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8.5RES 12RES 12RESL 12RESM1 12RESNT 12TRES Service

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2. 92 6 12 Fuel Systems cosi exea Rua Ra exa Qaa eques 93 6 124 Gas Piping 93 6 12 2 Fuel Solenoid Valve 93 6 12 3 Fuel Regulators Ee eR ERREUR AE E REA 93 6 12 4 Fuel Conversion 94 6 12 5 Digital Spark Advance Ignition 96 6 12 6 Fuel Metering Valve Adjustment 96 6 13 D m 98 6 14 Starter Relay sas sean REO EE RE EUER XE NEA Ru a 98 6 15 Continuity Checks 98 Section 7 Disassembly Reassembly 101 4A Jisassembly xc o ences oe eek EEE ru 101 7 2 Beassembly i cubo EAN aii tc Rn ud agen 105 Section 8 Wiring Diagrams 109 Appendix A Abbreviations 123 Appendix Common Hardware Application Guidelines 125 Appendix C General Torque Specifications 126 Appendix D Common Hardware Identification
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4. Ra ER dene 77 65 SIip RIligs eR eee bequem dba R a 78 6 6 Brushes eere eee aia Ced at e Moe Redux Ru 78 67 Voltage MP 79 6 7 1 Voltage Regulation 2 22 REPRE 79 6 7 2 Voltage 79 6 7 3 Volts per Hertz Hz Adjustments Droop 81 6 7 4 Voltage Connections Single Phase 81 6 7 5 Voltage Connections 3 Phase 82 6 8 Silicon Controlled Rectifier Module 82 Table of Contents TP 6196 10 09 Table of Contents continued 6 9 Electromechanical Governor 84 6 9 1 gt 84 6 9 2 Initial Checks and Operation 84 6 9 3 Hunting Surging 85 6 9 4 Governor System Magnetic Pickup Operation Test 85 6 9 5 Frequency Adjustment 88 6 10 Mechanical Governor 89 6 11 Fault Shutdown Tests 91 6 11 1 Controller Fault Shutdown Functions 91 6 11 2 Fault Shutdown 5
5. 50018 ANIONS MOlvIS 191 FINGOW weds LYVNS dSS 5 31 16 SS YOLOW N3livis WS GFMOYLNOD NOOlIIS 805 3OVJN3lNI AVIS 1 omd HOLIMS 3unss3Md 10 401 0015 01 N3TIOMINOO 01 AVI3H Sy ANNOYS YSTIONLNOD ONS 3NWA TANA Ad asna 3 YIANIS 3univs3dW3L LNVIOOD 519 X3LV3H HHO 89 3931 M3TIOMINOO 002224 535 ZI ABQNVIS 91 193 LON OQ Svo dl N OL 99 1O03NNOO SVO VHnlVN 1304 NINIL NOLLINOI 3svHd TIONIS 89 1335 5 MOIVH3N39 304 310N 03S 033dSH3A0 Awad 7035 S 35835 OV _ oy 130 935 0 93S 01 03H4 IMOGLNHS 1 122 4 Ear ADI 99 335 NOWINS E ANIONS Looe oplos 1 8 4 Se 318 9 ar y18 8
6. 12 14 NMOGLNHS Q34vT3Q 7035 IMVIS SANIN 3AMO 0134 SMa AYGA 235 NMOGInHS FOVLIOA OV 1O3NNOOSIO INYO MOT YOSNAS INVIOOD 8 1414 008 512 3s 9 NOSN3S 18 1000 8 14 iHM Uy sl ZNO LNOOD L dO1S IMVLS 92 19 4019 1415 ONY 92 14 e gt 107 034 eed 7935 O HO LIBIHNI J roms 553 10 51 19 4 1 NMOGLNHS Q3AVT30 aJ gt G3U IHM Zed SNOOP 8 20 401 734 99 940 66 950 6 7OMINOO 8 914 Ie eg d ANANI SNIGNIM XNY SNIGNIM 934 39VLIOA SNISN3S HSV 100 Awal HSY 7IOMINOO ATH Xhv 1304 L Ld NOL 4 61 19 INO 1304 VZ Ld 4139 7OMINOO ATH LUYIS HSvi4 21 uev 6 vid 18 9 1d 7 19 NOILINSI NES 224 29 2 624 cer NED Iuno 624 TE MT ozar 28 04 8 624 6 NE M3MOd NUD 224 THM 684 IM 18 2 24 18
7. 27 S dJntroductlon 3 2500 endo eae irte Bra abi ded 27 3 2 Jnitial CHECKS o iube etre e And d 27 3 8 Troubleshooting Chart 27 3 4 Controller Troubleshooting 33 Section 4 ADC 2100 DC 2200 Controllers 35 AA Jntroductlon 1 cet ede see 35 4 2 Controller Display and Keypad 36 43 Sequence of Operation 37 4 3 1 Starting Sequence Master Switch Moved to RUN 37 4 3 2 Starting Sequence Remote 37 4 3 8 Running Sequence 37 4 3 4 Stopping Sequence Master Switch Moved to OFF RESET 37 4 3 5 Stopping Sequence Remote Stop 37 44 ose e eb etri eei dob eed 37 4 4 1 Warnings 37 442 Shutdowns 37 6196 10 09 Table of Contents Table of Contents continued 4 5 ADC 2100 Controller Configuration and Adjustment 40 4 5 1 Controller Que ux oe cee 40 4 5 2 Controller Configuration 40 4 5 3 Voltage and Freq
8. D LLL T 57 5 4 2 ShutdOWnS asa tx Maes 57 5 5 Controller Configuration and Adjustment 59 5 5 1 Controller Time 59 5 5 2 Voltage and Frequency Adjustments 59 5 5 3 Controller Application Program Version Number 59 5 54 5 60 5 6 Voltage and Frequency Adjustments 62 5 6 1 Voltage Adjustment 62 5 6 2 Frequency Adjustment 63 5 7 Controller 66 5 8 Optional Relay Board 67 5 8 1 Relay Board Troubleshooting 67 5 8 2 Relay Board Replacement Procedure 69 5 9 Controller Replacement 70 Section 6 Component Testing and Adjustment 73 6 1 Theory of Operation ete reete Ee DR e RD ob 73 6 2 Separate 73 6 3 Stal rarene corn ate tet 74 6 4
9. from GM52541 1 P11 Relay board harness connection to the controller board Figure 5 19 Relay Board Harness Connection to Controller Circuit Board Section 5 ADC RES DC RET Controller 67 RELAY BOARD P14 P3 CONNECTIONS PIN 1 PF2A TO P1 2 32N TO P1 70N 2 5 PIN 1 71 NC P1 CONNECTIONS PIN 1 71 SW71 1804 206200 TO P2 5 70 1809 200200 TO Si 32N SW32N 1809 200200 1 4 2 N C N6 Ed 4 32N N6 SWN6 1804 206200 TO P2 2 8 N2 SWN2 1804 206200 P2 bral Nal 2 SWPF2 1804 206200 TO P2 IGN CO 69 2 amp IGN SWIGN 1804 206200 TO P2 70 70 5870 1804 206200 P2 NS DOQ N3 70 N3 SWN3 1804 206200 TO P2 rr 12 11 10 PF2A SWPF2A 1809 200200 TO N C TO ENGINE HARNESS TO CONTROL BOARD P11 GM52639 Figure 5 20 Relay Board Connection Harness GM52639 TB1 Terminal Label Description COMMON FAULT NC Common fault relay normally closed contact Opens fault COMMON FAULT COM Common fault relay common COMMON FAULT NO Common fault relay normally Figure 5 22 Relay Contact Ratings open contact Closes on a fault Contact Ratings 10A 120 VAC 10A 28 VDC Maximu
10. 5 no 80 v99 vea lO3NNOO ION 00 Sv9 dl N OL S9 5 9 WYNLWN 3dAL 1313 Nol 7 N9 Lag 3NION3 AINO 16 AINO OFZHI 335 ONINIL NOILINSI 553 3NION3 2 9 N 3 11 1d 6 046 0 36 1d 8 414 8 614 0 L E 61 4 c g 49 14 1 6 7ONINOO TANA 8 0914 Linv4 2 914 9 1d WEA 1 19 21 014 10028 1 5 77 CvNoudO 9 64 3SN3S OV 934 OV 193NNOOSIQ XNvHO 5 INVI009 21 19 laye H9IH MOSN3S LNVIOOD 81 19 M 1HM 1 014 HZ HONN3AOD 0ld WZ 2 014 81 MONH3AOS Oid VL NONH3AOS 8 64 110 AVIS 69 SMd 3NMO 0134 6d SANIN 39VLIOA OV 9 64 LNdNI 9NIONIM 53u 3ovI1oA 4 64 SNI
11. flash relay on RIB ADC 2100 Check for Flash LED illumination Check fuse F2 Replace relay board Section 4 8 flash relay on controller board ADC RES Check for Flash LED1 illumination Check fuse F2 If LED1 is lit but relay does not operate replace controller board Section 5 7 Operates erratically Air cleaner clogged Replace element Section 2 4 Spark plug s Replace and regap plugs Section 2 3 Spark plug wire s Replace spark plug wires Engine S M DSAI leads incorrectly connected or disconnected 12kW only Connect for natural gas Disconnect for LP Section 6 12 5 Fuel line restriction Check fuel lines Section 6 12 1 Fuel mixture adjustment incorrect Check and or adjust Section 6 12 Magnetic pickup connections Check for loose connections to the mag pickup Section 6 9 Governor adjustment incorrect Adjust governor stability Section 6 9 or 6 10 Ignition system Test and or replace components Engine S M Inadequate cooling hot engine only Inspect air inlet and outlet Section 2 5 Carbon buildup in engine Clean cylinder head Engine S M Engine valves not seating correctly Check cylinder pressures with leakdown test Inspect valves and valve seats Engine S M Air intake restriction inadequate cooling Inspect air intakes and exhaust for obstructions Chec
12. mes 9 11538 440 001290V viz ULUS 6 vid QNnONO 8 vld voz 1304 L tld IVAN 98 vid JOYLNOD AVI3H HSV S vld v vld JOMINOO AVI3M M3lMVIS vid AVI3M 11043 NOWWOO Z vld JOYLNOD AVI3H xnv T3n4 1 14 SNOILOSNNOD vid ON 11075 NOWWOO 9 14 ON AVI3N G ld ON AVI NAY b ld ON 110735 NOWAOO g eld Linvs NOWWOO NOWWOO Ebd SNOLLOANNOO 14 davoga AVI3H vv 8N Ov 6A LAGNI OV LL ZA 1 Ov 1 17 SNOIIO3NNOO SIF 99 LNdNI ONIONIM Xnv 9 914 65 914 4 SANIN 0135 919 SS ONIGNIM Xnv 6 914 INO Aviad 2 914 9 SMa G13 1 91 SNOILOSNNOS 917 6 4 103135 YIMOd SNONNILNOD 2 4 1 4 SNOILOSNNOO 24 2 6 99 O N 8 2 1 94 2 9 84 QNnON9 9 84 O N 26854 OXY 2 94 1 54 SNOILOSNNOO Sd axl 66 14 ANNOYS 14 NO 66 14 ANNOY 26 14 NNSIS HOSN3S JYNSSIYd 18 14 5 YOSNSS 55384 08 14 HOSN3S HA 62 14 6501 13 31 INY1009 82 14 ANNOYS 10 14 2 4015 14 15 92 14 dOlS IMV
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14. zo 181 i 1 Stde en 1 14 o 9 01 18 6 G Ld 958 1d SS3N HVH 3NION3 8 514 8 14 4 9 Gld 239 1d 14 ld JOYINOD TINA ld N0 9 2 614 Inv NONNOD 2 914 NZE Ed LOA WEA 1 19 2 4 01 614 3398VHO ng AN3LIVB Section 8 Wiring Diagrams 115 Figure 8 7 Schematic Diagram Single Phase 8 5 12RES w ADC RES Controller ADV 7592 TP 6196 10 09 L 2 a 29 A0V Lam mel OWS 534 21 58 OUVW3HOS CADSR NOU 10 BE SSW TY So HA M 2009 ISAN ONY THON SI NAYO SIL FS UTHON SAISIS O2 revzs v 335 60 1 8 100 9 v I33HS 335 60 02 2 zeree z 80 82 01 189998 CES ava YATIONLNOD 0012 OAV 534 MM 21 08 WEA olny
15. 30 ONY NOSO SIKL VSN 709 IM UHOM SNAISAS an aman OD H3 11HO3 we mr mur E S 89 AQY 335 5 N04 AJA TIS 5 ASN H3HSVM YVIS 7 MINIS SALON gt YOL VOL 1d 983 3unoss 1HM h8 NIL Nol 99 vO YOL ANIONS 5 4 319NIS 686 1385 5 39 X04 310N E W3ONVHO 59 C gt 583 N 335 AINO SZHO 193NNOO LON OG 193NNOO LON Od svo dl 403 LON 00 N 01 S9 103NNOO SV9 TWYNLYN OZHO 3dAL 1304 ONINLL NOLLINSI NOILONAF 5 9 41 Ad ANd N YOL leus VOL 983 N YOLON N3dd3ls NIS MOlvIS 115 FINGOW 1 455 QION310S SS 5 NS NilNVIS WS Q3T1041NOO MOS SOWANSINI AVI 193NNOO MOIND 30193NNOO dn MOld OLNOWN dN HOLIM
