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15RESA 30RESA Operation

1. AAA Hm er Section 1 Service Views Oil Makeup Kit optional for 30 kW only H 28 Note The Air clean Radiator OMANDOARWN Positive Oil drain 27 26 enclosure is not shown in these service views er ECM and EPR electronic fuel pressure regulator Pressure cap engine coolant fill Coolant overflow tube Belt guard Coolant overflow bottle LOP switch location battery connection point valve Fuel solenoid valves two required for UL 2200 Fuel inlet AC circuit breaker panel Generator set fuses Generator set master switch Advance d Digital Control ADC 2100 Nameplate Figure 1 1 TP 6726 10 11 RESA Service Views shown without enclosure ADV 7692 ADV 8159 Units with Customer Connection Box Spark plugs Oil fill on valve cover Engine fuses Oil check dipstick Remote customer interface connector Customer load lead access Battery cables Battery location battery not shown Lube oil filter Negative battery connection point Coolant drain
2. Part Number 358337 223316 223316 Description 10 Amp Auxiliary Winding 10 Amp Relay Interface Board 10 Amp Controller Figure 4 1 Generator Set Fuses 4 3 Faults 4 3 1 Fault Codes The Advanced Digital Control displays fault codes to aid in troubleshooting Fault codes descriptions and recommended checks are listed in Figure 2 4 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 4 5 4 3 2 Fault History Use the following procedure to view the last 20 fault codes on the controller Procedure to View Fault History 1 Press and HOLD the Select button on the controller Move the generator set master switch to the RUN position The generator set engine will not start Continue to hold the select button until the software version number vX XX is displayed on the controller 2 Release the Select button 3 Press and HOLD both arrow buttons until F__1 is displayed indicating the most recent fault 4 Press the UP arrow button to the view the fault code 5 Press UP again to view the generator run time hours at the time of the fault 6 Press UP to step to the next fault Section 4 Troubleshooting 29 7 Repeat steps 4 through 6 to step through the last 20 faults Press the Select button to return to the most recent fault if desired 8 To exit move the generator set master switch to the OFF RESET position Possi
3. Operation Residential Generator Sets Models 15RESA 30RESA Controller Advanced Digital Control ADC 2100 NATIONALLY REGISTERED KOHLER POWER SYSTEMS TP 6726 10 11b 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 Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number TP 6726 10 11 Table of Contents Product Identification Information oooccconncccnnno nn nenn nenn nennen nenne 2 Safety Precautions and Instructions oooooccccnccon
4. Cooling air inlet Oil makeup assembly with sight gauge optional for 30 kW Oil reservoir Load lead access behind panel Customer interface connection behind panel Section 1 Service Views 11 Notes 12 Section 1 Service Views TP 6726 10 11 2 1 Operating Area A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas present in exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air Keep the generator set area clear Maintain at least 1 5 m 5 ft of clearance on all sides of the generator set Verify that the
5. dry location for the storage period Recharge the battery once a month to maintain a full charge Follow the procedure below when storing your generator set for a long period 8 months or more 1 Start and run the generator set until it reaches operating temperature or about 15 minutes 10 Select a well ventilated not humid or dusty 2 Stop the generator set location to store the generator 3 Change the oil and oil filter see Section 3 3 5 Oil 11 Cover the entire unit with a dust cover and Filter Change Note Run the generator set once a month 4 Drain the fuel completely from the fuel tank to whenever possible prevent accumulated moisture from mixing with the fuel 28 Section 3 Scheduled Maintenance TP 6726 10 11 4 1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems Firstcheck for simple causes such as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of common problems possible causes of the problem and recommended corrective actions If the procedures in this manual do not explain how to correct the problem contact an authorized Kohler distributor dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and repairs or adjustments made to equipment 4 2 Circuit Protection If the generator set circuit breaker trips or the fuses bl
6. 10 11 3 8 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 sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or deat
7. A weighted low water level low water temperature meter milli 1 1000 mega 106 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQmilliohm MOhm MQmegohm MOV MPa Mpg mph MS ms nat gas metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas 34 Appendix NBS NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns oc OD OEM OF opt OS OSHA OV Oz P PP PC PCB pF PF ph Y PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC at aty R rad RAM RDO ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot rpm RS RTDs 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
8. can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 lb of bicarbonate of soda baking soda toa container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded Safety Precautions and Instructions 5 metal surface away fromthe battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury
9. cece eee 23 3 6 2 Draining Cooling System 0 cc ees 24 3 6 3 Filling Cooling System 0 cece 24 3 6 4 Flushing and Cleaning ccc cece nor 24 3 6 5 Pressure Cap iria a e ea ei bend 24 3 7 IGNITION SYSTEM us pat ea na on wie Peed 25 3 85 Ballet AA ete el aia eae Med aes 26 3 9 Belt Check aci pt aba Bali aan 27 3 10 Storage Procedure oocoocccccoccr nennen een en 27 Section 4 Troubleshooting rrie ia 29 AT Introduction ee aktuellen 29 4 2 Circuit Protetto sneen i kei aha 29 4 2 1 Line Circuit Breaker oooococooccoooror rennen 29 4 2 2 A ee een eure 29 SN Wars rar Boe tis oes ae PELE Eh welt ie N G 29 4 3 1 Fauilt de it a eaten Beal ea ed BES ie ae A 29 4 3 2 Fault Histony 2 3 Sr a CE Rata et A 29 4 4 Generator Set Troubleshooting 0000 cece cence eee eens 30 4 5 Controller Troubleshooting 0 0 cece cee ete et eee e eens 31 Appendix A Abbreviations 06 0 tenet e teen teens 33 TP 6726 10 11 Table of Contents 3 Notes TP 6726 10 11 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety pr
