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Models 10, 15, 20REOD REOZD Operation Manual

Contents

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2. opt OS OSHA OV OZ pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PTC PTO at aty R rad RAM RDO ref rem Res Coml RFI RH RHM mean time between overhauls mounting megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National 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
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4. Jumper lead Figure 5 1 100 120 Volt 3 Wire Configuration TP 6392 8 05 5 1 2 100 120 200 240 Volt Configurations The 100 120 200 240 volt configuration does not use a jumper lead If the unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 5 1 for location Select a two pole circuit breaker Application of two single pole circuit breakers does not conform to NEC requirements for supplying a 200 240 volt load even if the breakers are mechanically attached together Leads L1 and L2 are for different phases never connect them together LO Neutral LO ao GRD Ground 2 gt 11 Load Side O Single Pole Circuit Breaker 4 3 2 1 Stator Leads 60 Hz 50 Hz LO L1 100 120 Volt 100 120 Volt Figure 5 2 100 120 Volt 2 Wire Configuration Section 5 Reconnection Adjustments 39 5 1 3 200 240 Volt Configurations The 200 240 volt configuration does not use a jumper lead If the unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 5 1 for location See Figure 5 4 Factory Two Pole 5 LO Neutral z Circuit Eins Breaker O Ground GRD Side L1 Load Side 100 120 200 240 Volt Line Single Pole 4 3 2 1 3 Wire Side Circuit Stator Leads Breaker 60 Hz 50 Hz Tape to insulate LO L1 100 120 Volt 100 120 Volt fro
5. KOHLER ADVANCED DIGITAL CONTROL CODE DEFINITION AF Auxillary Fault CC Crank Cycle HB High Battery Voltage IE High Engine Temp B Low Battery Voltage LCL Low Coolant Level LOC Loss of Coolant Low Pressure Over Crank OF Over Frequency OS Over Speed OU Over Voltage UF Under Frequency UU Under Voltage OFF RESET GM28707A C 1 LED display 2 Select button 3 Upand down arrow buttons usefor setup and adjustment only 4 Generator set master switch Figure 2 1 ADC 2100 User Interface 2 3 1 ADC 2100 Controls and Indicators Figure 2 2 describes the controls and indicators located on the ADC 2100 The LED display indicates generator set status The LED display is activated when the generator set master Control or Indicator LED display Description Runtime hours Switch is moved to the RUN or AUTO position and remains active until the master switch is moved to the OFF RESET position or power to the controller is removed The LED display turns off 48 hours after generator set shutdown See Section 2 3 6 The buttons on the controller keypad are used only for system configuration and adjustment The system configuration is factory set and should not require changes under normal operating conditions Contact an authorized distributor dealer or service technician if adjustments are required 2 3 2 Local Operation Local Starting Move the generator set master switch to the RUN pos
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8. Charge or replace the battery TP 6392 8 05 2 3 6 Power Down The controller is powered by the generator set engine starting battery If the ADC 2100 is not configured for the optional Remote Digital Gauge communication setting the controller powers down after 48 hours of no activity when the master switch is in the AUTO position See the Installation Manual for more information about ADC 2100 controller settings A start signal from a remote start stop switch or a transfer switch connected to engine start leads 3 and 4 energizes the controller and initiates the crank cycle Moving the generator set master switch to the RUN position also turns the controller back on If the ADC 2100 is configured for the optional Remote Digital Gauge communications setting the controller remains active at all times when the generator set master switch is in the AUTO position Note The ADC 2100 consumes 250 mA when the master switch is in the AUTO position with the Remote Digital Gauge connected Exercise the generator set weekly and consider using a battery charger to maintain the battery 2 3 7 Controller Software Version Number The application software for controller operation 15 factory loaded onto the Advanced Digital Control At times itmay be necessary to check the software version number for troubleshooting purposes Use the following procedure Displaying the Software Version Number 1 Press and hold
9. Continue to hold the Select button for as long as you want the fuel priming pump to function typically 10 seconds Release the Select button and move the Master switch to the OFF RESET position Place the Master switch to the RUN position to start the unit TP 6392 8 05 ADV7031 A 1 ADC 2100 control 2 Select button 3 Generator set master switch Figure 3 6 ADC 2100 Control Section 3 Scheduled Maintenance 29 3 6 Air Cleaner At the interval specified in the service schedule inspect clean or replace the air cleaner element Clean the element more frequently if the generator operates in dirty dusty conditions Check the element for accumulated oil or dirt that could cause poor performance Replace a damaged air cleaner element Follow the procedure described below At the time of service clean the air cleaner breather pipe and remove all dust and foreign matter from the air cleaner housing Air Cleaner Element Cleaning or Replacement Procedure 1 Liftthe locking lever and rotate the air cleaner cover counterclockwise to remove it See Figure 3 7 2 Slide the air cleaner element from the tube 3 Tap the element lightly against a flat surface to dislodge loose surface dirt Do n
10. code race eb Dub E t Mee ebd 22 3 9 Service VIEWS cuui eed Wag eden ede pd ge b cet E 24 3 4 Lubrication System 25 3 4 1 Oil Specifications 25 3 42 OIlGheck ea ale Den 25 343 Oil Change 26 uE el System csse ne REDEEM Say Av fiet E 27 3 5 1 Fuel Specifications 27 3 5 2 Fuel Fiter er Pe ERE LB 27 3 5 3 Fuel Water Separator 28 3 5 4 Priming the Fuel System 29 3 6 ka ote ev ee cx aci aden cs 30 3 7 Exhaust System ihn oda ede 30 3 8 Cooling System el obe Be ita 31 3 8 1 Checking the Cooling System 31 3 8 2 Draining the Cooling System 31 3 83 Filling the Cooling System 31 3 8 Flushing and Cleaning 32 3 8 5 Pressure iia heed 32 3 9 Belt Gheck ui Ap be Saw a An E ewe ee ee vii 32 3 10 Battery iste Se lente Hk e MUR eat 33 TP 6392 8 05 Table of Contents 3 Table of Contents continued 3 11 Storage Procedure oi d tere 34 3 11 1 Lubr
11. A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply A 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 el
12. Ec SNA To set the engine type if necessary To step to the next parameter advanced configuration mode or save mode selection Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communications Press To enter advanced configuration mode Go to Figure 5 11 OR or VA To proceed to the save mode without entering the advanced configuration mode Go to Figure 5 12 Note Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed x denotes any number from 0 to 9 Figure 5 10 Configuration Mode system voltage frequency unit configuration and engine type parameters 44 Section 5 Reconnection Adjustments TP 6392 8 05 Pressing the up arrow key at the Adnc display See Figure 5 10 puts you into the Advanced Configuration Mode Press S set the engine data input type To enter battery voltage selection mode Nu or w toggle between 12 and 24 VDC 12 volt models To enter communications selection mode To set the communications parameter or N To enter SAVE mode Go to Figure 5 12 SIAIV E Note Shaded boxes show which nu
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14. automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure over again from the beginning ifthe controller exits the configuration mode before the settings have been saved 5 3 2 Configuration Mode Follow the instructions in Figure 5 10 to enter the configuration mode The settings are shown in Figure 5 7 An X in the Display column in Figure 5 10 indicates a number from 0 to 9 Press the Select button to step through to the Save mode as shown in Figure 5 12 When is displayed press the up arrow to save the new settings or the down arrow to discard the changes and exit the configuration mode without saving Pressing the Select button when SAVE is displayed returns to the first parameter system voltage frequency Uu Unit s system voltage Uu01 Single phase 60 Hz 120 240 VAC and frequency Also see Figure 5 8 0008 Three phase 50 Hz 115 230 200 400 Uu04 Three phase 60 Hz 138 277 or 240 480 VAC Uu06 Single phase 50 Hz 115 230 VAC Unit configuration UcO1 Standby generator set Engine type Eco2 10 15 20REOD RECZD Engine data input types Ed01 Units with standard oil pressure switch Ed02 Units with optional oil pressure sender installed i e for Remote Digital Gauge Btl2 Battery Voltage Battery voltage 12 VDC Communications No CAN
15. fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight 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 Ib Inc ind int int ext 1 0 IP ISO J JIS k K 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 kilo 1000 kelvin Appendix 53 kiloampere KB kilobyte 219 bytes kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kH
16. 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 TP 6392 8 05 Heavy Equipment Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools A WARNING Hot engine oil Can cause severe injury or death Avoid skin contact with hot oil Do not start or operate the generator set with the engine oil filler cap removed as hot oil can spray out Ensure that the lubrication system is not under pressure when servicing Do not work on the generator set until it cools Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove
17. memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw rly rms rnd ROM rot rpm RS RTV SAE scfm SCR 5 Sec Sl SI EO sil SN SPDT SPST spec specs sq sq cm sq in 55 std stl tach TD TDC TDEC TDEN TDES TDNE TDOE TDON temp term TIF TIR tol turbo typ UF UHF UL UNC UNF univ US UV VAC VAR VDC VFD VGA VHF WCR w w o xfmr relay root mean square round read only memory rotate rotating revolutions per minute right side room temperature vulcanization Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number single pole double throw single pole single throw specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unif
18. the Select button on the ADC 2100 2 Move the generator set master switch to the Run postion The generator set will not start 3 After approximately five seconds the software version number is shown on the ADC 2100 display TP 6392 8 05 For example 01 18 will be displayed for software version 1 18 4 Move the generator set master switch to the OFF RESET position and release the Select button 2 4 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly see Section 4 Troubleshooting for possible causes 2 4 1 Line Circuit Breaker A circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown in Figure 3 1 If the circuit breaker trips reduce the load and switch the breaker back to the ON position 2 4 2 Fuses The junction box contains three inline fuses Always identify and correct the cause of a blown fuse before restarting the generator set Refer to section 4 Troubleshooting for conditions that may indicate a blown fuse Obtain service from an authorized distributor dealer Controller Fuse A replaceable 10 amp fuse protects the controller circuitry If the controller display is dark check the battery and battery connections and then check the controller fuse Replace the fuse if it is blown Relay Fuse A replaceable 10 amp fuse protects the engine relays Ifthe gen
19. the cap after pressure has been completely released and the engine has cooled Checkthe coolant level atthe tank ifthe generator set has a coolant recovery tank 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 Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers in place A WARNING Airborne particles Can cause severe injury 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 rotor thrubolt counterclockwise can loosen the hardware Servicing the generator set when it is operating Exposed mov
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21. 1 Service Assistance a a ete as 12 SECTION t Features ii li ia 13 1 1 Specifications ss sis ede nina he ed 13 1 2 Alternator Features 13 1 3 Advanced Digital Control 13 Section 2 Operation os wu wu am ln eee a eee eee a 15 21 Prestart Checklist 15 2 2 Exercising the Generator Set 15 2 3 Generator Set Operation 16 2 3 1 ADC 2100 Controls and Indicators 16 23 2 nennen he es 16 2 8 8 Remote Automatic Operation 17 2 3 4 Faults eae ea 17 2 3 5 Resetting the Controller after Fault Shutdown 17 2 3 6 Power DOWN ha sms ca eae eee 19 2 3 7 Controller Software Version Number 19 2 4 Circuit Protection deena de a e cedure do 19 2 4 1 Line Circuit Breaker 19 2 4 2 ude LAETI DIU DR Rea 19 Section Scheduled Maintenance 21 3 1 General Maintenance 21 3 2 Service Schedule
22. 1 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 and internal engine component storage x sm 002 001 3 11 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 15 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 x sm 002 002 3 11 2 Cooling System Prepare the cooling system for storage as follows 1 Check the coolant freeze protection using a coolant tester 2 Add or replace coolant as necessary to ensure adequate freezing protection Use the guidelines included in the engine operation manual 3 Run the generator set for 10 15 minutes to redistribute added coolant x sm 002 003 34 Section 3 Scheduled Maintenance 3 11 3 Fuel System Prepare the fuel system for storage as follows Diesel Fueled Engines 1 Fill the fuel tank with 2 diesel fuel 2 Condition the fuel system with compatible additives to control microbial growth 3 Change th
23. 1V3H HIV 2 14 Tan WNOLLdO aN3931 MU rm LIOA 24 49 Section 6 Wiring Diagrams Figure 6 2 Schematic ADV 7030 Sheet 1 TP 6392 8 05 1V8A 0AfN 1 oinvO 13834 440 001 vi UALEVIS 6 vld QNnOHO 8 vid v02 13N3 27714 lV8A 9 tid TOHLNOO AV 13H HSV1d 5 4 3ALLVO3N NOILINDI b bLd H31HVIS vid AV 13H LINVS NOWAOO Z bLd Av 13H L vld SNOLLO3NNOO td ON LINVS NONWOO 9 Eld ONAVI3HNfH S ld ONAVI3HN H p Eld ON LINVS NONNOD ld NOMWINOO L10 V4 NONWOO Z3 Eld NOWWOO 1 619 SNOILOANNOO Eid 3OVJU3INI AV 13H LNANI DW sir 6A 1ndNI DW 11 20 INANI 1 817 SNOLLO3NNOO SIF 99 DNIGNIM XNV 9 9Ld 5 94 3 SNNIN 971314 91 Ss DNIONIM XNV 9Ld 1nO AVI38 HSYI4 2 91 6 4 1 914 SNOLLO3NNOO 9LF Zd 193138 AGOW H3MOd SNONNILNOD Z d SNOLLO3NNOO 24 6 Sd 8 Sd Z Sd 9 Sd S Sd 8 22254 Sd 5 c Sd 1 64 SNOIL
24. Figure 2 2 ADC 2100 Controls and Indicators 16 Section 2 Operation TP 6392 8 05 2 3 3 Remote Automatic Operation A remote switch or an automatic transfer switch ATS can be used to start and stop the generator set Connect the remote start stop switch or the ATS engine start contacts to ADC 2100 engine start leads 3 and 4 Move the generator set master switch to the AUTO position Automatic Starting With the generator set master switch in the AUTO position close the remote start contact connected to engine start leads 3 and 4 to signal the generator set to start 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 Automatic Stopping With the generator set master switch in the AUTO position open the remote switch or contact to stop the generator set If the generator set was started by a start signal from a remote start stop switch or ATS moving the generator set master switch on the ADC 2100 to the OFF RESET position also stops the generator set Note There is no engine cooldown time delay on the ADC 2100 controller 2 3 4 Faults Figure 2 3 lists fault codes displayed by the ADC 2100 If the generator set shuts down on a fault condition it cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 3 5 t
25. KA REMOTE DIGITAL GAUGE OPTION COC SINN EAN 6184 E DN gt N ME A FULL FEATURE CUSTOMER INTERFACE CONNECTION HARNESS PIGTAIL EXTENSION HARNESS EXTENSION HARNESS DOC IA El Eg E va MS ME 7 NU IT EL NI AX A 2 0000 e e NI RY ODO B EVO 2 g AG MS LE NA MANDAR o CUSTOMER INTERFACE CONNECTION CUSTOMER INTERFACE CONNECTION TO GENERATOR SEE GENERATOR WIRING DIAGRAM TO GENERATOR SEE GENERATOR WIRING DIAGRAM Figure 6 4 Accessory Connection GM33846 A TP 6392 8 05 Section 6 Wiring Diagrams 51 Notes 52 Section 6 Wiring Diagrams TP 6392 8 05 Appendix 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 Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min cal CARB CB cc CCA 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 Standar