16. H3JTIOHINOO 208 2 14 O3IVINSNINN 15 n m zNOOD 017 XETT 8 0 2 19 lve FIN ss3 96 05 SIN 918 N WL NOI SN 8 114 9N TN EL lld 1 1 114 ZN ZA Ez id IN zl zal t n 99 2553 1 2 zm em 14 N 04 244 9N 9 N n 11 14 NN 21 14 1v8A 01 14 wd 120 zu 13535730 u HOLIMS 01 8 5 66 04 sm 99 04 S 0 22509 519 a3ivinsNiNn 9 05 00 Z L 8 20 8A 1 Nid SNOILO3NNOO 114 SNOILO3NNOO 64 7 99 Vz v 84 vi 2 94 8 2 1 84 82 1 SNOILOANNOD vt HOLIMS WEA HOLIMS HOLIMS iz ena oc NI dN 15 INOOD 91 L 3 N SNOMOANNOD 14 T 9 L 8 Figure 8 14 Point to Point Wiring Diagram Three Phase 12TRES w ADC RES Controller GM63546 Sheet 3 TP 6196 10 09 122 Section 8 Wiring Diagrams Appendix Abbreviations The following list contains abbreviations
17. sz 9d 22 2 94 oz 6l 2 19 SNOILO3NNOO 14 5 2 Figure 8 10 Point to Point Wiring Diagram Single Phase 8 5 12RES w ADC 2100 Controller GM29358 E TP 6196 10 09 118 Section 8 Wiring Diagrams 2 1 S 9 L 8 1946709 32 W3TIOHINOO 002224 90 1 8 WE ame LNSIY 21 19 59 9 INS33 MM 1 8 S ABQNVIS L TRS NOUNS 0 OE 0 TW vane x ok OO HLM ROBIN M 0850 10N ISAN ky 18040843 S SHL VST 9709 IM UNHON SNAISAS NIMOA v OD zano peor 96 335 5 5 5 3SN 15 F M3HOS 2100 983 3uno3s 3NION3 uy VOL NOI pi 3SvHd 319 5 468G AQV 335 SNOLLO3NNOO MOIVH3JN39 310N 1 15 48 814
18. 1 19 BA gy ONS 8 7IOMINOO ATH 174 WOO 2 9 44 20 48 14 INO NOWNOO 4 NLL 4 l id INO 002220 22 19 le N 34 Zid 21 20 ALINE Figure 8 4 Schematic Diagram Single Phase 12RESL RESM1 w DC 2200 Controller ADV 7296A TP 6196 10 09 112 Section 8 Wiring Diagrams 2 962 9ATHOSUAN 7 7 INS3H M3TIOHINOO 002234 LAS3H 21 ABQNVIS 1 002220 13838 440 vv 8A Ov 4 Ov 11 INdNI Ov 1 81 SNOILOSNNOO 917 99 LNdNI ONIGNIM 9 94 3 N G 98ld 4 SANIN 2 91 99 1ndNI ONIGNIM 91d 110 HSYl4 2 914 9 smd INYA 0134 1 914 SNOILO3NNOO 6 99 8 2 94 9 4 cezsd 98 44 aX 26264 4 4 9 1 99 5 Sd 86254 66 14 v ld NO 68 14
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20. 127 Appendix E Common Hardware List 128 TP 6196 10 09 Table of Contents 5 6196 10 09 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ 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 operat
21. SS YOLON 31314416 WS 0311081 2 NOOMIS NOS QMVOB AVI3M 193NNOO YONO NOJO oma HOLIMS 3YNSS3Yd WO MOT 401 GALS 01 X08 YSTIONLNOD O1 AVI3H GY JOYLNOD NOI ANNOY XOB N3TIONINOO ONS 3NWA TANA Ad 3snj 4 M3ON3S 3univH3dW3L 1 00 SLO 4 WLISIG 150 Da 80 ON3931 W3TIOMINOO AINO TVILN3GIS3H mel 7 7 7 8 meo LAS3H 21 534 108856 15 961 Hse FIONIS 8 1335 5 3 MOIVH3N3O 310N AVI 035 870 Q33dSH3AO Aviad 7035 8 1 64 3SN3S Ov 035 01 0344 035 Ol 193NNOO LON OG 5 9 1 N OL S9 LOANNOO SVO IVYNIYN OvLHO 1303 335 NIWL NOILINSI AINO OFLHO GND 630 1 B3 mix 181 cerge
22. 983 1983 880 v T 006 11 1HM B S9 020 69 avis 11 84 N4 29 05 9 C 083 n 335 NINIL NOILINSI 193NNOO ION svo di OL S9 103NNOO SVO SHO 3dAL n3 NOLIINSI AINO SVS 1VN HOdNVA d i Ai NI YOL 02 1 583 N xog N3dddlS WLS 1 15 FINGOW 45 INVNS MdSS GION310S Y3LYYLS 55 18 16 WS Q3TIOMINOO NOONIS QHVOH AVT3H 3l1ovid3ogM MOS 30193NNOO HOLIMS 553 4 10 MOI 0115 01 X08 YATIONLNOD 401 2 AVI3Y GM M0103NNOO TOULNOD NOI 9 YSTIONLNOD 3NA 1303 ONS Ad asn4 4 3NION3 10983 HONS INVIOOO 30010 M3lv3H 519 85 186118 SVM 9821 0 335 5 YO 0 9 10087 Nou Ass 1015 43
23. Fuel line restriction Inspect fuel lines Fuel lines too long Check fuel line length Section 6 12 1 Air cleaner clogged Replace element Section 2 4 Blown fuse Check fuses F1 F2 and F3 Replace any blown fuses If fuse blows again test generator components Section 6 13 Spark plug s Replace and regap plug s Engine S M Engine overheated hot engine only Check air intake fuel adjustment oil level air inlet outlet Section 2 5 Section 2 2 Section 6 12 TP 6196 10 09 Low oil pressure LOP switch Attempt startup If unit shuts down remove lead from LOP switch and reset controller A successful restart attempt indicates a faulty LOP shutdown switch Note Check engine oil pressure before performing test and or replacing LOP shutdown switch Section 2 2 1 Section 6 11 2 Section 3 Troubleshooting 29 Troubleshooting Chart continued Problem Stops suddenly continued Possible Cause Fuel valve fuel regulator Corrective Action Check regulator valve operation Reference Section 2 Section 7 Engine overloaded Reduce electrical load Loss of generator output voltage to controller Check connections at P15 plug Check continuity of AC sensing leads 11 and 44 Section 8 Magnetic pickup connections Check for loose connections to the mag pickup Section 6 9 Ignition module Test and or replace Engine S M
24. IN HOLMS Nn O N ZZ HOLIMS O N 1 cinsN 10 06 940 dN GaLVINSNINN 15 zov HoS 134 HM 1 020 ZL zN090 uos SLO GALVINSNINN ZS 9L 5 ona o N ci i vi NI if S N EL don SNOIIO3NNOO 114 SNOIIO3NNOO 6d SNOILOSNNOO id 9 L 8 Figure 8 13 Point to Point Wiring Diagram Single Phase 8 5 12RES w ADC RES Controller GM66285 Section 8 Wiring Diagrams 121 TP 6196 10 09 2 ZH OS 00 062 777 8 6 53 MM 21 ABQNVIS 86 ONIMIM Avaovia 09L AUV 33S OUVW3HOS 002 8 NOI S9 59 AINO OrZHO wom NOOD 141 T T 035 3uno3s 9 m MalvaH E LM ZA 104 ved yi d N HI vs 1 553 304 20 0 SM 02 14 Zs3 SSS 17 16 45 105 y ss3a 153 029 6A 8 020 9N090 ZA n 4 3NION3 AINO NOI
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26. b Align the alignment mark on the top of the stator with the slot in the generator adaptor c Route the leads connected to the alternator end bracket through the opening in the base of the alternator frame d Place the end bracket onto the stator assembly lining up the alignment marks on the top of the stator and end bracket Section 7 Disassembly Reassembly 105 Thread the four overbolts with locating washers through the end bracket and into the generator adapter Position the locating tab of each washer to the outer edge of the oblong OBROUND hole on the end bracket See Figure 7 15 The overbolts should be parallel to the outside of the alternator If the overbolts are slanted rotate the locating washer 1 2 turn Do not final tighten the overbolts GM29253B P 1 OBROUND holes for overbolts 4 Figure 7 15 End Bracket 4 Secure the generator set to the skid a Raise the alternator end of the generator set and remove the block of wood from beneath the rear of the engine Lower the end of the generator set and reinstall the screws and washers that secure the vibromount mounting plate to the generator set skid See Figure 7 16 5 Tighten the hardware to the following torques See Figure 7 16 a Tighten the rotor thrubolt to 40 Nm 28 ft Ib It may be necessary to keep the engine flywheel from turning while torquing the rotor thrubolt Tighten the four alternator assembly overbolts t
27. 1 Exhaust outlet 2 Alternator air intake both sides 3 Engine air intake Figure 2 11 Cooling Air Intake and Exhaust 2 6 Exhaust System Remove combustible materials from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a safe distance from the exhaust outlet Check the area periodically for accumulated debris and seasonal grass or foliage Inspect exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks and corrosion Check for corroded or broken metal parts and replace them as needed e Check that exhaust outlet is clear 2 7 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 TP 6196 10 09 Battery electrolyte is 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 p
28. SNMP SPDT SPST spec specs sq 84 54 55 std stl tach root mean square round read only memory rotate rotating revolutions per minute right side remote terminal unit room temperature vulcanization 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 serial number simple network management protocol single pole double throw single pole single throw specification 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 total harmonic distortion 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 unified 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 tran
29. 103135 300W N3MOd 5 2 2 4 2 N 1 4 Zd O N 6 Gd O N 8 Gd O N L Gd 2 9 69 ONnOND S Sd 26454 6 64 OXY 26654 2 54 1 64 5 03 2 Sd QXL 26254 66 14 ANNOYS 8 14 NO IVE S ld 28 14 5 HOSN3S 38065384 16 14 BONNOS HOSN3S 38066384 08 14 MOSN3S MA 62 14 SSO1 13A31 1 1003 82 14 18 14 2 dOlS IMVIS 92 14 1 dOIS 1MVIS 92 14 IWEA 2 14 2 4 28 14 12 14 02 14 QNhON9 YOSNIS 553 61 14 ANNONO 81 14 NOSN3S HA 1 14 QNnOMO 91 14 HOLIMS 3HnSS3Nd 10 61 14 110 HOVL vi ld 100 1 13 3 21 14 NMOGLNHS 21 14 1 NYO TWNYSLXS 11 14 NYO 01 19 HOSN3S 191009 6 14 HOIH HOSN3S dW3l INVIOOD 8 14 SZ 9 01 14 YONYSA09 9 14 09 6 14 81 9 09 14 1 NONWOO 4 114110 2 14 1nO AVI3M 15 1 SNOHO3NNOO YATIONINOD 0012 50 Figure 8 3 Schematic Diagram Single Phase 8 5 12RES w ADC 2100 Controller ADV 6835B E Section 8 Wiring Diagrams 111 TP 6196 10 09 2 9 wa 620107 77 7 INS3H cl 5 Wvubovia RITE ATTEN
30. 6 14 RIAN 8 14 SNOILOSNNOO Sd Gd T la 901 983 1 14 t NIL N N 2 14 NGL 8 4 NOL N N IN see LN lbi 6 91 VIL 18 19 2 eza IM 1 Nid 5 924 ss svi 78 S ON vig 9 LHM 9 9 aHz szr p szn LHM e szr 002200 Sm 515 axivansNiNn 13 583 IN sew c log 224 29 2 ZM 1 65 ael SNOILOENNOO 824 O N se O N ve O N 91 O N 801 O N OO N vl 18 vid NOL 6 og OO N zl 0 82 083 z 8 4 6 ZINSN v 82 JHM 8 SN ON L N 9 3 ez N zz O N z vid vee oz ON NIL 1 SNOII23NNOO 14 7 Figure 8 11 Point to Point Wiring Diagram Single Phase 12RESL RESM1 w DC 2200 Controller 49761 Section 8 Wiring Diagrams 119 TP 6196 10 09 T 4 10 2 2 12 26