10. clears when the battery voltage returns to a voltage within the limits for more than 10 seconds The crank cycle time is preprogrammed and not adjustable Automatic Stopping With the generator set master switch in the AUTO position the generator set stops when the remote start stop switch contacts or engine start contacts on the ATS open 2 4 4 Fault Warnings and Shutdowns Warnings The controller displays a fault code but the generator set does not shut down under the high battery voltage HB and low battery voltage LB warning conditions shown in Figure 2 3 The controller resets automatically after a battery voltage fault condition is corrected Shutdowns The generator set shuts down automatically under the conditions listed in Figure 2 4 and the controller displays a fault code Correct the fault condition and then reset the controller before restarting the generator set See Section 2 4 5 to reset the controller after a fault shutdown Shutdown switches on the generator set automatically reset when the problem is corrected For example the high engine temperature switch on the generator set engine automatically resets when the generator set cools However the fault on the controller does not clear until the operator resets the controller LOP Shutdown The oil pressure switch shuts down the generator set if the oil pressure drops below a preset level providing some protection from major engine damage due to insufficien
11. generator set from the load using the line circuit breaker or ATS See the safety precautions at the beginning of this manual before proceeding 3 Identify and correct the cause of the fault shutdown 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 Stop the generator set by moving the generator set master switch to the OFF RESET position 6 Reconnect the generator set to the load using the line circuit breaker or ATS 7 If the generator set is connected to a transfer switch remote start stop switch or remote digital gauge move the generator set master switch to the AUTO position Note Opening and closing the remote start stop contact also resets the controller Always identify and correct the cause of the fault shutdown before restarting the generator set TP 6726 10 11 2 4 6 Controller Power Down The ADC 2100 is powered by the generator set s engine starting battery When the generator set master switch is in the AUTO position the controller may power down after a period of inactivity The controller s communication parameter Cn setting determines the power down mode See the installation manual TP 6341 for controller configuration information 48 hour power down default setting If the ADC 2100 communication parameter is set to Cn00 the cont
12. other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines A WARNING A Airborne particles Can cause severe injury or blind ness Wear protective goggles and clothing when using power tools hand tools or compressed air 8 Safety Precautions and Instructions Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set 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 Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armature become hot
13. power to the battery charger if equipped d Start the generator set and check for leaks around the oil filter e Stop the generator set and tighten the oil filter to stop any leaks f Reinstall the housing side panel 5 Stop the generator set Check the oil level Add oil as necessary to bring the level up to the Full mark Note Too high an oil level causes high oil consumption and engine carbonizing Too low a level damages the engine 22 Section 3 Scheduled Maintenance 3 4 Air Cleaner At the interval specified in the service schedule inspect clean or replace the air cleaner element Clean the element more frequently 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 Air Cleaner Service Procedure A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a flexible hose Refer to Figure 3 4 during this procedure 1 Cover 2 Spring clip s 3 Housing 4 Pressure tap 1 8 27 NPT 5 Primary element 6 Dust ejector Figure 3 4 Air Cleaner 1 Release the spring clips to open the housing and remove the air silencer element 2 Tap the element lightly against a flat surface to dislodge loose surfa
14. problem continues Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized Kohler distributor dealer for service if problem continues Underfrequency shutdown Shutdown occurs when the governed frequency falls below 90 of the nominal system frequency for more than 5 seconds or below 59 Hz for more than 60 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized Kohler 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 Kohler distributor dealer for service if problem continues Software Communication Fault 0 16 Section 2 Operation Indicates a software or communication problem within the ADC 2100 Figure 2 4 ADC 2100 Fault Shutdown Codes Replace the controller TP 6726 10 11 2 4 5 Resetting Controller After a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Move the generator set master switch to the OFF RESET position 2 Disconnect the
15. service schedule If the tension is not within specification adjust as necessary using the following procedure See Figure 3 11 Adjust the tension of the alternator fan belt so that the belt can be depressed about 7 10 mm 0 3 0 4 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 Section 3 Scheduled Maintenance 27 2 Loosen the pivot and adjusting screws 5 Check the engine coolant protection see Section 3 6 3 While prying the battery charging alternator outward tighten the adjusting screw Note Use antifreeze capable of withstanding the lowest possible temperatures 4 Tighten the pivot screw 6 Keep spark plugs in their holes or seal spark plug 5 Recheck and adjust as necessary holes with suitable threaded metal plugs 6 Reconnect the battery negative lead last 7 Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed Note Also check the fan belt for cracks or tears surfaces that may be subject to rust or corrosion and replace the belt if necessary 8 Seal the air inlet exhaust pipe and fuel tank cap 3 10 Storage Procedure ale 9 Disconnect and remove the battery Place the battery in a warm
