank cycle 1 code CC 1 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 When the engine comes up to speed the low oil pressure switch contacts open Note The controller circuit board prevents fault shutdowns during startup until the crank disconnect relay energizes The cyclic cranking cycle is programmed into the controller s application code and is not adjustable in the field The factory sets the cranking cycle for three cycles of 15 seconds on time and 15 seconds off time If the TP 6196 5 04 cranking cycle seems shorter than the factory setting check the engine starting battery 4 3 2 Starting Sequence Remote Start When the master switch is set to the AUTO position the generator set starts when the remote start switch or transfer switch engine start contacts close The start sequence proceeds as described Section 4 3 1 Starting Sequence Master Switch Moved to RUN 4 3 3 Running Sequence When the engine speed reaches 750 rpm the crank relay deenergizes and the cr
140. ter switch in the OFF position Disconnect the power to the battery charger Disconnect the generator set engine starting battery negative lead first Remove the oil drain hose from its retaining clip See Figure 2 2 Remove the cap from the oil drain hose and lower the hose into an oil collection container Open the oil drain valve on the engine Remove the dipstick and oil fill cap Allow time for the engine oil to drain completely Close the oil drain valve 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 Section 2 Scheduled Maintenance 4 a b Apply a light coat of clean oil to the rubber seal of the new oil filter 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 Fill with oil Fill with oil See Section 2 2 3 for oil selection and Figure 2 3 for oil capacity Replace the oil fill cap and dipstick Check for leaks a Check that the generator set master switch is in the OFF position Reconnect the generator set engine starting battery negative lead last Reconnect the power to the battery charger Start the generator set and check for leaks around the oil filter Stop the generator
141. tery charging alternator connections 5 Attach the weld ground connection close to the weld location High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure 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 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 or 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 Safety Precautions and Instructions 111 Heavy Equipment WARNING Unbalanced weight Improper lifting can caus
142. tion mode Go to Figure 4 8 or or SA To proceed to the save mode without entering the advanced configuration mode Go Figure 4 9 Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed Figure 4 7 Configuration Mode system voltage frequency unit configuration and engine type parameters 28 Section 4 Controller TP 6196 5 04 Pressing the up arrow key at the Adnc display See Figure 4 7 puts you into the Advanced Configuration Mode Press To set the engine data input type to Ed05 9 N 2 To enter battery voltage selection mode To toggle between 12 and 24 VDC Set this parameter to 12 VDC To enter communications selection mode To set the communications parameter to To enter SAVE mode Go to Figure 4 9 SIAIVIE Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Figure 4 8 Advanced Configuration Mode engine data input types battery voltage and engine communications There are 3 options
143. to regulate the output voltage See Section 4 9 A relay interface board RIB is used with the ADC controller Section 4 8 describes the standard and optional RIBs VIEW B B aam 1 Controller 2 SCR module 3 Ground stud 4 LO stud Figure 4 1 Advanced Digital Control ADC 2100 TP 6196 5 04 5 Relay interface board RIB 6 Line circuit breaker load connection 7 Engine harness to controller connection 8 Generator set master switch Section 4 Controller 21 4 2 Controller Display and Keypad The controller has an LED display and a three button keypad See Figure 4 2 The LED display shows runtime hours fault codes application program version number or controller parameters during configuration and adjustment See Figure 4 3 The keypad is used to enter the controller s configuration and adjustment menus and to change the controller settings A password key sequence is required to enter the configuration and adjustment menus Section 4 5 contains the instructions to enter the configuration and adjustment menus and change the settings using the controller keypad DIGITAL CONTROL CODE DEFINITION Auxillary Fault ral Voltage Under Fi OFF RESET GM28707A C 1 LED display 2 Select button use for setup and adjustment only 3 Up
144. tor set by an automatic transfer switch remote start stop switch or engine start command from a remote computer 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 5 21 6 Remove the hose fitting from the natural gas outlet port in the fuel block See Figure 5 21 7 Remove the plug from the LP port in the fuel block See Figure 5 21 Clean the plug with a dry cloth or brush apply fresh pipe sealant and install the plug into the natural gas outlet port 8 Clean the hose fitting with a dry cloth or brush apply fresh pipe sealant to the threads and install the fitting into the LP port Note Do not adjust the fuel metering valves 56 Section 5 Component Testing and Adjustment 9 Slide the hose onto the hose fitting and secure it with the clamp 10 For the 12RES only Connect the digital spark advance module DSAM leads together for natural gas Disconnect the leads for LP See Figure 5 23 11 Connect and turn on the new fuel supply 12 Checkthat the generator set master switch is in the OFF position 13 Reconnect the generator set engine starting battery leads negative lead last 14 Reconnect power to the battery charger 15 Startthe