31. 9 8 192198 oaov 2 0 Teaze 83108143038 9 18 9 5 1812 SNOLD3NNOO Sid SNOUDANNOD Old id 553 1 8 4 6 11 4 01 s14e 6 0144 0 6 014 8 814 23 8 614 L Sld N gt L ld 9 0 46 9 99 ld 1 8 Ed 1 gt ld IOMINOO T304 6 914 N0 1d NOWNOD Z id 26 814 1V8A 1 14 21 614 B 62262 ROIS 2764 3535 OV 536 Z NMOQINHS 938 3OVLIOA OV 193NNOOSIQ NYO NMOGLNHS Q34vi3 MOT NOSN3S dW3l INVIOOD 41 19 pa y8 7035 6 QNnONO 91 19 4 25 Li HOIH YOSNIS 1 1002 81 19 1HM 1 0035 5 AIGIHNI 035 06 553 4 10 tiesi olo F NMOGINHS Q34v13d 8 64 INO HsYl4 64 SMd MA 6d SANIN 39VLIOA OV 6 14 GNNOYS 01 14 BN Z d01S 14V1S 310W34 6 14 i dOIS INVIS 310W3N 8 14 8 114 INBA Ibid lVBA 1 14 401 Nn 11 14 9 64 INANI 9 XNY yy 18 21 19 pa an 1 64 1NdNI ONIONI
32. M24 3 00 x 90 M24 3 00 x 120 M24 3 00 x 160 M24 3 00 x 200 Hex Head Bolts Full Thread M933 04006 60 M933 05030 60 M933 05035 60 M933 05050 60 M933 06010 60 M933 06012 60 M933 06014 60 M933 06016 60 M933 06020 60 M933 06025 60 M933 06030 60 M933 06040 60 M933 06050 60 M933 07025 60 M933 08010 60 M933 08012 60 M933 08016 60 M933 08020 60 M933 08025 60 M933 08030 60 M933 08030 82 M933 10012 60 M961 10020 60 M933 10020 60 M933 10025 60 M961 10025 60 M933 10025 82 M961 10030 60 M933 10030 60 M933 10030 82 M961 10035 60 M933 10035 60 M933 10035 82 M961 10040 60 M4 0 70 x 6 5 0 80 x 30 5 0 80 35 5 0 80 50 6 1 00 10 M6 1 00 x 12 M6 1 00 x 14 M6 1 00 x 16 M6 1 00 x 20 M6 1 00 x 25 M6 1 00 x 30 M6 1 00 x 40 M6 1 00 x 50 M7 1 00 x 25 M8 1 25 x 10 M8 1 25 x 12 M8 1 25 x 16 8 1 25 x 20 M8 1 25 x 25 M8 1 25 x 30 8 1 25 x 30 M10 1 50 x 12 M10 1 25 x 20 M10 1 50 x 20 M10 1 50 x 25 M10 1 25 x 25 M10 1 50 x 25 M10 1 25 x 30 M10 1 50 x 30 M10 1 50 x 30 M10 1 25 x 35 M10 1 50 x 35 M10 1 50 x 35 M10 1 25 x 40 Part No Dimensions Hex Head Bolts Full Thread continued M933 12016 60 M933 12020 60 M961 12020 60F M933 12025 60 M933 12025 82 M961 12030 60 M933 12030 82 M961 12030 82F M933 12030 60 M933 12035 60 M961 12040 82 M933 12040 60 M933 12040 82 M961 14025 60 M933 14025 60 M961 14050 82 M961 16025 60 M933 16025 60 M961 16030 82
33. Press To enter advanced configuration mode Go to Figure 4 9 or or To proceed to the save mode without entering the advanced configuration mode 5 Go to Figure 4 10 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 2 Shaded boxes show which number the controller display changes when the or down arrow key is pressed Figure 4 8 Configuration Mode system voltage frequency unit configuration and engine type parameters 42 Section 4 ADC 2100 and DC 2200 Controllers TP 6196 10 09 Pressing the up arrow key at the Adnc display See Figure 4 8 puts you into the Advanced Configuration Mode Press To set the engine data input type to Ed05 To enter battery voltage selection mode To toggle between 12 and 24 VDC Set this parameter to 12 VDC To enter communications selection mode To set the communications parameter to To enter SAVE mode Go to Figure 4 10 SIAV Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Figure 4 9 Advanced Configuration Mode engine dat
34. Section 6 12 Low output or excessive drop in voltage Generator overloaded Reduce load Incorrect controller configuration Check and adjust the controller configuration parameters Section 4 5 or 5 5 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 4 5 3 or 5 6 Alternator or control system Perform separate excitation procedure to isolate problem to the alternator or the control system Section 6 2 SCR module Check wiring and connections to the SCR module Check auxiliary winding fuse F1 Replace SCR module and test voltage Section 6 13 Section 6 8 Controller Check controller settings Check controller fuse wiring and connections Before replacing controller replace SCR module and test voltage Section 4 5 or 5 5 Section 6 8 Rotor open grounded or shorted windings Test and or replace Section 6 4 Stator open grounded or shorted windings Test and or replace Section 6 3 Brush connection Check for loose brush connections Check the resistance through the brushes Resistance through the brushes should be low 0 1 0 2 ohms without meter lead resistance Section 6 6 Low engine speed causing voltage roll off Check system voltage frequency Uu and engine type Ec parameters Adjust engine governor speed Troubleshoot engine Section 4 5 or 5 5 Section 6 9 or 6 10
35. Service Residential Commercial Generator Sets Models 8 5RES 12RES 12RESL 12RESM1 12RESNT 12TRES Controllers ADC 2100 ADC RES DC 2200 DC RET P2901 mum POVVER SYSTEMS NATIONALLY REGISTERED KOHLER POWER SYSTEMS Table of Contents Safety Precautions and Instructions 7 Introduction khac I 11 List of Related Materials 11 Service ape sasa aipa a eee ee RETE MEE ep arene are 12 Section 1 Specifications 13 1 1 Ded hansen aed 13 1 2 Controller Specifications 13 K3 Engine ona Rr RERO Er a t beg e gts 13 1 4 Engine Specifications 14 1 5 Torque Specifications assesses RR ye Rd 14 1 6 Alternator Specifications 15 1 VIEWS cuui bete pup ER En Ua atta pun aati 16 Section 2 Scheduled 19 24 Service Schedule ere RI DEGREE RAA EARS 19 2 2 Lubric
36. Supply Pressure Fuel Type kPa in water column Natural Gas 1 2 2 7 5 11 LP 1 7 2 7 7 11 Figure 6 34 Fuel Supply Pressure 1 Hose fitting 2 Plug 3 Fuel metering valve factory sealed do not adjust 4 Secondary regulator 6 12 4 Fuel Conversion The multi fuel system allows conversion from natural gas to LP vapor or vice versa in the field while maintaining emissions standard compliance A trained technician or authorized distributor dealer can convert the fuel system Two fuel connections on the fuel metering valve allow field conversion between natural gas and LP vapor The fuel metering valves are factory set and sealed to comply with applicable emission standards and to provide the best possible hot and cold starting Regulator Side View TP 6196 5 Fuel solenoid valve 6 Fuel inlet 1 2 in NPT 7 Fuel lockoff do not adjust 8 Inlet pressure check location Figure 6 35 Fuel Regulator Fuel Metering Valve and Fuel Solenoid Valve 94 Section 6 Component Testing and Adjustment TP 6196 10 09 Fuel Conversion Procedure Use the following procedure to convert from natural gas to LP vapor See Figure 6 36 for the fuel system component locations WARNING P 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
37. 1 914 dvi 519 FE AS IE Dg 01 19 81 19 IHM 5 84 gos D z 91d ZN SN ae 81 119 9 14 9N ez la IN ANIONS 9 N N oz 23 9N 9 N 11 14 NN 81 14 1v8A 01 14 p 13538 430 1 5 114 Lov uos zov uos 29 05 9N090 20 5 123 03 64 z zz 2 iz n 02 940 5 21 8 810 91 i 2 i Nid 5 Id HOLIMS LBA 5 oinv 1105 0 ZINSN 2 9 N ao 9 2 8 Figure 8 12 Point to Point Wiring Diagram Single Phase 12RESL RESM1 RESNT w DC RET Controller GM52471 C TP 6196 10 09 120 Section 8 Wiring Diagrams 58822999 VIIN3GIS3H M3 Nvsovid 2h xen C6SZ AQV 335 5 04 QQA 6 124 180 eg 2 04 18 ZN 8 124 O Se 9 19 9 7128 MEET M 1 T 7
38. 2 Controller circuit board location Figure 5 17 Relay Board Location inside controller junction box 5 8 1 Relay Board Troubleshooting First check for loose connections Check the relay board harness connections to the relay board control board and engine harness See Figure 5 18 Figure 5 19 and Figure 5 20 Check for loose customer connections to terminal strip on the relay board See Figure 5 18 and Figure 5 21 Check the harness and wiring for open circuits or shorts Replace the harness or customer wiring as necessary Check that the ratings of the customer s connected equipment do not exceed the contact specifications shown in Figure 5 22 An LED is associated with each relay See Figure 5 18 The LED indicates power to the corresponding relay If the LED is illuminated but the relay is not activated the relay is faulty The individual relays are not replaceable If one or more relays are faulty replace the entire RIB See Section 5 8 2 Relay Board Replacement Procedure TP 6196 10 09 K1 common fault CF relay LED1 for K1 CF relay Connect P14 from RIB harness GM52639 to P14 on the relay board LED2 for K2 aux run relay K2 auxiliary run relay Connect customer equipment to TB1 14 AWG max Figure 5 18 Optional Relay Board
39. 5 Shim 6 7 Correctly positioned brush 8 Incorrectly positioned brush 1 Brush holder 2 Slip ring 3 Brush es 4 Retainer wire Figure 6 10 Brush Assembly TP 6196 10 09 6 7 Voltage 6 7 1 Voltage Regulation Voltage regulation is performed by the Advanced Digital Control ADC and the SCR module The ADC monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module 6 7 2 Voltage Adjustment The factory sets the voltage for correct generator operation under a variety of load conditions Usually the voltage needs no further adjustment Adjust the voltage when necessary according to the following procedure The adjustment procedure requires a meter that can measure voltage and frequency Use the ADC controller to adjust the voltage gain and volts Hz Refer to Section4 5 for instructions to adjust each setting and save the changes using the controller keypad Note Be sure to save your settings as instructed The ADC controller will time out and exit the adjustment mode after approximately 1 minute if no buttons are pressed Any unsaved changes are discarded if the controller times out before the settings are saved Voltage Adjustment voltage Adjusts generator output Gain Stability Adjustment circuitry to reduce light flicker Fine tunes regulator Volts Hz Adjustment Determines frequency Hz at which generator output voltage begins to