16. 0 clean softened water to inhibit rust corrosion and prevent freezing 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 Section 3 Scheduled Maintenance 23 When checking the coolant level also check the rubber seal of the radiator s pressure cap and replace a cracked or deteriorated cap The pressure cap raises the boiling point of the coolant enabling higher operating temperatures Ifthe cap leaks replace it with the same rating type of cap Find the pressure cap rating in Figure 3 5 Remove dirt and other debris from the pressure cap and filler neck Pressure cap 97 kPa 14 psi 91 C 195 F Thermostat Figure 3 5 Pressure Cap and Thermostat Rating 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 3 6 2 Draining Cooling
17. 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 of the water pump and battery charging alternator belt s Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components for cracks and corrosion exhaust manifold exhaust pipe exhaust clamps and silencer e Check for corroded or broken metal parts and replace them as needed e Check that there are no combustible materials near the exhaust outlet e Check that the exhaust outlet is unobstructed Carbon Monoxide Detectors Check for the installation and operation of carbon monoxide CO detectors on each level of any building near the generator set Oil Level Maintain the oil level at or near not over the full mark on the dipstick Section 2 Operation 13 2 3 Exercising Generator Set Operate the generator set under load once each week for 20 minutes The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set a
18. System The radiator contains a coolant drain valve to drain the cooling system When draining the coolant remove the radiator s pressure cap which 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 6 3 Filling Cooling System 1 Close the radiator s coolant drain valve 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 2 Fill the radiator with the recommended coolant mixture of 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing The coolant capacity is shown in Figure 3 6 15kW 11 5 L 3 0 gal 30kW 11 5 L 3 0 gal Figure 3 6 Coolant Capacity 24 Section 3 Scheduled Maintenance 3 Operate the engine with the radiator cap removed until the thermostat opens and the upper radiator hose becomes hot 4 Stop the engine and allow it to cool 5 Add coolant to the radiator to just below the overflow tube on the filler neck See Section 1 Service Views for the overflow tube location 6 Replace the radiator s pressure cap 7 Maintain the coolant level in the coolant overflo
19. 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 Gh 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 carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 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 6 Safety Precautions and Instructions minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguishe
20. ands 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 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 See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized Kohler distributor dealer perform generator set service Engine Service Perform generator set engine service at the intervals specified by the engine operation manual 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 runtime hours shown on the ADC 2100 to determine when to schedule routine maintenance Service generator sets that are subject to extreme weather or dusty or dirty conditions more frequently Maintenance and Service Parts Obtain maintenance and service parts from an authorized Kohler distributor dealer Section 3 Sche
21. anization read write 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 simple mail transfer protocol serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol 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 total harmonic distortion telephone influence factor tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency user interface Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal uniform resource locator web address 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 write only without weight transformer TP 6726 10 11 TP 6726 10 11b O 2009 2010 2011 by Kohler Co All rights r
22. ation and adjustment instructions DEFINITION Auxillary Fault Onder Fregue Inder Freque Under Voltage Y OFF RESET GM28707A C 1 LED display 2 Up and down arrow buttons use for setup and adjustment only 3 Generator set master switch 4 Select button use for setup and adjustment only Figure 2 1 ADC 2100 Controls Displays total generator set runtime hours Crank indication Displays CC_1 CC_2 or CC_3 to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Fault codes Section 2 4 4 Flashes a 2 or 3 letter fault code to indicate various fault conditions See Software version See the generator set installation manual Select and arrow buttons Keypad The keypad is used for controller setup and adjustment only Have setup and adjustments performed only by an authorized Kohler distributor dealer The setup and adjustment functions are password protected Generator set master switch RUN OFF RESET AUTO Three position switch Figure 2 2 ADC 2100 Controls and Indicators 14 Section 2 Operation Switch functions as the generator set operation and controller reset switch TP 6726 10 11 2 4 2 Local Operation Starting Move the generator set master switch to the RUN position The ADC 2100 attempts to start the generator set three times If the generator se