26. Note original voltage and reconnect as needed Generator Connections Single Phase Some sets not rated for single phase see manuals CT3 Not 110 220 Volt 50 Hz 120 240 Volt 60 Hz Remove V9 from terminal strip and tape 3 Phase Delta 110 220 Volt 50 Hz 120 240 Volt 60 Hz 3 Phase WYE 190 208 Volt 50 Hz 208 240 Volt 60 Hz 3 Phase WYE 380 416 Volt 50 Hz 416 480 Volt 60 Hz Notes CTs not used on all generator sets Current transformers dot or HI toward generator Figure 5 5 12 Lead Generator Reconnection TP 6392 8 05 EM 250000 Section 5 Reconnection Adjustments 41 5 3 ADC 2100 Adjustment after Reconnection KOHLER ADVANCED DIGITAL CONTROL CODE DEFINITION AF Auxillary Fault CC Crank Cycle HB High Battery Voltage Figure 5 6 Advanced Digital Control ADC 2100 The controller is factory set for the generator set voltage and frequency and normally does not require adjustment If adjustment is necessary follow the procedures in this section to set the system voltage and frequency parameter Uu and then adjust the output voltage Note The unit configuration UC engine type EC and engine data input type ED are factory set and should only be changed by an authorized Kohler dealer distributor Incorrect settings will make your unit non functional Parameter Setting Definition 5 3 1 Configuration Mode Time Out The controller will
27. OANNOO Sd 258 SE Ld 1 NO LVBN Id Z ld IWNSIS HOSN3S 38NSSIVA 18 14 30HNOS HOSN3S 3ENSS3HA 06 14 HOSN3S 62 1d 8807 13A37 1NV1009 82 1 GNNOWD 42 14 Z dOLS LEVIS 31OW3H 92 Ld 1 dOLS LEVIS 31OW3H S2 Ld vZ Ld 2 Id GNNOYD ZZz ld LZ Ld 02 Id HOSN3S 3ENSSIVA 61 14 GNNOUD 81 14 MO1HOSN3SHA 21 14 GNNOUD 91 14 HOLIMS JENSSIUA 10 91 19 LNOHOVL 91 19 AV138 1 NMOGLNHS 21 14 1NVO IVNH3IX3 1 H NYO IVNH3IX3 01 14 MO1HOSN3S ANAL INVIOOD 6 14 HOIH HOSN3S dWIL INVI009 8 1d 82 4 14 HONH3AOD 9 14 VLHONH3AOD 5 14 91 HONH3AOD b Ld INV NONWOO Ld 1109 Av3H H31V3H HIV OL IVNDIS 2 19 1 AVI38 H3lHVIS 1 14 SNOILOSNNOO Id H3TIOH INOO 0012 ADV7030B Figure 6 3 Schematic ADV 7030 Sheet 2 TP 6392 8 05 50 Section 6 Wiring Diagrams DIGITAL GAUGE P23 CONNECTIONS YEL EXTERNAL CAN GRN EXTERNAL CAN REMOTE START STOP 1 REMOTE START STOP 2 EXTERNAL CAN SHIELD 30 AUX SHUT DOWN 70A FUEL RELAY GROUND 120 OHM RESISTOR 2 5 _____ 927 BOAO SII SAB EY Ce OY NE x A vl DO YELLOW INSUL1 UNINSULATED INSUL3 YEL GRN GREEN INSUL2 J22 CONNECTIONS 56 D PIN
28. Operation Industrial Generator Sets Models 10 15 20REOD REOZD Controller ADC 2100 Advanced Digital Control NATIONALLY REGISTERED KOHLER POVER OVS B osa a California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description ADC 2100 Engine Identification Record the product identification information from the engine nameplate Manufacturer Yanmar Model Designation Serial Number TP 6392 8 05 Table of Contents Product Identification Information 2 Safety Precautions and Instructions 5 Introduction 2 5 2 0 2 RA RE I onda US Isi EUG m E RE cui ed 11 List of Related Literature 11 Maintenance and Service Parts 1
29. TEM Battery charger Recharge after engine start instructions Battery electrolyte level Battery manufacturer s Battery specific gravity charge state instructions Remove corrosion clean and dry battery and rack Clean and tighten battery terminals Tighten DC electrical connections Service more frequently if operated in dusty areas D Daily before operation Weekly Consult your local distributor dealer for service Y Yearly Monthly Do not break manufacturer s seals or internally inspect these 2Y Every 2 years or 2000 hours Quarterly devices R Replace as necessary Six months Number Hours of operation Battery charger operation charge rate 22 Section 3 Scheduled Maintenance TP 6392 8 05 System Component AC ELECTRICAL SYSTEM General Inspection Circuit breakers fuses Wire abrasions where subject to motion Tighten control and power wiring connections Wire cable insulation breakdown ENGINE AND MOUNTING General inspection check for leaks M 3Y or 500 Ww Air cleaner service S S Valve clearance 3 Y or 500 Bolt torque REMOTE CONTROL SYSTEM ETC Compartment condition 3 Y or 500 Remote control GENERATOR General inspection Rotor and stator Bearing condition Exciter Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier disconnected Blow
30. WARNING KS 5 X Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe 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 TP 6392 8 05 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 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 N
31. aks in the lubrication system Check the oil level and add oil if the level is low Overcrank shutdown Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest The generator set also shuts down if no engine rotation is sensed during cranking Shuts down 1 second after the fault is detected Check the fuel supply spark plug and battery Check for loose connections Contact an authorized distributor dealer for service if problem continues Overfrequency shutdown Shutdown occurs when the governed frequency exceeds 110 of the system s frequency setpoint for more than 5 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service if problem continues Overspeed shutdown Shutdown occurs if the engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer service if problem continues Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service if problem continues Underfrequency shutdown Shutdown occurs when the governed frequency falls blow 90 of the nominal system frequency for more than 5 seconds This protective becomes active 10 se
32. ance information 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 operation Inspect the parts often and perform required service atthe prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition List of Related Literature Figure 1 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Part Number TP 6393 TP 6392 TP 6412 TP 6395 Service Manual Generator TBD TP 6293 Literature Type Installation Manual Operation Manual Generator Operation Manual Engine Parts Catalog Service Manual Engine One manual combines Generator and Engine information Figure 1 Generator Set Literature x in 001 005 TP 6392 8 05 Introduction Maintenance and Service Parts Figur
33. circuit breaker or ATS 7 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Note The controller s LED display remains off until an engine start command is received Opening and closing a remote start stop contact also resets the controller Section 2 Operation 17 Auxiliary fault input shutdown Description Input from a customer supplied contact that closes on a fault condition The generator set shuts down 2 seconds after the fault is detected and will not start when the fault is active input is grounded Check the condition and operation of customer supplied equipment connected to the auxiliary fault input P21 6 on the customer interface connector High engine temperature shutdown 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 Low coolant level Not used Loss of coolant Not used Low oil pressure shutdown 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 le
34. cluding sections of this manual the generator set service manual S M the generator set installation manual and the engine service manual Engine S M to correct the indicated problem Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment x gt 001 002a Possible Cause Controller LED display No power to the controller is off Problem connected Controller fuse F3 is blown Low or no battery voltage The controller automatically powers down if the generator set has not run for 48 hours or longer if start command is received or the generator set master the optional Remote Digital Display is not 4 1 Fault Codes The Advanced Digital Control displays fault codes to aid in troubleshooting Fault codes descriptions and recommended actions are listed in Figure 2 3 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 3 5 4 2 Controller Troubleshooting Figure 4 1 contains troubleshooting diagnostic a
35. communications Cn01 J1939 use for Remote Digital Gauge Factory settings Figure 5 7 Controller Parameters 42 Section 5 Reconnection Adjustments TP 6392 8 05 Voltage Part 333702 333700 333701 333703 333704 333705 333708 333803 333800 333802 333805 333806 333807 Voltage Connection VAC 60 Hz Single phase 60 Hz Three phase 120 240 120 208 127 220 120 240 139 240 220 380 277 480 110 220 110 190 110 220 220 380 230 400 240 416 50 Hz Single phase 50 Hz Three phase Figure 5 8 Uu Parameter Settings for Available Voltage Connections 5 3 3 Voltage Adjustment After setting the system voltage parameter Uu check the output voltage and adjust if necessary using the following procedures Follow the instructions in Figure 5 13 to adjust the voltage gain and volts Hz while the engine is running An X in the Display column in Figure 5 13 indicates a number from O to 9 Use the up arrow to increase a setting or the down arrow to decrease the setting Pressing the Select button when SAVE is displayed returns to the first parameter voltage adjust 1P Note A digital multimeter that measures voltage and frequency is required for these adjustments 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 c