40. Carburetor mounting holes Figure 6 20 Stepper Motor and Carburetor Check that the carburetor throttle linkage is connected to the stepper motor as shown in Figure 6 20 Y Check for broken or loose wiring or connections and other items in step 2 Y Check stepper motor operation at startup Does it move to fully open and then move V s to and stay in the fully closed position No See step 3 Check the magnetic pickup See steps 4 6 Disconnect the magnetic pickup and check the stepper motor operation again See steps 7 9 Checkthe magnetic pickup connections to the controller Check the stepper motor connections to the controller P1 17 P1 18 and P1 29 See step 10 Check the stepper motor coils See step 11 Troubleshoot the controller See step 12 Figure 6 21 Governor System Operation Test Procedure Summary Section 6 9 4 TP 6196 10 09 Section 6 Component Testing and Adjustment 85 Governor System Operation Test Procedure 5 If the voltmeter displays less than 1 75 volts AC check the air gap as described in the following steps before replacing the sensor Verify that the magnetic pickup air gap is 0 5mm 0 020 in Measure the air gap at 3 or 4 places to get an accurate reading See Figure 6 23 1 Verify that the carburetor throttle linkage is connected to the stepper motor as shown in Figure 6 20
41. Cooling system 14 Section 1 Specifications Air cooled 1 5 Torque Specifications Torque Specifications Nm ft Ib 8 5 12 kW Alternator overbolts 7 5 Alternator thrubolt 40 28 Cylinder head nuts 30 40 7 Generator adapter screws 40 28 Muffler flange bolts 24 17 7 Oil filter 5 7 9 0 4 2 6 7 Spark plug 24 4 29 8 18 22 TP 6196 10 09 1 6 Alternator Specifications Alternator Specification Frequency Hz 8 5 12 kW 1 phase 12TRES 3 phase 50 60 Phase Single Phase Number of leads 4 Excitation method Static Excited Voltage regulator type Digital Coupling type Direct Thrubolt torque Nm ft Ib 40 28 Overbolt torque Nm Ib 7 60 Insulation rotor and stator Epoxy varnish vacuum impregnated Class 180 H Winding material Copper Bearing number and type 1 replaceable ball Circuit protection Controller Aux winding Generator AC output 10 amps 20 amps Dependent on voltage configuration Rotor resistance ohms cold 4 0 4 2 Stator resistance ohms cold Single Phase Leads 1 2 3 4 Three Phase Leads 1 4 2 5 3 6 7 10 8 11 9 12 Leads 11 44 55 66 0 07 N A N A 0 18 0 14 N A 0 70 0 15 Stator output voltage with separately excited rotor using 12 volt battery minimum Single Phase Leads 1 2 3 4 Three Phase Leads 1 4 2 5
42. Engine starting battery location battery purchased separately DSAI ground screw Starter solenoid Positive battery connection Negative battery connection Figure 1 1 Generator Set Service View 12 kW Model with ADC RES Controller 16 Section 1 Specifications TP 6196 10 09 1 Emergency stop button 2 Field connection terminal block and circuit breakers 3 Cable inlet area Figure 1 2 Additional Components 3 Phase Models TP 6196 10 09 Section 1 Specifications 17 0 18 17 16 15 27 5 P PN 28 4 eL ap 8 4 8 T a Starter non service side Enclosure Muffler Oil check Oil fill Air cleaner Spark plug locations both sides Controller Generator set master switch RUN OFF RESET AUTO Nameplate Line circuit breaker Battery charger Air intake Engine starting battery location Oil drain hose High engine temperature HET sensor located on non service side Oil drain valve Section 1 Specifications Fuel System Detail Oil filter Air intake alternator Exhaust Spark arrestor not visible in this view Relay interface board RIB SCR module Digital spark advance module leads DSAM leads ignition timing Multi fuel block Secondary fuel regulator assembly Fuel solenoid valve Starter solenoid Positive battery connection Sta
43. M933 16030 82 M933 16035 60 M961 16040 60 M933 16040 60 M961 16045 82 M933 16045 82 M933 16050 60 M933 16050 82 M933 16060 60 M933 16070 60 M933 18035 60 M933 18050 60 M933 18060 60 M933 20050 60 M933 20055 60 M933 24060 60 M933 24065 60 M933 24070 60 M12 1 75 x 16 M12 1 75 x 20 M12 1 50 x 20 M12 1 75 x 25 M12 1 75 x 25 M12 1 25 x 30 M12 1 75 x 30 M12 1 50 x 30 M12 1 75 x 30 M12 1 75 x 35 M12 1 25 x 40 M12 1 75 x 40 M12 1 75 x 40 M14 1 50 x 25 M14 2 00 x 25 M14 1 50 x 50 M16 1 50 x 25 M16 2 00 x 25 M16 1 50 x 30 M16 2 00 x 30 M16 2 00 x 35 M16 1 50 x 40 M16 2 00 x 40 M16 1 50 x 45 M16 2 00 x 45 M16 2 00 x 50 M16 2 00 x 50 M16 2 00 x 60 M16 2 00 x 70 M18 2 50 x 35 M18 2 50 x 50 M18 2 50 x 60 M20 2 50 x 50 M20 2 50 x 55 M24 3 00 x 60 M24 3 00 x 65 M24 3 00 x 70 Pan Head Machine Screws M7985A 03010 20 M7985A 0301 2 20 M7985A 04010 20 M7985A 04016 20 M7985A 04020 20 M7985A 04050 20 M7985A 04100 20 M7985A 05010 20 M7985A 0501 2 20 M7985A 05016 20 M7985A 05020 20 M7985A 05025 20 M7985A 05030 20 M7985A 05080 20 M7985A 05100 20 M7985A 06100 20 M3 0 50 x 10 M3 0 50 x 12 M4 0 70 x 10 M4 0 70 x 16 M4 0 70 x 20 M4 0 70 x 50 M4 0 70 x 100 5 0 80 10 5 0 80 12 5 0 80 16 5 0 80 20 5 0 80 25 5 0 80 30 5 0 80 80 5 0 80 100 6 1 00 100 Flat Head Machine Screws M965A 04012 SS M965A 05012 SS M965A 05016 20 M9
44. QNnOND 26 14 MNOIS HOSN3S 3M SS3Hd 18 14 5 MOSN3S 34155359 08 19 62 14 O N 82 14 ONnOND 12 14 Z 4015 1 15 92 14 dOLS IMVLS 62 14 IVA vZ ld ONnOND 62 14 089 22 14 12 14 02 14 2 QNnONO MOSN3S 34055384 61 19 81 14 voz mE O N 11 14 QNnOMD 91 14 EM ANON NOLL HOLIMS 3MnSS3Hd 10 61 14 JOMINOO AvI3H MilMVIS O N 1 1 JOMINOO AvI3M Linvd NONWOO 100 Avi3s 1304 61 14 AVTSY NOY 1303 21 14 SNOUDINNOD Fld 11 14 SNOIIO3NNOO tid 01 18 YOSNAS 1 1002 6 14 5 35 dW3l 1 100 8 14 41 14 9 14 85 14 id 82 14 82 14 1 YSLYVLS l id 5 14 QBHVOH 3OVJH3INI AVTSY M3TIOHINOO 002200 Figure 8 5 Schematic Diagram Single Phase 12RESL RESM1 w DC 2200 Controller ADV 7296B Section 8 Wiring Diagrams 1138 TP 6196 10 09 2 tn d gem OUVA3HOS ml ona NOUNSAN 80 NOSIO 20 SU TW L me won IN NOULDINNOD COS 38 ION ISAN ovana NY 02 ONV SIKL YS 77086 IM TION SNAISAS 3 THON EE 3NI5N3 H3ddils WLS 1416 GIONFIOS
45. YOLOW YSLYVIS WS 33141034 GFMOYINOD NOONIS 305 3OVJN3lNI LOJNNOD NOID dObiold OUENOWN dN HOLIMS 53 10 401 GALS O1 Y3TIONLNOD 01 JOXINOD ANNOY N3TIOMINOO ONS 3AWA TANA Ad asna 4 SYNLVYadNSL INVIOOO 510 30010 09 M3 v348 80 0937 5384 MM 21 98 ABQNVIS 1 Hsnad 193NNOO LON 00 103 0 LON 00 5 9 41 103 LON OQ N OL 89 1O3NNOO Svo OZHO SdAL 1313 NOOD3 NOI puc 3NION3 AINO OCHO QCON4 RED BLK WHT 335 yl NOILINO 8 8 8 d 3NION3 AINO SCHO 1 5 1335 SNOLLO3NNOO 31ON AV130 3035 0 13345 3 0 Aviad 935 S 035 01 0334 3SN3S OV Aviad 035 0 NMOGInHS 81 4 2 94 yu yido 9d no a s San OH 1 9 4 8 9 7134 99 7134 99 9 914
46. fuel conversion procedure moving the hose fitting to the natural gas port and plugging the LP port For the 12kWmodel disconnect the DSAI leads for LP vapor See Figure 6 37 6 12 5 Digital Spark Advance Ignition The digital spark advance ignition DSAI on the Model 12kWoptimizes the engine timing for the selected fuel natural gas or LP The location of the DSAI leads is shown in Figure 6 36 Connect the DSAI leads in the air intake compartment together for natural gas fuel Disconnect the leads if LP is used See Figure 6 37 See the engine service manual for DSAI service information 6 12 6 Fuel Metering Valve Adjustment The fuel system is factory adjusted to comply with applicable emission standards and to provide the best possible hot and cold starting Note Adjusting the fuel metering valves on emissions certified generator sets may void the emission certification Use a universal exhaust gas oxygen UEGO sensor to check the fuel mixture after replacing the fuel regulator carburetor or silencer Use the following procedure to check the fuel mixture after the engine has reached normal operating temperature The fuel metering valves are sealed to prevent field adjustments If the fuel metering valve requires adjustment do not break the seals on the fuel metering valve Obtain a new fuel metering valve from the manufacturer and replace the sealed valve with the new part See Figure 6 36 for the fuel metering valve l
47. program version number will be displayed on the controller display For example 01 04 will be displayed for program version 1 04 The DC 2200 controller application program version number is displayed at controller powerup Section 4 ADC 2100 and DC 2200 Controllers 41 Controller Configuration Mode Hold the Select button Display Move the generator set master switch to the RUN 0 position The generator set engine will 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 To set the system voltage and frequency See Figure 4 7 for settings To step to the next parameter unit configuration Uc To set the unit configuration setting to UcO1 if necessary To step to the next parameter engine type Ec To set the engine type to if necessary To step to the next parameter advanced configuration mode or save mode selection Press Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communications