23. ble Cause Battery weak or dead Problem The generator 4 4 Generator Set Troubleshooting Figure 4 2 contains generator set troubleshooting diagnostic and repair information Check for loose connections before replacing parts Corrective Action Recharge or replace the battery set does not Battery connections reversed or poor Check the connections k En Controller fuse F3 blown Replace the fuse Contact an authorized Kohler Relay interface board fuse F2 blown distributor dealer for service if fuse blows repeatedly Engine fuse blown Generator set master switch in the OFF position Move the master switch to the RUN position The generator Air cleaner clogged Clean and or replace the air cleaner set cranks but Battery weak or dead does not start Recharge or replace the battery starts hard Battery connection poor Clean and tighten the battery connections lacks power or Spark plug wire connection loose Check the spark plug wires operates Low oil pressure shutdown erratically Check for oil leaks Check the oil level and add oil if necessary Fuel pressure insufficient Check the fuel supply and valves Engine fuse blown Replace the fuse If the fuse blows again contact an authorized Kohler distributor dealer Engine malfunction Contact an authorized Kohler distributor dealer No AC output AC circuit breaker
24. 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 TP 6726 10 11 Hazardous Voltage Moving Parts A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving parts 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 lf 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 Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circ
25. ccording to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks 2 4 Advanced Digital Control Operation Figure 2 1 illustrates the user interface on the Advanced Digital Control ADC 2100 Note Have setup and adjustments of the ADC 2100 performed only by an authorized distributor dealer The setup and adjustments are password protected 2 4 1 Controls and Indicators Figure 2 2 describes the controls and indicators located on the controller The LED display indicates generator set status as shown in Figure 2 2 The display is active when the master switch is in the RUN or AUTO position and remains active until the generator set master switch is moved to the OFF RESET position or the power to the controller is removed Depending on the controller configuration the LED display may turn off after a period of inactivity when the master switch is in AUTO See Section 2 4 6 Control or Indicator LED display Description Runtime hours The buttons on the controller keypad are used only for system configuration and adjustment The ADC 2100 is factory set and should not require configuration or adjustment under normal operating conditions If the generator set is reconnected to a different voltage and or frequency refer to an authorized Kohler distributor dealer for system configur
26. ce dirt Do not clean the element in any liquid or use compressed air as these will damage the filter element 3 Examine the element and housing for damage Replace the element or housing if necessary 4 Wipe the cover and housing with a clean rag to remove dirt Make sure the sealing surfaces fit correctly and reattach the spring clips TP 6726 10 11 3 5 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level ofthe building Locate the detectors to adequately warn the building s occupants of the presence ofcarbon monoxide Keepthe detectors operational atalltimes Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions At the interval specified in the service schedule inspect the exhaust system components exhaust manifold exhaust outlet exhaust line exhaust clamps and muffler for cracks leaks and corrosion Exhaust System Inspection Points e Check for corroded or broken metal parts and replace them 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 authorized Kohler distributor dealer e Visually inspect for exhaust leaks blowby C
27. cnn nenn nn nennen nn nenn 5 Introduction 00 ee ee 9 Service Assistance ensure 10 Section T Service VIEWS A a ida 11 Section 2 Operation 3 2 24 A a li 13 2 1 Operating Area 4 28 nce ates ae a ba geek Bet dr 13 22 Prestant Checklist eicere be dene enter 13 2 3 Exercising Generator Sebega a a E T a ete t teens 14 2 4 Advanced Digital Control Operation 00s 14 2 4 1 Controls and Indicators 0 cece cette erences 14 2 4 2 Local Operation 00 0 a a teens 15 2 4 3 Automatic Operation 000 cece eet 15 2 4 4 Fault Warnings and Shutdowns 00 oo 15 2 4 5 Resetting Controller After a Fault Shutdown 00 00 ee 17 2 4 6 Controller Power Down 0 000s eect tees 17 Section 3 Scheduled Maintenance cc cece cece nenn nn nennen nn nenn 19 3 1 General Maintenance 0 0 ccc cette teens 19 3 2 Service Schedule a Re Ra e da ee 20 3 3 Lubrication System soii ken oe ee 21 3 3 1 Oil Specifications u 4 ne rasen 21 NA 21 3 3 3 Optional Oil Makeup Kit oooooooococonocooorrr nenn 21 3 3 4 Oil Additions o oooocoocononoroo een een 21 3 3 5 Oil and Filter Change 0 cece cect nenn 21 3 4 sAlP Cleanehc sate ssi da ts 22 3 5 Exhaust System iii dee tae ean Gada ee eee eens 23 3 6 7 Cooling SYSTEM cid AA al a A 23 3 6 1 Checking and Filling Coolant 00
28. 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 Check for leaks 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 Kohler 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 Kohler 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 Kohler distributor dealer for service if
29. duled Maintenance 19 3 2 Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set Reference Before 400 Hr Perform Service at Intervals Indicated X Section Starting Yearly Fuel System Check the fuel level and fill as necessary LP Check the solenoid valve operation Check flexible fuel lines and connections Replace as necessary Check the fuel piping Lubrication System Check the oil level and add oil as necessary Change the oil Replace the oil filter Intake Exhaust System Inspect and clean the air cleaner element Replace the air cleaner element Check and clear the exhaust outlet area Inspect the exhaust system components Check the installation and operation of CO detectors Check the exhaust gas condition during operation Cooling System Check the coolant level and fill as necessary Inspect the radiator and hoses Check the belt tension and condition Check the coolant protection and tighten the hose 6 x clamps Flush the cooling system 6 x 1000 hr Ignition System Clean and regap the spark plugs Replace the spark plugs x 1000 hr Electrical System Keep the battery charged and in good condition Check and tighten electrical connections Clean the battery cables as required Engine And Mounting Check for fuel co