36. conds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Undervoltage shutdown Shutdown occurs if the voltage falls below 80 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Check the battery rating and condition Check the battery charger operation Low battery voltage warning 18 Section 2 Operation Fault code is displayed if the engine starting battery voltage falls below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 10 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Figure 2 3 ADC 2100 Fault Codes Check the battery rating and condition Check the battery charger operation
37. ds Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring 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 6392 8 05 cfm CG CID CL cm CMOS cogen com coml Coml Rec cont 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 exh cubic
38. dust out of generator GENERAL CONDITION OF EQUIPMENT Any condition of vibration leakage unusual noise temperature or deterioration Y X Y 2 Y or 300 2 Y or 300 Ww Run generator set exercise Ensure that system is set for automatic operation Interior of equipment room or outdoor weather housing Service more frequently if operated in dusty areas Consult your local distributor dealer for service Do not break manufacturer s seals internally inspect these devices Daily before operation Weekly Yearly Monthly Quarterly Six months Every 2 years or 2000 hours Replace as necessary Number Hours of operation TP 6392 8 05 Section 3 Scheduled Maintenance 23 3 3 Service Views Service Side View 10 11 n _ 650 N N N Fuses F1 F2 and F3 Advanced Digital Control ADC 2100 Alternator cooling air inlet Run Off Reset Auto switch Runtime hour display Air intake silencer cleaner Fuel inlet connection Fuel water separator Lifting eye Fuel return connection Fuel filter Oil fill engine top Mechanical governor Coolant overflow tube Pres
39. e inspect the exhaust system Inspection Points Check for exhaust leaks and blockages Check the muffler and piping condition and check for tight exhaust system connections Inspect the exhaust system components for cracks and corrosion exhaust manifold exhaust line exhaust clamps and muffler e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Check the exhaust gas color If the exhaust is blue or black contact your local distributor dealer e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed 6392 8 05 3 8 Cooling System A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure fromthe cooling system before removing the pressure cap To release pressure coverthe pressure cap with athick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has co
40. e 2 identifies maintenance and service parts for your generator set Obtain a complete list of maintenance and service parts from your authorized generator distributor dealer Part Description Part Number Air Cleaner Element for 10REOD REOZD 15REOD REOZD Air Cleaner Element for 20REOD REOZD Belt GM42428 GM32359 225259 GM42265 GM42266 Fuel Filter Element Fuel Water Separator Element Fuse Auxiliary Winding F1 GM39266 223316 223316 223316 252834 221292 20 amp for 12 lead generator sets 10 amp for 4 lead generator sets Fuse Relay Interface Board F2 10 amp Fuse Controller F3 10 amp Oil Filter Spray Paint Black Figure 2 Maintenance and Service Parts x in 001 004 Introduction 11 Service Assistance For professional advice generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Look labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 21 122 12 rue des Hauts Flouviers 94517 Th
41. e fuel filter separator and prime the fuel system x sm 002 004 3 11 4 Exterior Prepare the exterior for storage as follows 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To 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 x sm 002 006a 3 11 5 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to the battery manufacturer 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 TP 6392 8 05 Section 4 Troubleshooting This section contains generator set troubleshooting diagnostic and repair information Use the following charts as a quick troubleshooting reference The table groups generator set faults and suggests likely causes and remedies The table also refers you to more detailed information in
42. e1souuJ8U L 8 2 uonoes le e Bunelado jeuuou juejooo ay eJo1seH Jue 009 Ge pue g g suonoes ay 19591 pue jane Bunejedo peuou 1uejooo ay aJo sey UMOPINUS 1uejooo W o pue se uonoesg Uleis s Buiooo eui ueu umop ooo eui umopmys yBiH sBuiuedo sBuiuedo uoiws e10UJ8J ay Y98049 SLY JO Y9 IMS e 91 dojs 1545 11009 ay une YOUMS 19159 Je o uoo eui dois ueis Jo 1910 09 uonoes eui 19594 G M Z uonoes BU SMO q esnj ay asny ay 14 asn G M uonoes BU SMO q BSN BU y asn esejajul eui 24 aveau ejey G M Z uonoes BY 1 0 ureBe
43. ected carcinogen Avoid contact with skin Thoroughly wash your hands and nails with soap and water shortly after handling used engine oil Wash or dispose of clothing or rags containing used engine oil Dispose of used engine oil ina responsible manner Contact your local recycling center for disposal information and locations 3 4 1 Use oil that meets the American Petroleum Institute API classification of CD or CF Using an unsuitable oil or neglecting an oil change may result in damage anda shorter engine life Figure 3 2 shows the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges Oil Specifications Note Failure to observe the oil specifications may cause inadequate lubrication oil pressure and cold starting difficulties TP 6392 8 05 SAE Service Grade 0 20 40 60 Operating Temperature Figure 3 2 Engine Oil Selection 3 4 2 Oil Check Check the oil level in the crankcase daily or before each startup to ensure that the level is in the safe range To check the oil level remove the dipstick and wipe the end clean reinsert as far as possible and remove Maintain the oil level between the Min and Max marks on the dipstick as shown in Figure 3 3 See Figure 3 1 for dipstick location Note Do not operate the set if the oil level is below the Min mark or above the Max mark OM ZN SA Al 1 Max level 2 Min level Figure 3 3 Oil Level Chec
44. ectrically 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 Welding on the generator set Can cause severe electrical equipment damage Before welding the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances TP 6392 8 05 Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect t
45. ed SNOLLOANNOO ttd e bld nooo 719 NOLLONNP So Jm Wo YSLVSH HIV EY 1993 N ss sz e 14 25 fon N 28 02 sz via ridyll 25 4 59 40 Lyu ae sa o oe ns Tm er 2 Y 556 dns CATA ss Lva vog dol es c3 d 08 02 8 029 52 2 1 04 04 voz cy 54 2083 IVNOLLAO Sao BN Fosa 1 18 IHM d 0 1 8 61 1 002 8 ua au ss d SNOILOANNOO Vil Nid 2083 NOL 1983 Oo SNOLLO3NNOO Vdd 6 10 8 19 LHM Vi SNOLLO3NNOO 4 SNOLLOANNOO 22d 5 vog NOL 7 AIN va nor 6 12 N N s8 02y N GM39874 A GM39874 A iagram D iring Figure 6 1 TP 6392 8 05 48 Section 6 Wiring Diagrams 5 85 1335 SNOLLOSNNOO i s HOLVH3N39 HOW ILON ADV7030A Lu
46. engine block s coolant drain valve s and tighten the hose clamps Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until engine has cooled 3 Fill the radiator with the recommended coolant mixture of 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing See Figure 3 9 for coolant capacities Note A coolant solution of 50 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F A coolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications 4 Replace the radiator s pressure cap 5 Operate the engine until the thermostat opens and the radiator upper hose becomes warm Engine amp Unit Mounted Radiator L Qts 4 1 4 3 9 1 9 6 9 3 9 8 Engine L Qts 1 8 1 9 2 0 2 1 2 7 2 8 Model 10REOD REOZD 15REOD REOZD 20REOD REOZD Figure 3 9 Coolant Capacities Section 3 Scheduled Maintenance 31 6 Stop the engine and allow it to cool 7 Remove the radiator s pressure cap 8 Add coolant to
47. erator set does not crank check the battery and battery connections and then check the relay fuse Replace the fuse if it is blown Auxiliary Winding Fuse A replaceable 10 amp fuse for 4 lead generator sets 20 amp fuse for 12 lead generator sets protects the alternator Section 2 Operation 19 Notes 20 Section 2 Operation TP 6392 8 05 31 General Maintenance A WARNING Qe aS x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe 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 A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place Servicing the generator set when it is operating Exposed mov