48. sensor Remove the oxygen sensor from exhaust manifold Apply a small amount of antiseize compound to exhaust plug and reinstall the plug into the exhaust manifold Check that the generator set master switch is in the OFF position Reconnect the generator set engine starting battery negative lead last Reconnect power to the battery charger OOO DODD 8 gt OOOS 9 4 Battery power supply connection 2 Digital voltmeter DVM connection 3 Air fuel control module connection 4 Oxygen sensor connection Figure 6 40 UEGO Sensor Interface Harness GM28981 Electrical Connections TP 6196 10 09 Section 6 Component Testing and Adjustment 97 6 13 Fuses Three fuses are located the junction box next to the controller display keypad Early models may have the fuses located in the wiring harness See Figure 6 41 Another 10 amp fuse protects the battery charger Part Number 292937 Auxiliary Winding 20 amps Relay Interface Board 10 amps 223316 Controller 10 amps 223316 Battery Charger 10 amps 223316 Figure 6 41 Fuses Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 3 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts 6 14
49. the generator set output voltage and frequency If the output voltage or frequency needs adjustment use the voltage and frequency adjustment procedure in Section 6 7 2 and the controller voltage and speed adjustment instructions in Section 5 6 Also see the frequency adjustment procedure in Section 6 9 5 A DANGER ia Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure Controller Replacement Procedure 1 Remove the service door and the front panel to access the controller junction box See Figure 5 23 2 Place the generator set master switch in the OFF position 3 Disconnect power to the battery charger 4 Disconnect the generator set engine starting battery negative lead first 70 Section 5 ADC RES and DC RET Controller ADV 7466C 1 Service side door 2 Front panel Figure 5 23 Enclosure Roof and Door Logic Board Replacement 5 Note the connections on the logic board and then disconnect See Figure 5 24 6 Pull the old board straight off the mounting standoffs 1 52541 P8 switch membrane connection P11 to engine harness and optional relay board if equipped P12 not
50. 0 sere 0300V 124 024 181 1 SNOUDINNOD 3NOISnO 1 0 8 18 Sid 9 8 SNOUSSNNOD Old id 9 0 62262 SNO MAN SS3NNVH 3NIN3 OL vis 68 ss 59 v 0 09 M 983 N 48 8 114 244 180 v c 180 11 181 11 41 89 1 1 15 1 81 18 21 41 283 1415 v T gus Yy 1Y1S 01 181 01 01 9 91 1 5 99 Nd 4 898 i 181 QNS ss dvi 1 Nid SNOILO3NNOO 914 AVT3H MH3lNVIS na 1416 11 3 11S v 94 583 01 14 6 112 2 14 NOL 21 819 1 21 9 114 OO N o 01 6 2 234 8 Evla NOL NL z vid SNOILO3NNOO vid NOISE SNOILO3NNOO fld MJTIOMINOO 203 6 020 983 583 6 914 Gd 19 VOL
51. 2 Look for broken or loose wiring or plug connections if the stepper motor moves erratically Check the condition of the throttle linkage and verify that the throttle plate closes completely a Stop the generator set Remove housing panels as required to gain access to the front of the engine 3 Check the operation of the stepper motor at b Remove the engine blower housing startup c Use feeler gauge to check the gap The gap If the throttle moves to the fully open throttle should be 0 5 mm 0 020 in position and then steps to and remains in the fully closed position the engine speed input is d Adjust the air gap if necessary by loosening probably missing The engine starts and then the locknut and turning the pickup See shuts down on an overspeed fault Proceed to Figure 6 23 step 4 to check the magnetic pickup e Hold the pickup in position and retighten the b Ifthe throttle linkage moves erratically or not at locknut all at startup proceed to step 7 to check the Stepper motor f Verify the magnetic pickup air gap after tightening the locknut 4 Verify the operation of the magnetic pickup by connecting a voltmeter to the magnetic pickup g Reinstall the engine blower housing leads See Figure 6 22 Ifthe air gapis correct the voltage should be 1 75 volts AC minimum during h Reinstall the junction box and housing panels engine cranking removed to gain access to the front of the engine 6 Aft
52. 2 1 4 20 Spiralock X 465 10 1 4 20 1 75 6024 3 7 a 4x 2 6210 6 1 4 28 Spiralock X 465 11 1 4 20 x 2 00 2 a x 2 6210 7 5 16 18 Spiralock X 465 12 1 4 20 x 2 25 A 21 650 X 6210 8 5 16 24 Spiralock X 465 14 1 4 20 x 2 75 OVEM i X 6210 9 3 8 16 Spiralock X 465 21 1 4 20 x 5 00 X 129 15 1 2 13 x 75 X 6210 10 3 8 24 Spiralock X 465 25 1 4 28 x 38 129 17 1 2 13 1 00 6210 11 7 16 14 Spiralock X 465 20 1 4 28 x 1 00 X 129 18 1 2 13 x 1 25 X 6210 12 1 2 13 Spiralock TOR 1 129 19 1 2 13 1 50 6210 15 7 16 20 Spiralock 125 33 5 16 18 50 129 20 1 2 13 1 75 6210 14 1 2 20 Spiralock X 125 23 5 16 18 x 62 X125 3 5 16 18 x 75 X 129 21 1 2 13 x 2 00 129 22 1 2 13 2 25 X 85 3 5 8 11 Standard 2 2 E 15 X 129 23 1 2 13 x 2 50 X 88 12 3 4 10 Standard 125 5 16 18 x 1 X 129 24 1 2 13 x 2 75 X 89 2 1 2 20 Standard X 125 24 5 16 18 x 1 25 X 129 25 1 2 13 x 3 00 X 125 34 5 16 18 x 1 50 125 25 5 16 18 x 1 75 X 129 27 1 2 13 x 3 50 129 29 1 2 13 4 00 Washers X 125 26 5 16 18 x 2 00 X 129 30 1 2 13 x 4 50 Bol 230578 5 16 18 x 2 25 463 9 1 213 x 5 50 olt X 125 29 5 16 18 x 2 50 j Part ID OD Thick Screw 125 27 5 16 18x 2 75 1 243 600 125 28 5 16 18 3 00 129 51 1 2 20 75 25 46 125 250 022 4 125 22 5 16 18 4 50 129 45 1 2 20 1 25 25 9 156 375 049 6 125 32 5 16 18 5 00 129 52 1 2 20 1 50 X 25 48 188
53. 3 6 7 10 8 11 9 12 11 44 55 66 132 V N A N A 115 V 264 V N A 145 V 150 V Rotor field voltage current readings at rated output voltage hot No load Full load 12 V 2 0 amps 14 V 2 8 amps 47 V 7 4 amps 78 V 11 5 amps Brush length new 19 05 mm 0 75 in Most ohmmeters do not give accurate readings when measuring less than 1 ohm The stator can be considered good if a low resistance reading continuity is obtained and there is no evidence of shorted windings discoloration Do not confuse a low resistance reading with a reading indicating a shorted winding TP 6196 10 09 Section 1 Specifications 15 1 7 Service Views See control detail Muffler Oil check Oil fill Air cleaner Controller user interface switch membrane Generator set master switch RUN OFF RESET AUTO Load circuit breaker 1 phase models Fuses RS 232 connector for application program updates Field connection terminal block location Spark plug locations both sides Oil drain hose Oil drain valve Oil filter Exhaust 19 ADV 7466 Control Detail Fuel System Detail Equipment ground Starter relay Battery charger DSAI lead location Fuel block Gas regulator assembly Fuel solenoid valve Fuel inlet Air intake
54. 55 24 Ca S 1 td D 11 181 1144189 21 181 21 11 289 ayol voc 8 11d 239 vd id 01 181 01 01 ASS i ld 11415 1 rivis 1VIS 189 1 cov wos 99 8 94 591 38 0 9 181 wis 88 SS 0 983 ZN 983 NOL SS dvi f Nid SNOIIO3NNOO 914 983 SOLON N3ddils WIS Molvis 1415 SINGON wNvds LYWNS MdSS 5 i3iNVIS SS s3lNVIS WS Q3T1081NOO NOONIS 805 QMVO8 3OVJM31NI AVI3M 88 193NNOO f No20 30193NNOO dNX ld OU3NOVA dM HOLIMS 38055384 TIO MOT 401 GALS O1 Y3TIONLNOD O1 1 GNNOYS HJTIOMINOO ONS 3NIVA 1303 Ad asni 4 QNnONO 2018 ANIONS 983 3ON3S INYIOOO SLO 1 910 1450 30010 a 1082 QON3931 5798 1 15 1915 11 14 vis SS3NYVH 3NI9N3 OL Deas 2515 j
55. 8 1 25 60 8 1 25 70 8 1 25 70 8 1 25 75 8 1 25 80 8 1 25 90 8 1 25 95 8 1 25 100 8 1 25 110 8 1 25 120 8 1 25 130 8 1 25 140 8 1 25 150 8 1 25 200 10 1 25 405 10 1 50 40 10 1 50 45 10 1 50 50 10 1 25 505 10 1 50 55 10 1 50 60 10 1 50 65 10 1 50 70 10 1 50 80 10 1 25 805 10 1 50 90 10 1 50 905 10 1 50 100 10 1 50 110 10 1 50 120 10 1 50 130 10 1 50 140 10 1 50 180 10 1 50 235 10 1 50 260 10 1 25 330 12 1 75 45 M12 1 25 50 12 1 25 505 12 1 75 50 12 1 75 505 12 1 75 55 12 1 75 60 12 1 75 605 12 1 75 65 12 1 75 75 12 1 75 80 12 1 75 90 12 1 75 100 12 1 75 110 Head Bolts Partial Thread continued 960 16090 60 931 16090 60 931 16100 60 931 16100 82 931 16120 60 931 16150 60 931 20065 60 931 20090 60 931 20100 60 931 20120 60 931 20140 60 931 20160 60 931 22090 60 931 22120 60 931 22160 60 931 24090 60 931 24120 60 931 24160 60 931 24200 60 Dimensions M16 1 50 x 90 M16 2 00 x 90 M16 2 00 x 100 M16 2 00 x 100 M16 2 00 x 120 M16 2 00 x 150 M20 2 50 x 65 M20 2 50 x 90 M20 2 50 x 100 M20 2 50 x 120 M20 2 50 x 140 M20 2 50 x 160 M22 2 50 x 90 M22 2 50 x 120 M22 2 50 x 160
56. Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 7 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