30. e bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board Category 5 network cable circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6726 10 11 cfm CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL cu in cw CWC DVR E2PROM E emer ECM EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories 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 sing
31. e Figure 3 8 and Figure 3 9 Attain electrode against the cylinder head Rotate the a correct gap when the feeler or wire passes spark plug clockwise until you feel resistance between the spark plug electrode It should pass easily but with some resistance or drag otherwise 12 Use a torque wrench to torque each spark plug to adjust as necessary 25 Nm 18 ft Ibs Otherwise hand tighten the spark plug until you feel resistance 10 Use a gapping tool to gently bend the side electrode closer to or farther from the center 13 Use a ratchet wrench to final tighten an additional electrode to set the correct gap See Figure 3 10 1 4 turn Do not overtighten as doing so may strip Position the side electrode directly over the center the threads or alter the electrode gap setting electrode 14 Check the spark plug wire connector in the boot for Model Sparkpluggap accumulated dirt grease and other debris and 0 9 mm 0 035 in clean as necessary Figure 3 8 Recommended Spark Plug Gap 15 Firmly push the spark plug boot onto the spark plug 16 Check that the generator set master switch is in the OFF position 17 Reconnect the generator set engine starting battery negative lead last 18 Reconnect the power to the battery charger if equipped 1 0 9 mm 0 035 in gap 2 Spark plug electrodes Figure 3 9 Spark Plug Gap Inspection Figure 3 10 Spark Plug Gap Adjustment 26 Section 3 Scheduled Maintenance TP 6726
32. ecautions 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 missing or damaged decals TP 6726 10 11 Accidental Starting A WARNING FAS 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 follo
33. 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 Safety Precautions and Instructions 7 Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment 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 installations to prevent the connection of standby and
34. enough to cause severe burns Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Notice NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground TP 6726 10 11 This manual provides operation instructions for 15 and 30 kW residential generator set models listed on the front cover This generator set is approved for use in stationary applications in locations served by a reliable utility power source Have the generator set installed by an authorized Kohler distributor dealer or service technician Refer to the Installation Manual for installation instructions See the List of Related Literature below 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 obligatio
35. eserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
36. h 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 Bes RE Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 6726 10 11 Section 3 Scheduled Maintenance A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep h
37. h 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 Donot 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 TP 6726 10 11 Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together 3 9 Belt Check Check the belt tension at the intervals specified in the
38. heck for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed e Check that all covers and doors are undamaged in place and locked e Check for the installation and operation of carbon monoxide CO detectors on each level of any building near the generator set TP 6726 10 11 3 6 Cooling System A WARNING Y 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 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 the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank 3 6 1 Checking and Filling Coolant Maintain the coolant level in the coolant overflow bottle between the High and Low markings See Section 1 Service Views for the coolant overflow bottle location Note Periodically check the coolant level by removing the radiator s pressure cap Do nat rely solely on the level in the coolant overflow bottle Add fresh coolant until the level is just below the overflow tube opening Use a coolant mixture of 50 ethylene glycol and 5
39. in the OFF position Place the circuit breaker in the ON position AC circuit breaker tripping because of overload Reduce the load on the generator set circuit AC circuit breaker tripping because of short Contact an authorized Kohler distributor dealer for service Auxiliary winding fuse F1 blown Replace the fuse Contact an authorized Kohler Engine fuse blown distributor dealer for service if fuse blows repeatedly Low output or Generator set overloaded excessive drop in voltage Reduce the load Generator set Low oil pressure shutdown stops suddenly Check for oil leaks Check the oil level and add oil if necessary Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact an authorized Kohler distributor dealer Controller fuse F3 blown Replace the fuse If the fuse blows again contact an Engine fuse blown authorized Kohler distributor dealer Auxiliary winding fuse F1 blown Replace the fuse Contact an authorized Kohler distributor dealer for service if fuse blows repeatedly Overspeed shutdown Reset the controller If the overspeed fault occurs again contact an authorized Kohler distributor dealer position Generator set master switch in the OFF RESET Move the switch to the correct position RUN or AUTO switch remote digital gauge or ATS Remo