48. et models include a fuel water separator The fuel water separator helps to remove water and sediment from the fuel system Fuel Water Separator Draining Procedure At the interval specified in the service schedule drain the water from the fuel water separator Hold a suitable container beneath the fuel water separator and push up on the drain valve See Figure 3 5 Release the valve when fuel free of water flows from the fuel water separator Fuel Water Separator s Element Replacement Procedure At the interval specified in the service schedule replace the fuel water separator element 1 Close the fuel valve at the nearest point to the water filter inlet or at the fuel tank 2 Remove the water drain plug or push up the drain valve and allow water and fuel to flow into a suitable container Note Depending upon the location of the fuel valve a considerable amount of fuel may drain out 3 Remove the separator s element from the mounting head by twisting in a counterclockwise direction 4 Remove the bowl from the fuel water separator element Wipe the excess fuel from the bowl and the O ring Do not discard the bowl or O ring 5 Inspect the components for wear or damage Replace parts as necessary 6 Lubricate the O ring with clean diesel fuel and replace it in the bowl 28 Section 3 Scheduled Maintenance 7 Install the bowl onto a new fuel water separator filter element 8 Lubricate the bowl elemen
49. ever contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Section 6 Wiring Diagrams 47 0 02 Adv 338 OLLVWAHOS 404 HOLVLS LVLS GION310S HALEVLS SS HOLON H31HVLS WS 431411934 Q3T10H1NOO NOONIS HOS AV 13H Id 193NNOO NODO HOLO3NNOO 3UNSSIUA 10 SdO HOLIMS 3Hn SS3Hd 110 MOT GNLS 01 ANC I3H MNVHO 027 OVP HOLO3NNOO Mr ANFINSNI INSNI XO H3TIOHLNOO 105 190 54 TAN 38N3 4 3NION3 983 30010 LNVIOOO SLO 92 ONIOHVHO AH3LLV8 VO 831V3H HIV HHY U31V3H Hlv Hv GN3931 zov Hos 19 99 0 10 ss 14 Ong 9 SNOILO3NNOO 91 4 HOLVLS GVAT ZL SSVHd SL8S AQV 335 SNOLLOSNNOO HOIVHSN39 BLON G s 1 15 iva Sid 8A 1 61 2 anaon zov uos 99 SS HOLVLS QV3l STONIS 89 1335 ALON 777 INCON IVA 4
50. feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current 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 exhaust ext F fglass FHM fl oz flex freq FS ft ft Ib ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt external Fahrenheit female
51. he 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 Servicing the day tank Hazardous voltage can cause severe injury or death Service the day tank electrical control module ECM as prescribed in the equipment manual Disconnectthe power to the day tank before servicing Press the day tank ECM OFF pushbutton to disconnect the power Notice that line voltage is still present within the ECM when the POWER ON lightis lit Ensure thatthe generator set and day tank are electrically grounded Do not operate the day tank when standing in water or on wet ground 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 contact electrical connections with tools or jewelry while making adjustments repairs Remove all jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power
52. iais Cedex France Phone 33 1 41 735500 Fax 33 1 41 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 12 Introduction China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 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 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Fax TP 6392 8 05 1 1 Specifications The spec sheets for each generator set provide specific alternator and engine information The controller spec sheet provides specifications particular to the controller Refer to the respective spec sheet for data not supplied in this manual Consult the generator set service manual generator set installation manual engine operation manual and engine service manual for additional specifications 1 2 Alternator Features The Model REOD alternator is equipped with Kohler s PowerBoost voltage regulation system which provides instant response to load changes PowerBoost is a unique system that ensures reliable
53. iations s hte pde u Da Ri Etats t ete 53 Appendix Operating Hour Service Log 55 4 Table of Contents TP 6392 8 05 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets 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 A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace mis
54. icating System 34 311 2 Cooling System v eb de ee te ek cA ttc eld 34 311 3 Fuel System Nass anta eu cete be BIS Ola ees 34 AMAS Exterior odorem Meh aed werd ble eae 34 371 5 Battery s cot ok ae dec chee aia idad 34 Section 4 Troubleshooting 35 44 Fault Codes cocina pos EXE ete RR d PRU 35 4 2 Controller Troubleshooting 35 Section 5 Reconnection Adjustments 39 5 1 Four Lead Reconnection 39 5 1 1 100 120 Volt Configurations 39 5 1 2 100 120 200 240 Volt 5 39 513 200 240 Volt Configurations 40 5 2 Twelve Lead Reconnection 41 5 3 ADC 2100 Adjustment after Reconnection 42 5 3 1 Configuration Mode Time Out 42 5 8 2 Configuration Mode 42 5 8 8 Voltage 43 Section 6 Wiring Diagrams 47 Appendix A Abbrev
55. ice schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Air Shrouding Check for securely installed and positioned air shrouding Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater Drive Belt s Check the belt condition and tension of the water pump and battery charging alternator belt s Exhaust System Check for exhaust leaks and blockages Check the muffler and piping condition and check for tight exhaust system connections Inspect the exhaust system components for cracks and corrosion exhaust manifold exhaust line exhaust clamps and muffler e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed e Check that the exhau
56. ied fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer 6392 8 05 Appendix Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed Enter hours to the operating hours on your generator set and the dates nearest quarter hour Operating Hours Service Record Date Total Service Run Hours Date TP 6392 8 05 Appendix 55 Notes 56 Appendix TP 6392 8 05 TP 6392 8 05 Notes 57 58 Notes TP 6392 8 05 6392 8 05 2005 by Kohler Co All rights reserved KOHLER POVVER SYSTEMS KOHLER 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 6264 6422 Fax 65 6264 6455
57. ing parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6392 8 05 This manual provides operation instructions for Model 10 15 20REOD REOZD generator sets Refer to the engine operation manual for generator set engine scheduled mainten
58. ing 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 TP 6392 8 05 Section 3 Scheduled Maintenance NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Usethe correct size tools to prevent rounding of the bolt heads and nuts 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 Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Exercise Operate the generator set without load once each week for 20 minutes If the transfer switch does not have an exercise option exercise the unit in the presence of an operator Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual If the generator set operates under dusty or dirty conditions use dry compressed air to blow dust out of the alternator With the generator set running direct the stream of air in through the cooling slots at the alternator end Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the run
59. ion Reconnect the generator set engine starting battery negative lead last Reconnect the power to the battery charger if equipped Start the generator set and check for leaks around the oil filter Stop the generator set and tighten the oil filter to stop any leaks x sm 001 003 TP 6392 8 05 3 5 Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Fuel tanks Explosive fuel vapors can cause severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system 3 5 1 Fuel Specifications Use a clean good quality diesel fuel oil with a cetane number of 45 or greater Clean fuel prevents the diesel fuel injectors and pumps from clogging Fuel Recommendations United States ISO 8217 DMA BS 2869 A1 or A2 United Kingdom BS 2869 1983 Part 2 Class A2 DIN 51 601 1978 Japan JIS No K2204 2 Germany Note Never store diesel fuel in galvanized containers diesel fuel and the galvanized coating react chemically to produce flaking that quickly clogs filters or causes fuel pump or injecto
60. ircuits 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 6392 8 05 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 With the generator set off connect a digital voltmeter to the output leads or an electrical outlet on the load side of the generator set Set the meter to measure voltage 2 Start the generator set by moving the generator set master switch to the RUN position 3 Use the ADC controller to adjust the voltage parameter 1P until the output voltage reaches the desired value See Figure 5 9 Measured Voltage VAC Approximate Voltage Change per Step VAC Fine Adjust Coarse Adjust Figure 5 9 Voltage Adjustment 4 Adjust the voltage stability gain para