57. Engine S M Light flicker Voltage stability gain setting Check and adjust the voltage stability gain setting using the controller keypad Section 4 5 3 High output voltage TP 6196 10 09 Incorrect controller configuration Check and adjust the controller configuration parameters Section 4 5 or 5 5 Incorrect controller voltage settings Check and adjust the controller voltage settings Section 4 5 3 Engine speed too high Check engine speed using tachometer or frequency meter Adjust governor as necessary Section 6 9 or 6 10 Loose voltage sensing connections Check connections stator leads 11 and 44 and P15 controller connection Section 8 SCR module Check wiring and connections to the SCR module Check auxiliary winding fuse F1 lead 55 Replace SCR module and recheck voltage Section 6 8 Section 6 13 Section 6 8 Controller Check fuses wiring and connections Before replacing controller replace SCR module and test voltage Section 4 9 Section 3 Troubleshooting 31 Troubleshooting Chart continued Problem No output voltage Possible Cause AC output circuit breaker open Corrective Action Check for AC voltage on the generator side of circuit breaker If there is AC voltage on the generator side of the breaker then a problem in the load circuits is causing the line circuit breaker to trip Check for and correct short circuits
58. Starter Relay The starter relay contains an internal diode across the relay coil See Figure 6 42 Continuity checks across the coil terminals will show continuity low resistance in one direction and an open circuit in the other Figure 6 43 shows the starter relay connections 86 A 85 SCHEMATIC SINGLE POLE DOUBLE 1 Figure 6 42 Starter Relay 98 Section 6 Component Testing and Adjustment Relay Terminal Lead Figure 6 43 Starter Relay Connections 6 15 Continuity Checks 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 Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment TP 6196 10 09 To further check generator set components disconnect iri Zero ohms continuity across the battery and remove wiring harness plugs from the RUN and COM terminals controller circuit board Use an ohmmeter to check the continuity of the components listed in Figure 6 45 Also see Section 8 Wiring Diagrams Master Switch in Figure 6 45 gives resistance readings for functi
59. Starting Sequence Master Switch Moved to RUN 56 Section 5 ADC RES and DC RET Controller 5 3 3 Running Sequence When the engine speed reaches 750 rpm the crank relay deenergizes and the crank LED turns off When the output voltage on leads 11 and 44 reaches about 30 VAC the flash relay deenergizes and the flash LED turns off 5 3 4 Stopping Sequence Master Switch Moved to OFF RESET Place the generator master switch in the OFF RESET position The run relay deenergizes and the run LED 1 turns off The generator set stops 5 3 5 Stopping Sequence Remote Stop The generator set master switch must be in the AUTO position for remote start stop by a remote switch or automatic transfer switch When the remote start contact across leads 3 and 4 opens the run relay deenergizes and the run LED 1 turns off The generator set stops 5 3 6 Standby Mode When the generator set master switch is in the AUTO position the controller is in standby mode Engine runtime hours are shown on the display A remote start signal contact closure will start and run the generator set If there is no start signal for 48 hours the controller goes into sleep mode 5 3 7 Sleep Mode When the generator set master switch is in the AUTO position the controller powers down automatically if there is no start signal for 48 hours after shutdown The controller display is dark and battery draw is minimized A remote start signal from a transfer s
60. Testing and Adjustment Engine Speed Frequency Adjustment Mechanical Governor Use the adjusting nut shown in Figure 6 28 to adjust the engine speed if necessary Recommended engine speeds with no load and full load are shown in Figure 6 29 1 With the engine running loosen the lock nut 2 If the engine is running too slow frequency is low turn the adjusting nut clockwise to increase the speed 3 If the engine is running too fast turn the adjusting nut counterclockwise backing the nut out and decreasing the speed 4 Verify that the engine speed is correct and tighten the locknut photo5005 1 Speed adjusting nut and lock nut Figure 6 28 Engine Speed Adjustment Generator Set Load Engine Speed No Load 3780 RPM 63 Hz Full Load 3600 RPM 60 Hz Figure 6 29 Recommended Engine Speed TP 6196 10 09 6 11 Fault Shutdown Tests Verify the operation of the generator set overspeed overcrank and low oil pressure shutdowns by performing the following tests If these tests are inconclusive test individual shutdown circuit components wiring harness switch etc as described elsewhere in this section 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 itis operating Exposed moving parts can cause severe injury or death Keep hands feet hair
61. adjustment mode See Section 4 5 4 DC 2200 Application program version number is displayed at controller powerup Figure 4 4 Controller LED Display The ADC 2100 keypad is used to enter the controller s configuration and adjustment menus and to change the controller settings password key sequence is required to enter the configuration and adjustment menus Section 4 5 contains the instructions to enter the configuration and adjustment menus and change the settings using the controller keypad TP 6196 10 09 4 3 Sequence Operation The following sections describe the controller sequence of operation during generator start run stop and fault shutdown modes Use this as a starting point for controller and relay board fault identification Refer to the wiring diagrams in Section 8 to assist in the troubleshooting procedure 4 3 1 Starting Sequence Master Switch Moved to RUN When the master switch is moved to the RUN position there is a delay of about 2 seconds before the controller attempts to start the engine The electronic governor moves to its start position The run relay energizes and the run LED 1 turns on The crank and flash relays energize and the corresponding LEDs 2 and 3 turn on 0 5 seconds later The controller display indicates the crank cycle 1 code CC 1 The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the g
62. and supply leads Refer to the schematic in Figure 6 6 when performing the following steps 6 Contact the ohmmeter leads and readjust the ohmmeter to read zero ohms V8 n 10 7 MAIN FIELD Pld 2 4 1 12 LEAD STATOR Figure 6 6 Three Phase Alternator Stator Leads 7 Check the cold resistance of the stator windings by connecting the meter leads to stator leads 1 2 3 4 and 55 66 See Section 1 6 Alternator Specifications for stator winding resistances Most ohmmeters do not provide accurate readings below 1 ohm Low resistance readings continuity and no evidence of shorted windings heat Section 6 Component Testing and Adjustment 75 discoloration indicate a stator in good condition See Figure 6 7 Continuity 1 and 2 1 and 11 2 and 11 4 3 and 44 4 and 44 55 and 66 1 and 3 4 44 55 or 66 2 and 3 4 44 55 or 66 3 and 1 2 11 55 or 66 4 and 1 2 11 55 or 66 Any stator lead and ground on stator housing or frame laminations Figure 6 7 Continuity Test Results on a Good Stator single phase Continuity 1and4 2 and 5 3 and 6 7 and 10 8 and 11 9 and 12 55 and 66 1and2 3 7 8 0r9 1 and 55 Any stator lead and ground Figure 6 8 Continuity Test Results on a Good Stator 8 phase 76 Section 6 Component Testing
63. assembly aside GM29253A 1 Thrubolt and magnetic actuator 2 Rotor strike surface 3 Generator adaptor Figure 7 12 Rotor and Thrubolt 8 Remove the four engine adapter mounting bolts See Figure 7 13 Remove the generator adapter A 358000A B 1 Generator adapter 2 Generator fan guard 3 Engine adapter mounting holes 4 Alternator adapter guard Figure 7 13 Generator Adapter TP 6196 10 09 7 2 Reassembly 1 Reinstall the generator adapter onto the engine a Attach the generator adapter and alternator adapter guard to the engine using four 7 16 14 x 1 0 hex cap bolts and washers See Figure 7 13 b Torque the bolts to 40 Nm 28 2 Install the rotor See Figure 7 12 Clean the crankshaft stub and mating surface on the fan hub Do not use antisieze compound when reassembling the rotor b Install the rotor onto the engine crankshaft c Thread the thrubolt through the actuator and rotor into the crankshaft Do not tighten the thrubolt 3 Install the stator and end bracket a Align the stator so that the alternator frame vibromount points down toward the generator base See Figure 7 14 Install the stator assembly around the rotor GM29253A 1 End bracket 2 Alternator frame vibromount Figure 7 14 Generator Set Right Side typical
64. bolts 3 Heat shield 4 Flange connection 5 Heat shield bolts Figure 7 6 Muffler and Heat Shield 4 Remove the exhaust shield and alternator air inlet duct See Figure 7 7 TP 6196 10 09 jq Top View GM29253 1 Exhaust shield screws 2 Alternator air inlet duct screws Figure 7 7 Shield and Alternator Air Inlet Duct Top View a Remove two bolts securing the exhaust shield at the exhaust end and remove the shield b Remove three bolts securing the alternator air inlet duct to the base and remove the duct 5 Remove the alternator end bracket a Remove the nuts securing the alternator end vibromount mounting plate to the skid See Figure 7 8 1 GM29253A F 1 Alternator end vibromount Figure 7 8 Generator Set Right Side typical Section 7 Disassembly Reassembly 103 Raise the alternator end the generator set retainer wire hole See Figure 7 10 and enough to place a thin block of wood beneath Figure 7 11 the rear of the engine See Figure 7 9 GM29253A GM29253B P 1 Engine support block Figure 7 9 Generator Set Right Side 0 Side View c Remove 4 screws securing the brush cover to 8 the alternator end bracket See Figure 7 10 2 1 Brush holder 5 Shim 2 Slip ring 6 Spring 3 Brush es 7 Correctly positioned brush 4 Retainer wire 8 Incorrectly posit