40. in the oil a Place the generator set master switch in the OFF position b Disconnect the power to the battery charger if equipped c Disconnect the generator set engine starting battery negative lead first d Remove the housing side panel e Place an oil collection container below the oil drain and remove the oil drain plug f Open the oil drain valve on the engine g Allow time for the engine oil to drain completely h Close the oil drain valve i Replace the oil drain plug Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Clean the contact surface of the oil filter adapter c Apply a light coat of clean oil to the rubber seal of the new oil filter Section 3 Scheduled Maintenance 21 d Install the new oil filter following the instructions provided with the filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner 3 Fill with oil See Figure 3 1 for oil selection and Figure 3 3 for oil capacity moa l on 15 30 kW 3 5 3 7 5 4 5 7 30 kW with oil makeup kit Figure 3 3 Oil Capacity 4 Check for leaks a Check thatthe generator set master switch is in the OFF position b Reconnect the generator set engine starting battery negative lead last c Reconnect the
41. le throw disconnect switch digital voltage regulator EEPROM electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exh ext F FHM fl oz flex freq FS ft ft Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt exhaust external Fahrenheit female flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP ISO J JIS k K kA KB KBus kg hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexag
42. lt Al ANSI AO APDC API approx APU AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CAT5 CB CC cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management District 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 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 pressur
43. n 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 maintenance requirements are very important to safe and efficient operation Inspect the parts often and perform required maintenance at the prescribed intervals Obtain service from an authorized Kohler distributor dealer or service technician to keep equipment in top condition TP 6726 10 11 Introduction 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 Literature Type Part Number Installation Manual 15 30 kW TP 6725 Parts Catalog TP 6729 TP 6724 TP 6198 TP 6719 One Parts Catalog combines generator and engine information Service Manual Engine Service Manual Generator Set Wiring Diagram Manual Generator Set Figure 1 Generator Set Literature Introduction 9 Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest authorized Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Elec
44. ncing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of the building Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Keep the detectors operational at all times Periodically test and replace the carbon monoxide detectors according to the manufacturer s instructions Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not
45. 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 pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay root mean square round read only read only memory rotate rotating revolutions per minute right side Resistance Temperature Detectors RTU RTV RW SAE scfm SCR s sec SI SI EO sil SMTP SN SNMP SPDT SPST spec specs sq sq cm sq in SMS SS std stl tach TB TCP TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo typ UF UHF UIF UL UNC UNF univ URL US VAC VAR VDC VFD VGA VHF WCR w WO w o xfmr remote terminal unit room temperature vulc
46. olant and oil leakage t Retighten all nuts and bolts as required Check for visible wear or damage Remote Control System Check the remote control operation Generator Set Exercise the generator set Check and clean the interior of the enclosure Clean collector ring and inspect brushes 1000 hr Contact your local authorized Kohler distributor dealer for service Read WARNING found at the beginning of manual regarding moving parts Consult battery manufacturer s instructions 20 Section 3 Scheduled Maintenance TP 6726 10 11 3 3 Lubrication System 3 3 1 Oil Specifications Use oil that displays the American Petroleum Institute API Starburst certification mark FOR GASOLINE ENGINES on the container Do not use oils that are specifically formulated for diesel engines CC or CD classification oils even when labeled Heavy Duty or For Natural Gas Engines are not acceptable Multi viscosity oils are recommended Figure 3 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for a given operating temperature Ambient Temperature SAE Viscosity Grade 10W 30 18 C 0 F or above Below 18 C 0 F 5W 30 Figure 3 1 Engine Oil Selection 3 3 2 Oil Check Check the oil level in the crankcase every 24 hours of operation or before the engine is started each day Do not check the oil level while operating the unit St
47. on mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second International Building Code 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 internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 21 bytes Kohler communication protocol kilogram Appendix 33 kg cm kgm kg m kHz kJ km kOhm kQ kPa kph kV kVA kVAR kW man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level
48. op the generator set and keep the generator set level to get an accurate reading To check the oil level remove the dipstick and wipe the end clean reinsert and remove Maintain the oil level between the Full and Add marks on the dipstick as shown in Figure 3 2 See Section 1 Service Views for the dipstick location Note Do not operate the set if the oil level is below the Add mark or above the Full mark on the dipstick 1 Full mark 2 Add mark Figure 3 2 Oil Level Check 3 3 3 Optional Oil Makeup Kit On 30 kW generator sets equipped with the optional oil makeup kit check the oil level in the oil reservoir and at the sight gauge Refer to the instructions provided with the oil makeup kit for more information TP 6726 10 11 3 3 4 Oil Additions Adding some oil between oil changes is normal The amount varies with generator set usage Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device See Section 1 Service Views for the oil check and oil fill locations 3 3 5 Oil and Filter Change Change the oil according to the service schedule or before generator set storage Change the oil more frequently if the generator set operates under dirty dusty conditions Change the oil while the engine is still warm See Section 1 Service Views for oil fill oil check and oil filter locations Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Dra