61. ition to start the generator set The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault Local Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Note There is no engine cooldown time delay on the ADC 2100 controller Displays total generator set runtime hours while the generator set is running and when no other codes are displayed Crank indication Displays 1 CC 2 or CC to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 2 3 4 Fuel Displays FUEL during fuel pump priming procedure See Section 3 5 4 Software version See Section 2 3 7 number Keypad Select and arrow The keypad is used for controller setup and adjustment only Have setup and adjustments buttons performed only by an authorized distributor dealer The setup and adjustment functions are password protected Generator set master Three position switch switch Switch functions as the generator set operation and controller reset switch
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63. k Section 3 Scheduled Maintenance 25 3 4 3 Oil Change See the Service Schedule in Section 3 2 for oil change and oil filter replacement intervals Change the oil more frequently if the generator operates under dirty dusty conditions See Figure 3 4 for oil capacities Model 10REOD REOZD 15REOD REOZD 20REOD REOZD Figure 3 4 Oil Capacities Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position Disconnect the power to the battery charger if equipped Disconnect the generator set engine starting battery negative lead first Place an oil collection container below the oil drain and remove the oil drain plug Allow time for the engine oil to drain completely Replace the oil drain plug 26 Section 3 Scheduled Maintenance 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench 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 3 Fill with oil Add new oil of the weight grade and quantity specified in Section 3 4 4 Check for leaks a Check that the generator set master switch is in the OFF posit
64. k the belt tension at the intervals specified in the service schedule If the tension is not within specification adjust as necessary using the following procedure Note Also check the fan belt for cracks or tears and replace the belt if necessary Adjust the tension of the alternator fan belt so that the belt can be depressed about 12 7 mm 0 5 in when applying finger pressure Use the following procedure to adjust the belt 1 Battery charging alternator pulley 2 Adjusting screw 3 Check the alternator belt tension here 4 Alternator pivot screw Figure 3 11 Belt Tension Belt Tensioning Procedure 1 Disconnect the battery negative lead first 2 Loosen the pivot and adjusting screws 3 While prying the battery charging alternator outward tighten the adjusting screw 4 Tighten the pivot screw 5 Recheck and adjust as necessary 6 Reconnect the battery negative lead last 6392 8 05 3 10 Battery Consult the battery manufacturer s regarding battery care and maintenance instructions A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted 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 sea
65. led battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid TP 6392 8 05 A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Section 3 Scheduled Maintenance 33 3 1
66. m ground LO L2 100 120 Volt 100 120 Volt L1 L2 200 240 Volt 200 240 Volt 4 1 3 2 200 220 240 Volt Figure 5 3 100 120 200 240 Volt 3 Wire Stator Leads 2 Wire Configuration 60 Hz 50 Hz LO L1 200 240 Volt 200 220 240 Volt Figure 5 4 200 220 240 Volt 2 Wire Configuration 40 Section 5 Reconnection Adjustments TP 6392 8 05 5 2 Twelve Lead Reconnection The reconnection procedure that follows details voltage reconnections only If the generator set requires frequency changes adjust the governor and voltage regulator See the generator set service manual for information regarding frequency adjustment In all cases follow National Electrical Code NEC guidelines Reconnect the stator leads of the generator set to change output phase or voltage Refer to the following procedure and connection schematics Follow all safety precautions at the front of this manual and in the text during reconnection procedure 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 Twelve Lead Reconnection Procedure 1 Move generator set start stop switch to the STOP position 2 Disconnect engine starting battery negative lead first Disconnect power to battery charger if equipped 3 Use Figure 5 5 to determine generator set voltage configuration
67. m runtime hours X to the program version number 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 pe To raise or lower the voltage in large increments approximately 5 7 volts per step To enter fine voltage adjustment mode To raise or lower the voltage in smaller increments approximately 0 5 0 7 volts per step 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 xy p To raise or lower the volts Hz 00 low 09 high See Figure 5 12 to save a Shaded boxes show which character in the controller display changes for each adjustment x in the examples above denotes any number from O to 9 The actual values may vary from model to model Figure 5 13 Output Voltage Adjustments 46 Section 5 Reconnection Adjustments TP 6392 8 05 Section 6 Wiring Diagrams A
68. mber in the controller display changes when the up or down arrow key is pressed x denotes any number from 0 to 9 Figure 5 11 Advanced Configuration Mode engine data input types battery voltage and engine communications There are 3 options when the display says SAVE Press To return to the first parameter system voltage frequency Uu to check or change settings before saving See Figure 5 10 or To save changes or 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 x x x x 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 x in the runtime hours display above denotes any number from 0 to 9 Now move the master switch to OFF RESET Figure 5 12 Save Mode after configuring generator set parameters TP 6392 8 05 Section 5 Reconnection Adjustments 45 Output Voltage 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 fro
69. meter 2P to minimize light flicker 5 Readjust the voltage if necessary 6 Adjust the volts Hz parameter 3P until the voltage level measured by the voltmeter begins to drop When the volts Hz is set correctly the generator as load is applied attempts to maintain normal output until the engine speed drops below the cut in frequency 7 Readjust the voltage stability gain parameter 2P if necessary 8 Readjust the voltage parameter 1P if necessary 9 Stop the generator set Section 5 Reconnection Adjustments 43 Controller Configuration Mode Use with Figure 5 7 Controller Parameters Hold the Select button Display Move the generator set master switch to the RUN 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 Press To set the voltage frequency setting for 60 Hz or 50 Hz models or To step to the next parameter unit configuration Uc uod or To set the unit configuration setting if necessary To step to the next parameter engine type
70. motor starting and consistent voltage levels PowerBoost utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage 1 3 Advanced Digital Control The generator set is equipped with the Kohler Advanced Digital Control ADC 2100 Controller features include the following e Compact controller e Integrally mounted to the generator set e LED display e Runtime hours e Crank cycle status e Diagnostics TP 6392 8 05 Section 1 Features e LED display communicates faults e High battery voltage e High engine temperature e Low battery voltage e Low oil pressure e Overcrank safety e Overspeed e Overfrequency e Overvoltage e Underfrequency e Undervoltage e Membrane keypad for configuration and adjustment e Password protected user access to menus e System configuration e Voltage adjustment e Master control switch Run Off Reset Auto e Remote two wire start stop capability e Superior electronics protection from corrosion and vibration e Potted electronics e Sealed connections e Digital voltage regulation 1 5 RMS no load to full load e Automatic start for programmed cranking cycle Section 1 Features 13 Notes 14 Section 1 Features TP 6392 8 05 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the serv
71. n accident occurs seek medical attention immediately Any fluid injected in the skin tissues must be surgically removed within a few hours or gangrene may result 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 Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Fuel tanks Explosive fuel vapors can cause severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Hazardous Noise