65. death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines WARNING 2 Airborne particles Can cause severe injury blindness Wear protective goggles and clothing when using power tools hand tools or compressed air 10 Safety Precautions and Instructions Heavy Equipment WARNING Unbalanced weight Improper lifti
66. delay of about 2 seconds before the controller attempts to start the engine The electronic governor moves to its start position The fuel run relay energizes and the corresponding LED on the control board turns on See Section 4 8 for relay information Then the crank and flash relays energize and the corresponding LEDs turn on The controller display indicates the crank cycle 1 code CC 1 The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault When the engine comes up to speed the low oil pressure switch contacts open Note The controller circuit board prevents fault shutdowns during startup until the crank disconnect relay energizes The cyclic cranking cycle is programmed into the controller s application code and is not adjustable in the field The factory sets the cranking cycle for three cycles of 15 seconds on time and 15 seconds off time If the cranking cycle seems shorter than the factory setting check the engine starting battery 5 3 2 Starting Sequence Remote Start The generator set master switch must be in the AUTO position for remote start stop by a remote switch or automatic transfer switch The remote start contact closes across engine start leads 3 and 4 to start the generator set The start sequence proceeds as described in Section 4 3 1
67. down arrow buttons to select the appropriate setting for the application See Figure 5 9 The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved 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 60 Section 5 ADC RES and DC RET Controller Voltage frequency setting Uu Select the system voltage and frequency from the table in Figure 5 8 Note The Uu parameter sets the system s rated voltage and frequency To adjust the output measured voltage and frequency see Section 5 6 Voltage and Frequency Adjustments Engine configuration Ec The engine configuration must match the generator set engine type Communication Sleep Mode Setting Cn Available on controllers with application code version 1 13 or higher The communication setting enables or disables J1939 communication and also disables or enables the sleep mode When J1939 communication is enabled the sleep mode is turned off to allow uninterrupted communication with a personal computer running remote monitoring software If remote monitoring is not used the communication can be turned off enabling th
68. e Leads FP and FN at the rotor e Repair or replace the component causing the blown fuse Section 8 ADV 7325 If fuse continues to blow and the previous step did not identify the cause check the continuity of leads FP and FN and the leads from the P14 connector Replace any bad leads Use pin pusher to remove leads from the connector if necessary If replacing the leads does not solve the problem replace the controller circuit board Section 8 ADV 7325 Section 4 8 or 5 7 Generator set master switch Check connections to the master switch Section 6 15 Test function of master switch Section 6 15 Poor ground connection Clean and retighten Starter relay Check connections to the starter relay Section 1 7 Check continuity of circuit Section 6 15 Section 8 Check that the starter relay picks up when 12VDC is applied at lead 71A connection Section 8 Starter Check starter connections Section 1 7 Section 8 Rebuild or replace starter Engine Service Manual S M Controller Check controller connections and operation Check for power to the controller Move generator set master switch to OFF RESET and then to RUN Section 4 or 5 Section 8 Cranks but does not start No fuel Open turn on manual fuel valve Check fuel supply tank LP Insufficient fuel pressure Check fuel pressure to the generator set Verify adequate fuel pres
69. gain adjustment menu Adjust the voltage gain parameter 2P until the light flicker minimizes Save the settings 5 Check and readjust the voltage if necessary 6 Set the voltmeter to measure frequency Adjust the engine speed to the cut in frequency shown in Figure 6 13 by adjusting the engine governor speed parameter 4P through the ADC controller See Section 4 5 Cut In Frequency 60 Hz 57 5 Hz 50 Hz 47 5 Hz Figure 6 13 Cut In Frequencies 80 Section 6 Component Testing and Adjustment 1 LO Li L2 L3 GM66010 Measure voltage across circuit breaker terminals LO and 11 L2 or L3 Figure 6 14 Voltage Measurement Three Phase T 10 11 12 Models Set the voltmeter to measure voltage Adjust the volts Hz parameter SP until the voltage level measured by the voltmeter begins to drop When set the generator as load is applied attempts to maintain normal output until the engine speed drops below the cut in frequency set in step 6 Note See Section 6 7 3 for more information on the volts Hz droop adjustment Setthe voltmeter to measure frequency Adjustthe engine speed to the operating frequency 50 or 60 Hz by adjusting the engine governor speed parameter 4P through the ADC controller Readjust the voltage gain parameter 2P until the light flicker minimizes if necessary Check the voltage Readjust the voltage parameter 1P if necessary Save th
70. generator set Setthe meter to measure AC voltage 2 Startthe 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 Refer to the flowcharts in Figure 5 13 through Figure 5 15 for instructions to adjust the output voltage See Figure 5 11 for the approximate change in voltage per step Voltage Change per Step VAC Coarse Fine Measured Voltage VAC 85 132 180 251 1P00 99 1P00 99 Figure 5 11 Voltage Adjustment approximate 4 Adjust the voltage stability gain parameter 2P to minimize light flicker 5 Readjust the voltage if necessary 6 Set the multimeter to measure frequency 7 Adjust the engine speed to the cut in frequency shown in Figure 5 12 by adjusting the engine governor speed parameter 4P Cut In Frequency 60 Hz 57 5Hz 50 Hz 47 5 Hz Figure 5 12 Cut In Frequencies 8 Adjustthe volts Hz parameter 3P until the voltage level measured by the multimeter 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 set in step 7 Note See Section 6 7 3 for more information about the volts Hz droop adjustment TP 6196 10 09 9 Reset the engine speed to the operating frequency 50 or 60 Hz by adjusting engine the gov
71. 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 lt 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 KT To enter volts Hz adjustment mode To raise or lower the volts Hz O00 low 09 high lt Continued on Figure 4 12 Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 4 11 Output Voltage and Frequency Adjustments 44 Section 4 ADC 2100 and DC 2200 Controllers TP 6196 10 09 Continued from Figure 4 11 Display Press To enter engine governor speed coarse adjustment mode To raise or lower the engine speed in large increments lt el To enter engine governor speed fine adjustment mode To raise or lower the engine speed in smaller increments lt To enter engine governor stability gain coarse adjustment mode To
72. not touch hot engine parts The engine and exhaust system components become extremely hot during operation Open the generator set output circuit breaker before beginning the test See Figure 4 1 for the circuit breaker location Connect a DVM to measure the output frequency Start the generator set and manually adjust the engine speed by moving the throttle linkage Note Be careful not to touch the hot silencer when reaching in to adjust the throttle linkage Increase the engine speed parameter 4P to at least 115 of the rated engine speed 69 Hz on 60 Hz models or 58 Hz on 50 Hz models Verify that the generator set shuts down on an overspeed fault OS If the overspeed shutdown does not operate the generator set should shut down on an overfrequency fault OF after approximately 5 seconds If the controller does not indicate an overspeed fault OS check the wiring to the magnetic pickup red and black leads P1 17 and P1 29 Check the magnetic pickup air gap and voltage output see Section 6 9 4 Low Oil Pressure LOP Shutdown Connect a jumper wire from the LOP switch lead 13 to the generator set ground Startthe generator set Verify that the generator set shuts down after approximately 25 85 seconds of operation Remove the jumper wire from the LOP switch and ground Startthe generator set and run it for at least 25 35 seconds to verify that the generator set does not shut down Section 6 Component Testing and A