49. ow repeatedly contact an authorized Kohler distributor dealer for service 4 2 1 Line Circuit Breaker The line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load Ifthe circuit breaker trips reduce the load and switch the breaker back to the ON position 4 2 2 Fuses Three 10 amp fuses are located on the junction box near the circuit breaker panel See Figure 4 1 Four additional engine fuses are located inside the engine fuse box See the service views in Section 1 for the fuse locations Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Figure 4 2 Troubleshooting Chart for conditions that may indicate a blown fuse Obtain replacement parts and service from an authorized Kohler distributor dealer Auxiliary Winding Fuse F1 A replaceable 10 amp fuse protects the alternator Relay Fuse F2 Areplaceable 10 amp fuse protects the engine relays Ifthe generator set does not crank check the battery and battery connections and then check the relay fuse Controller Fuse F3 A replaceable 10 amp fuse protects the controller circuitry Ifthe controller display is TP 6726 10 11 Section 4 Troubleshooting dark check the battery and battery connections and then check the controller fuse Engine Fuses Four engine fuses are located in the engine fuse box Contact your distributor or dealer for replacement fuses
50. r Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaustfumes when working on or near the generator set Never operate the generator set inside a building 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 monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experie
51. r if equipped Disconnect the generator set engine starting battery negative lead first Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling Do not pull the wire Pulling on the wire rather than the boot may damage the wire or terminal Loosen the spark plug with a ratchet and 5 8 in spark plug socket with a rubber insert to prevent spark plug damage Means of Identification closing Built up deposits and gap between electrodes 6 Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber Remove spark plugs one at a time and examine Identify a normal spark plug in good operating condition by observing a light tan or gray deposit on firing tip See Figure 3 7 to evaluate engine condition by color condition of a problem spark plug Clean spark plugs by wiping them with a rag File the center electrode to keep it parallel to the side electrode Note Do not sandblast wire brush scrape or otherwise service spark plugs in poor condition Obtain a new plug for best results Possible Cause Solution Oil or carbon fouling Clean and regap the spark plug Oil fouled spark plug and electrodes Wet black deposits on the insulator shell bore Excessive oil entering combustion chamber through worn rings and pistons excessive clearance between valve guides and stems or
52. re are no windows air vents or other openings in the building within 1 5m 5 ft of the generator set exhaust outlet in any direction Notice Do not locate patios decks play areas or animal shelters near the generator set Keep items such as lawn furniture toys sports equipment and all combustible materials away from the generator set exhaust outlet Remind family members children and visitors to use caution near the generator set Generator sets connected to automatic transfer switches start automatically during exercise periods and power outages Some generator set components become hot when the generator set is running and remain hot for a time after the generator set shuts down TP 6726 10 11 Section 2 Operation 2 2 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 service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for 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 Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance
53. replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donot operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels TP 6726 10 11 Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per the manufacturer s instructions Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both preventbubble formation Asuccessful test depends on the ability of the solution to bubble Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can
54. roller automatically powers down after 48 hours of inactivity Aremote start signal from atransfer switch or a remote start stop switch connected to P21 connector leads 3 and 4 or moving the generator set master switch to the RUN position turns the controller back on Continuous power mode If the ADC 2100 communication parameter is set to Cn01 the controller will not power down The controller remains powered at all times to maintain CANbus communication and to allow remote start commands from a remote CAN gauge A battery charger is recommended to maintain the engine starting battery Note The ADC 2100 draws 250 mA when the master switch is in the AUTO position and the unit is configured for CAN communication 1 hour power down Setting the communications parameter to Cn06 will cause the controller to power down after 1 hour of inactivity In this mode a remote digital gauge using CAN communication will not be able to activate the controller after power down A remote start signal from a transfer switch or a remote start stop switch connected to P21 connector leads 3 and 4 or moving the generator set master switch to the RUN position turns the controller back on Controller application code version 1 21 or higher is required for the 1 hour power down option Section 2 Operation 17 Notes 18 Section 2 Operation TP 6726 10 11 3 1 General Maintenance A WARNING i AS k Accidental starting Can cause severe injury or deat