72. nd repair information for the Advanced Digital Control Corrective Action Controller display will automatically activate when a remote switch is moved to the RUN position Replace the fuse If the fuse blows again contact the distributor dealer Check connections Check generator set battery position Generator set master switch is in the OFF RESET Move generator set master switch to the AUTO or RUN position reset Figure 4 1 Controller Troubleshooting Chart TP 6392 8 05 Generator set master switch in AUTO but no start command has been received since last controller No action required Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position Use the remote switch to start generator set and activate the controller display if desired Section 4 Troubleshooting 35 W S 10 W O Jayem eui eoejdai Jo ue1uBi Jayem SIU uuojied je eep 40inquisip sones Ue aney 38945 oeds s s enue 5 enuey enuen uone eisu qW 195 ues eutBu3 Bua yoyms 6 v jJenueuu sjy jo uonoes pejequinu uomnoeg 995 y w s Jeisouueu eui aoejdey e nejedoul 1
73. o reset the controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected The shutdown switches on the generator set automatically reset when the problem is corrected The TP 6392 8 05 high engine temperature switch automatically resets when the generator set cools However the fault does not clear until the controller is reset The controller displays a fault code but the generator set does not shut down under the high and low battery voltage warning conditions 2 3 5 Resetting the Controller after Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Move the generator set master switch to OFF RESET 2 Disconnect the generator set from the load using the line circuit breaker or ATS See the safety precautions at the beginning of this section before proceeding 3 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this section before proceeding Refer to Section 4 Troubleshooting 4 Start the generator set by moving the generator set master switch to RUN Test operate the generator set to verify that the cause of the shutdown has been corrected 5 Move the generator set master switch to OFF RESET 6 Reconnect the generator set to the load using the line
74. oled Check the coolant level at the tank if the generator set has a coolant recovery tank 3 8 1 Checking the Cooling System To prevent generator shutdown or damage because of overheating keep the cooling air inlets clean and unobstructed at all times Inspect the radiator s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins Check the hoses and connections for leaks and replace any cracked frayed or spongy hoses When checking the coolant level also check the rubber seal of the radiator s pressure cap Replace a cracked or deteriorated cap See Section 3 8 5 Remove dirt and other debris from the pressure cap and filler neck See Figure 3 8 for the thermostat rating Thermostat Rating 82 C 179 F All Models Figure 3 8 Thermostat Rating TP 6392 8 05 3 8 2 Draining the Cooling System The radiator contains a coolant drain valve to drain the cooling system When draining the coolant remove the radiator s pressure cap this will allow the entire system to drain and will prevent air pockets from forming and restricting coolant passage to the block Note Pay special attention to the coolant level After the coolant drains allow time for complete refill of the engine water jacket Check the coolant level as described earlier 3 8 3 Filling the Cooling System 1 Remove the radiator s pressure cap 2 Close the radiator s and or
75. or fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Servicing the air cleaner on a turbocharged engine A sudden engine backfire or turbocharger compressor failure can cause severe injury or death Do not operate the generator set with the air cleaner removed Burns from hot turbocharger components may occur Foreign objects sucked into the turbocharger can cause mechanical damage and the potential for high velocity projectiles Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Using engine starting fluid A sudden backfire can cause severe injury or death Do not use starting fluid or similar agents to start an engine equipped with air preheating glow plugs starter element The starter element may cause an explosion in the inlet manifold Engine Fluids and Chemical Products A WARNING Handling caustic engine fluids and chemical products Can cause severe chemical burn
76. ortly after handling used engine oil Wash or dispose of clothing or rags containing used engine oil Dispose of used engine oil in a responsible manner Contact your local recycling center for disposal information and locations Fire damaged or burned O rings may cause the formation of hydrofluoric acid Contact with hydrofluoric acid may cause severe skin irritation and chemical burns O rings and other fluoroelastomer seals exposed to fire or temperatures above 316 C 600 F i e during welding may decompose forming hydrofluoric acid Avoid inhalation or skin contact Do not incinerate O rings Dispose of O ring waste material in a responsible manner TP 6392 8 05 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon mono
77. ot clean the element in any liquid or use compressed air as these will damage the filter element 4 Wipe the cover and base with a clean rag to remove any dirt 5 Ensure tight clamps at the inlet outlet connections 6 Slide the air cleaner element into the tube 7 Position the cover with the dust ejector pointing down Rotate the cover clockwise until the locking lever snaps into place Locking lever Cover Dust ejector Element Figure 3 7 Air Cleaner Components 30 Section 3 Scheduled Maintenance 3 7 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even shorttime Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building At the interval specified in the service schedul
78. r failure Note Avoid storing fuel for more than one month Take special precautions to keep all dirt water and other contaminants out of fuel to prevent the growth of microbes Microbes form slime that clogs the fuel filter and lines Note Do not run the generator set out of fuel because the fuel lines will draw in air and necessitate priming the fuel system before restarting the unit TP 6392 8 05 3 5 2 Fuel Filter The quality and condition of the fuel largely determine the filter s useful life Replace the fuel filter element as listed in the service schedule Figure 3 1 shows the typical location of a fuel filter Use the applicable procedure below to replace the fuel filter Fuel Filter Cleaning Replacement Procedure 1 Close the fuel supply valve 2 Loosen the fuel filter by turning it counterclockwise Remove the fuel filter and use rags to clean up spilled fuel oil Dispose of the fuel filter in an approved manner 3 Clean the contact surface of the fuel oil filter adapter 4 Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil Thread the filter on the adapter until the gasket makes contact hand tighten the filter an additional one half turn Wash hands after any contact with fuel oil 5 Open the fuel supply valve 6 Prime the fuel system See Section 3 5 4 Priming the Fuel System Section 3 Scheduled Maintenance 27 3 5 3 Fuel Water Separator These generator s
79. s nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rustproofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user information found on the packaging Avoid inhalation and skin contact Use only in well ventilated areas and use a protective mask when spraying Store engine fluids and chemical products in a locked cabinet Contact your local recycling center for disposal information and locations TP 6392 8 05 A WARNING 7 d 4 Flammable engine solvents and cleaners Can cause severe injury or death Do not smoke or permit flames or sparks near flammable engine solvents and cleaners Read and follow the user information found on the packaging Use only in well ventilated areas Never use gasoline or low flash point solvents as cleaning agents Leaking or accumulated engine fluids A fire can cause severe injury or death Clean up engine fluids including fuel oil grease and coolant Determine the source of engine leaks and correct before starting the generator set Keep the generator set area clean and remove combustible materials Used engine oil Contact with used engine oil may cause severe skin irritation Repeated and prolonged skin exposure may have other health risks Used engine oil is a suspected carcinogen Avoid contact with skin Thoroughly wash your hands and nails with soap and water sh