145. touch hot engine parts The engine and exhaust system components become extremely hot during operation Fuel Mixture Check Fuel Metering Valve Adjustment Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Remove the oxygen sensor plug from the exhaust manifold See Figure 5 25 for location 4 Install the oxygen sensor in the exhaust manifold where the plug was removed Connect the snesor to the engine starting battery control module and voltmeter as shown in Figure 5 24 5 Reconnect power to the battery charger 6 Place the controller master switch in the RUN position to start the generator set 7 Allow the generator set to run until the engine reaches normal operating temperature 8 With the generator set at normal operating temperature apply rated load 9 Connect one of the DVM leads to the oxygen sensor lead Connect the other DVM lead to ground and measure the output voltage of the oxygen sensor potential to ground Section 5 Component Testing and Adjustment 57 1 p 0 DDAA DOLO PODE 4 Battery power supply connection 2 Digital voltmeter DVM connection 3 Air fuel control module connection 4 Oxygen sensor connection Figure 5 24 UEGO Sensor I
146. trolled Rectifier SCR Module 35 4 10 Controller Replacement 36 Section 5 Component Testing and Adjustment 39 5 1 Theory of Operation 1 Phase Generator Sets 39 5 2 Separate 39 5 3 StdlOl coe Dee UE etaed eod eid re 41 54 Main Field Rotor 42 5 4 1 Rotor Continuity and Resistance Tests 42 5 5 es oo pes Sade eel salle ues mtus 44 5 6 865 2 064 aed 44 bu eR tA 45 5 7 1 Voltage Regulation 45 5 7 2 X Voltage 45 5 7 3 Voltage Connections 46 5 8 Governor System isse sues ded sew v x er eT Y a em 47 5 8 1 Operation 2 Wea eed ie IS 47 5 8 2 Initial Checks and Operation 47 583 Hunting Surging 47 5 8 4 Governor System Magnetic Pickup Operation Test 48 5 8 5 Frequency Adjustment
147. troller Controller Top View GM29253A F 1 Controller box location 2 Line circuit breaker 3 SCR module 4 Load connection terminal LO Figure 6 4 Alternator Connections inside Controller Box TP 6196 5 04 3 Remove the engine exhaust muffler and alternator heat shield See Figure 6 5 a Disconnectthe muffler from the engine exhaust pipe at the two flange connections b Remove the bolts holding the muffler to the alternator heat shield and remove the muffler c Remove the bolts securing the heat shield to the alternator and remove the heat shield 4 Remove the exhaust shield and alternator air inlet Top View duct See Figure 6 6 GM29253 1 Exhaust shield screws 2 Alternator air inlet duct screws a Remove two bolts securing the exhaust shield at the exhaust end and remove the shield Figure 6 6 Shield and Alternator Air Inlet Duct Top Vi b Remove three bolts securing the alternator air eu inlet duct to the base and remove the duct 5 Remove the alternator end bracket a Remove the nuts securing the alternator end vibromount mounting plate to the skid See Figure 6 7 b Raise th
148. u vds LHVIWS dSS GION310S HALYVLS SS H31HVIS HS HOLOW H31HVIS WS H3ldlLO3H II3TIOHINOO NOOTIIS HOS 2 95908 1 AV T3H ds 1O3NNOO XOIN NOOD HOLO3NNOO 094 OLL3NOVIN dN HOLIMS 668 TIO 401 NEN 4115 O1XO8 H3TIOHLNOO O1 HO1O3NNOO 7051409 NOLLINOI NOI H3TIOHINOO GND SAWA 1909 Ad NOLLONn 9 20 409 9 bw vid 14 13838 340 9 L 6 14 GALVINSNINN 1 7 98 9 24 88 66 ved 6 GALVINSNINN 15 ved 16 moD 06 ved 06 lt Not 2 ON 68 ved 6 voz amp 1 Nid ze ON 3snd 09 MOD ie rid Nu node 90078 JNIENI Woes SNOILOSNNOO SNOILOSNNOO i E E 9 ON wu WNOLLdO vee OIN Ob 89 2 QN3931 c VEN z1nsN LHM 88 vtd n si Es e 3 vo 13 e 9d v CIT z NMOHS SGOW H3MOd 8
149. watt 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 Pipe 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 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 s
150. when the display says SAVE Press Uu to check or change settings before saving See To return to the first parameter system voltage frequency Figure 4 7 To save changes To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET X in the runtime hours display above denotes any number from O to 9 Figure 4 9 Save Mode after configuring generator set parameters TP 6196 5 04 Section 4 Controller 29 Output Voltage and Frequency Adjustment Mode Display Move the generator set master switch to the RUN position The generator set engine starts and the controller display shows the engine runtime hours Hold Wait about 5 seconds until the display changes from runtime hours Or to the program version number x Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password The controller is now in the voltage coarse adjustment mode Press K N To raise or lower the voltage in large increments approximately 5 7 volts per step To enter fine voltage adjustment mode
151. witch is in d Connect the 3 pin plug P15 to the mating the OFF position connector on the ADC controller b Reconnect the generator set engine starting battery negative lead last c Reconnect power to the battery charger if equipped 13 Turn on the fuel supply Move the generator set master switch to the RUN position and check for leaks with the engine running 9 g Alternator SCR 14 Move the generator set master switch to the Connections OFF RESET position Move the switch to the Top View AUTO position if an automatic transfer switch or Controller Box remote start stop switch is used 15 Reinstall the generator set housing service side door KOHLER POWER SYSTEMS GM29253A F 1 SCR module 2 Neutral terminal LO 3 Line circuit breaker 1 Roof 2 Service side door Figure 6 20 ControllerTop View Typical 3 Front panel air intake end 4 Mounting pad 5 Rear panel alternator end Figure 6 21 Generator Set Enclosure TP 6196 5 04 Section 6 Disassembly Reassembly 69 5 70 Section 6 Disassembly Reassembly TP 6196 5 04 Section 7 Wiring Diagrams 7 1 Specification Numbers At the time of print this manual applied to the model numbers specification spec numbers Figure 7 1 On occas
152. y or death Do not smoke or permit flames or sparks near fuels or the fuel system 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 Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed l Safety Precautions and Instructions Exhaust System 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 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 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 presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to th

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