55. t does not start in three attempts the system shuts down on an overcrank fault The crank cycle time is preprogrammed and not adjustable Stopping Run the generator set with no load for at least 2 minutes to allow the engine to cool down Move the generator set master switch to the OFF RESET position The engine stops 2 4 3 Automatic Operation The generator set can be connected to an automatic transfer switch ATS remote start stop switch or remote digital gauge Move the generator set master switch to the AUTO position to allow starting and stopping by one of these devices Refer to the instructions provided with the ATS remote start stop switch or remote digital gauge for operation instructions Note Have an authorized Kohler distributor dealer install and connect the ATS remote start stop switch or remote digital gauge Automatic Starting The generator set crank cycle starts when the remote switch or engine start contacts on the ATS close The ADC 2100 attempts to start the generator set three times If the generator set does not start in three attempts the system shuts down on an overcrank fault Fault Description High battery Fault code is displayed if the engine starting battery voltage rises voltage warning above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition
56. t oil pressure However the low oil pressure switch is not a low oil level indicator Check the oil regularly as described in the service schedule and add oil as required to keep the oil level at or near the full mark on the dipstick or optional gauge Check Check the battery rating and condition Low battery Figure 2 3 ADC 2100 Fault Warning Codes TP 6726 10 11 The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Fault code is displayed if the engine starting battery voltage falls below Check the battery rating voltage warning 9 5 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 and condition Charge or replace the battery Section 2 Operation 15 Auxiliary fault input shutdown Description Input from a customer supplied switch that closes when the fault is active The generator set shuts down 0 3 seconds after the fault is detected and will not start when the fault is active input is grounded This protection becomes active 3 seconds after crank disconnect Check the cause of the auxiliary fault 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
57. te stop command received from a remote Check the remote switch position Engine malfunction Figure 4 2 General Troubleshooting Chart 30 Section 4 Troubleshooting Contact an authorized Kohler distributor dealer TP 6726 10 11 4 5 Controller Troubleshooting Figure 4 3 contains troubleshooting information for the Advanced Digital Control Problem Possible Cause Corrective Action Controller LED Controller may power down if the generator set Controller display will automatically activate when a display is off has not run in the last hour or 48 hours remote start command is received or the generator depending on the controller s On setting See set master switch is moved to the RUN position Section 2 4 6 Controller Power Down Controller fuse F3 is blown Replace the fuse See Figure 4 1 If the fuse blows again contact an authorized Kohler distributor dealer Low or no battery voltage Check connections Check generator set battery See Figure 4 2 Generator set master switch is in the Move generator set master switch to the AUTO or OFF RESET position RUN position Figure 4 3 ADC 2100 Troubleshooting Chart TP 6726 10 11 Section 4 Troubleshooting 31 Notes 32 Section 4 Troubleshooting TP 6726 10 11 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP a
58. tric e Visit the Kohler Power Systems website at KohlerPower com e Look atthe 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 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6726 10 11 10 9 18 19 20 bn y
59. uits Turn offthe main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger
60. w bottle between the High and Low markings See Section 1 Service Views for the coolant overflow bottle location 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 6 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 6 5 Pressure Cap The cooling system utilizes a pressure cap to raise the boiling point of the coolant enabling higher operating temperatures If the cap leaks replace it with a cap of the same rating Find the pressure cap rating in Figure 3 5 TP 6726 10 11 3 7 Ignition System Service the spark plugs at the interval specified in the service schedule using the following procedure 1 Problem Condition Gap bridged spark plug Place the generator set master switch in the OFF position Disconnect the power to the battery charge
61. worn or loose bearings Replace the spark plug Carbon fouled spark plug Black dry fluffy carbon deposits on insulator tips exposed shell surfaces and electrodes Incorrect spark plug weak ignition clogged air intake overrich fuel mixture or excessive no load operation Clean and regap the spark plug Lead fouled spark plug Dark gray black yellow or tan deposits or a glazed coating on the insulator tip Caused by highly leaded fuel Replace the spark plug Pre ignition damaged spark plug Melted electrodes and possibly blistered insulator Metallic deposits on insulator suggest internal engine damage Wrong type of fuel incorrect timing or advance too hot a plug burned valves or engine overheating Replace the spark plug Overheated spark plug White or light gray insulator with small black or gray brown spots with bluish burned appearance on electrodes Engine overheating wrong type of fuel loose spark plugs too hot a plug low fuel pressure or incorrect ignition timing Replace the spark plug Worn spark plug Severely eroded or worn electrodes Figure 3 7 Engine Evaluation Using Spark Plug Condition TP 6726 10 11 Caused by normal wear and failure to replace spark plug at prescribed interval Replace the spark plug Section 3 Scheduled Maintenance 25 9 Check the spark plug gap before installing any 11 Reinstall the spark plug Do not bump the spark plug Se
62. ws 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles 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 burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid

15RESA 30RESA Operation

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