80. sing or damaged decals TP 6392 8 05 Accidental Starting A WARNING FS 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 froma remote computer Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and b
81. st outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed TP 6392 8 05 Section 2 Operation Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 2 Exercising the Generator Set Operate the generator set without load once each week for 20 minutes If the generator set does not have a programmed exercise mode or an automatic transfer switch ATS with an exercise option exercise the unit in the presence of an operator The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in Section 2 3 2 of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks Check the air inlets and outlets and remove any items restricting the air flow Section 2 Operation 15 2 3 Generator Set Operation Figure 2 1 illustrates the user interface on the Advanced Digital Control ADC 2100 generator set controller
82. sure cap at radiator Figure 3 1 Service Views 24 Section Scheduled Maintenance Engine End View With Radiator Removed 59 ADV7031 A Oil fill front gear cover Radiator V belt Oil check dipstick Coolant overflow bottle Lube oil filter Oil drain Fuel feed pump Nameplate Circuit breaker location Remote customer interface connector Load lead connection Water inlet connection Water outlet connection Exhaust outlet 6392 8 05 3 4 Lubrication System See Figure 3 1 for the oil drain oil check oil fill and oil filter locations A WARNING RMT MS Handling caustic engine fluids and chemical products Can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rustproofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user information found on the packaging Avoid inhalation and skin contact Use only in well ventilated areas and use a protective mask when spraying Store engine fluids and chemical products in a locked cabinet Contact your local recycling center for disposal information and locations Used engine oil Contact with used engine oil may cause severe skin irritation Repeated and prolonged skin exposure may have other health risks Used engine oilis a susp
83. t assembly with clean fuel Install the bowl element onto the filter mounting head 9 Replace the water drain plug if removed and close the vent 10 Remove the air bleed screw from the fuel water separator 11 Open the fuel supply valve 12 After fuel fills the water separator allow fuel to flow from the air bleed hole until all airis displaced fuel flows free of air bubbles 13 Replace the air bleed screw 1 Air bleed screw 2 Drain plug 3 Drain valve Figure 3 5 Fuel Water Separator TP 6392 8 05 3 5 4 Priming the Fuel System Prime the fuel system under the following conditions e Before starting the engine for the first time e After running out of fuel and adding fuel to the tank e After fuel system maintenance such as changing the fuel filter draining the fuel water separator or replacing a fuel system component Note Do not open the air vent valve while priming the fuel system The fuel filter has an internal air bleed port Do not crank the engine to prime the fuel system Use the following procedure Fuel System Priming Procedure 1 Press and hold the Select button located on the ADC 2100 See Figure 3 1 and Figure 2 1 Move the generator set master switch to the RUN position The controller displays the engine runtime Continue to hold the Select button After 10 seconds the ADC 2100 will display Fuel and the fuel priming pump will start
84. the radiator to just below the overflow tube on the filler neck 9 Replace the radiator s pressure cap 10 Maintain the coolant level in the coolant overflow bottle between the High and Low markings Note Periodically check the coolant level by removing the radiator s pressure cap Do not rely solely on the level in the coolant overflow bottle Add fresh coolant until the level is just below the overflow tube opening 3 8 4 Flushing and Cleaning For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Flushing and Cleaning Procedure 1 Remove the pressure cap and open the radiator s coolant drain valve and let the system drain completely Remove the pressure cap to simplify draining 2 Drain clean and flush the coolant overflow bottle 3 Flush the system with clean water 4 Close the radiator s coolant drain valve 5 Fill the system with the recommended coolant 6 Replace the pressure cap 3 8 5 Pressure Cap The cooling system utilizes a pressure cap to raise the boiling point of the coolant enabling higher operating temperatures Ifthe cap leaks replace it with a cap ofthe same rating See Figure 3 10 Pressure Cap Rating 10REOD REOZD 15REOD REOZD 20REOD REOZD Figure 3 10 Pressure Cap Rating for inline radiator models 97 kPa 14 psi 83 110 kPa 12 16 psi 32 Section Scheduled Maintenance 3 9 Belt Check Chec
85. time hours shown on the ADC 2100 to determine when to schedule routine maintenance Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions Service Log Use the Operating Hour Service Log located in the back of this manual to document performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on Section 3 Scheduled Maintenance 21 3 2 Service Schedule a System Component Section FUEL Day tank level Flexible lines and connections Main tank supply level Fuel water separator Filter s Drain tank and replace fuel Fuel piping Tank vents and return lines for obstructions Fuel injection system LUBRICATION Oil level Crankcase breather Change oil First 50 Replace filter s then 250 COOLING Block heater operation Coolant level Flexible hoses and connectors Water pump s Fan and alternator belts Air ducts louvers lt lt 2 Louver motors and controls Radiator exterior EXHAUST SYSTEM Drain condensate trap Leakage Insulation fire hazards Flexible connector s Excessive back pressure Hangers and supports DC ELECTRICAL SYS
86. ur body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING 7 d 4 Fire Can cause severe injury 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 fuel injection system 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
87. urn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid 15 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 notsmoke orpermitflames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from yo
88. uunsuoo Jen eunsseJd SjeauJaAQ Jewod sx9e7 jueppns sdo s eDeyo A 1ndino 10 ON sueis peys jou seop queJo you suiojdui AS 6392 8 05 38 Section 4 Troubleshooting Section 5 Reconnection Adjustments 5 1 Four Lead Reconnection The following information illustrates the reconnection of four lead generator sets In all cases conform to the National Electrical Code NEC 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 511 100 120 Volt Configurations If the installation requires a factory two pole circuit breaker do not connect the load side terminals of the circuit breaker together see Figure5 1 If the installation requires a 100 120 volt 2 wire system use single pole circuit breaker See Figure 5 2 When connecting stator phase leads together size the output lead L1 to handle the amperage Use jumper lead on the line side of the circuit breaker to balance the load of the generator set LO Neutral LO Ground 2 GRD gt m L2 Load Side Two Pole Line Circuit Side Breaker A 60 Hz 50 Hz LO L1 100 120 Volt 100 120 Volt LO L2 100 120 Volt 100 120 Volt
89. xide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles 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 Copper tubing exhaust systems Carbon monoxide can cause severe nausea fainting or death Do not use copper tubing in diesel exhaust systems Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems resulting in exhaust leakage Fuel System A WARNING b Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels A WARNING Avoid high pressure fluids Can cause severe injury or death Do not work on high pressure fuel or hydraulic systems without protective gloves Avoid the hazard by relieving pressure before disconnecting fuel injection pressure lines Search for leaks using a piece of cardboard Always protect hands and body from high pressure fluids If a
90. z kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld 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 m min 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 mQ 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 MTBF mean time between failure 54 Appendix MTBO mig MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns

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