73. or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Separate Excitation Procedure Perform the following procedure to use an external voltage source to excite the main field rotor 1 Disconnect the black FN and FP leads from the alternator at the SCR module and terminals 2 Connect a DC ammeter 20 amp fuse and a 12 volt automotive battery to the positive FP and negative FN brush leads as shown in Figure 6 3 Note and record the ammeter reading TP563274 SCR module FN lead disconnected from SCR FP lead disconnected from SCR 10 amp fuse DC ammeter 12V battery Brushes Slip rings Main field rotor Figure 6 3 Separate Excitation Connections 74 Section 6 Component Testing and Adjustment Note The approximate ammeter reading should be the battery voltage divided by the specified rotor resistance See Section 1 Specifications for specified rotor resistance values Example 12 volts battery voltage rotor current 4 ohms rotor resistance 3 Start the engine and check that the ammeter reading remains stable increasing meter reading indicates a shorted rotor A meter reading decreasing to zero or an unstable reading suggests a running open Refer to Section
74. remaining screws to remove the non service side housing panel 2 Note the alternator connections inside the controller box for reconnection later Disconnect Controller Box Top View GM29253A F the alternator leads inside the controller box See Figure 7 4 or Figure 7 5 and the wiring diagrams 1 Controller box location or Figure 7 5 mne 9 9 2 Line circuit breaker ection 8 3 SCR module 1 4 Neutral connection terminal LO 3 Remove the engine exhaust muffler and alternator heat shield See Figure 7 6 Figure 7 4 Alternator Connections inside Controller Box ADC 2100 a Disconnect the muffler from the engine exhaust pipe at the two flange connections b Remove the bolts holding the muffler to the alternator heat shield and remove the muffler c Remove the bolts securing the heat shield to the alternator and remove the heat shield 102 Section 7 Disassembly Reassembly TP 6196 10 09 Junction Box Detail GM57149 Line circuit breaker Neutral LO Ground terminal SCR module Fuses Figure 7 5 Alternator Connections inside Controller Box ADC RES 1 Engine exhaust muffler 2 Muffler
75. shown in Figure 6 40 Reconnect power to the battery charger Place the controller master switch in the RUN position to start the generator set Allow the generator set to run until the engine reaches normal operating temperature With the generator set at normal operating temperature apply rated load Connect one of the DVM leads to the oxygen sensor lead Connect the other DVM lead to ground and measure the output voltage of the oxygen sensor potential to ground Adjust the fuel metering valve as required to obtain the output from the oxygen sensor specified in Figure 6 39 The output of the oxygen sensor reads high when the mixture is fuel rich and close to zero volts when the mixture is lean Oxygen Sensor Reading VDC Natural Gas LP 2 40 0 05 2 25 0 05 2 60 0 05 2 60 0 05 Figure 6 39 Acceptable Oxygen Sensor Readings 1 11 12 13 14 15 16 17 18 19 20 21 When the fuel mixture is correct use thread sealant to seal the metering valve adjustment screws Remove the load and allow the generator set to run unloaded to cool for at least 5 10 minutes Place the generator set master switch in the OFF position Disconnect the generator set engine starting battery negative lead first Allow the generator set exhaust system to cool Disconnect the DVM leads from the oxygen
76. start 10 second inhibit Check system frequency setting parameter UU on controller Measure output frequency and adjust if necessary Check governor system condition and operation Overspeed Shutdown occurs if the engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Check governor settings and operation Overvoltage Shutdown occurs if the voltage exceeds 120 of the system nominal voltage for more than 2 seconds Check AC voltage Check wiring and connections Underfrequency Shutdown occurs when the governed frequency falls blow 90 of the nominal system frequency for more than 5 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Undervoltage Shutdown occurs if the voltage falls below 80 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Check wiring and connections Check controller configuration system voltage and frequency parameter UU Check AC voltage and adjust if necessary Replace the SCR module and test voltage again Separately excite unit Check stator continuity Software Communication Fault 0 Indicates a software or communication problem within the ADC 2100 Replace the controller Not applicable on DC 2200 controllers with software versions below 1 26 DC 2200 software
77. the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 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 65 264 6422 Fax 65 264 6455 12 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 6196 10 09 1 1 Introduction The spec sheets for each generator set provide specific generator and engine information Refer to the generator set spec sheet for data not supplied in this manual Consult the generator set installation manual engine operation manual and engine service manual for additional specifications Check the generator set nameplate for specific generator set ratings 1 2 Controller Specifications For specific description of the c
78. the governor response Check the frequency reading Repeat steps 3 and 4 if necessary to obtain the rated frequency and stable operation Save settings See Figure 5 15 Section 5 ADC RES DC RET Controller 63 Output Voltage and Frequency Adjustment Mode Display Move the generator set master switch to the RUN position The generator set XIXIXIx engine starts and the controller display shows the engine runtime hours Hold Wait about 5 seconds until the display changes from runtime hours Or to the program version number x Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password The controller is now in the voltage coarse adjustment mode Press To raise or lower the voltage in large increments approximately 5 7 volts per step Parameter 1P To enter fine voltage adjustment mode To raise or lower the voltage in smaller increments approximately 0 5 0 7 volts per step Parameter 1P lt enter coarse voltage stability gain adjustment mode To raise or lower the voltage stability gain in large increments Parameter 2P To enter fine voltage stability gain adjustment mode To raise or lower the voltage stability gain in smaller increme
79. the run relay deenergizes and the run LED 1 turns off but the controller does not power down The controller remains powered and displays the engine runtime hours Note Disconnecting the P7 jumper if equipped on the back of the controller will allow the controller to power down 48 hours after generator set shutdown See Section 4 6 Continuous Power Mode 4 4 Faults 4 4 1 Warnings The fault conditions listed in Figure 4 5 will cause the controller to display a fault code but will not shut down the generator set 4 4 2 Shutdowns Under the fault conditions listed in Figure 4 6 the controller displays a fault code and the generator set shuts down Always identify and correct the cause of a fault shutdown before restarting the generator set Refer to Section 3 Troubleshooting for instructions to identify and correct the cause of the fault Move the generator set master switch to the OFF RESET position to reset the controller after a fault Section 4 ADC 2100 and DC 2200 Controllers 37 shutdown Then move the switch to the AUTO RUN position Generator sets with serial numbers below 2051415 were built with controllers equipped with the continuous power mode jumper If the power jumper is removed and the controller powers down after a fault shutdown move the master switch to OFF RESET and then to RUN to display the fault code Then move the switch to OFF RESET again to clear the fault See Section 4 6 for more in
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83. 4v130 SANIN 013 SMd INYA SNIONIM ONIONIM 3OVLI0A ONISN3S HSV14 O N Ld 4 103135 3Q0W Y3MOd SNONNILNOO Z Zd 1 4 1nO AVI3H HSY 81 14 100 AVTaY 1303 14 170 11043 1 19 LNO AVIY YILYVIS QNnONO amp 144 N 0014 20 ON IInv4 NOAWOO ON AVIY ON Av13H NOY ON Linv4 NOWWOO NOWNOS NOU 9 24 S bed y ved 2 1 vid MOT YOSN3S MA LL Ld 4 18 ANBA pas ER 401 HOLIMS MBdSNVHL NO SIOVINOO 7 lMVIS 3NION3 YO HOLMS 1816 3LOW3Y SIWNINB3L Y3WOLSNO OL M3dWhf M3MOd MOT Z OL YSdWNMYSMOd SNONNILNOD WddWn Ld AON SNOILO3NNOO Zd 39H A318 E j Figure 8 2 Schematic Diagram Single Phase 8 5 12RES w ADC 2100 Controller ADV 6835A E 6196 10 09 ing Diagrams Ir ion 8 Wi 110 Sect 2 1 S 89 AQV 2 2 ONTESEOSAGY 777 534 MM 01 48 OILVW3HOS AYNOVIO ENE WIGAN 80 NOSSO 30 SR TV TION KU NOLQNNOO 14533 CSN 38 LON ISON 09 SI ONY ROS30 SNC YSN
84. 5 seconds the application program version number will be displayed on the controller display For example 01 10 will be displayed for program version 1 10 The DC RET application program version number is displayed during the first 2 seconds of the crank cycle Section 5 ADC RES DC RET Controller 59 5 5 4 System Parameters The controller configuration for each generator model is set at the factory and should not normally require changes The controller s configuration mode allows adjustment of the system parameters listed in this section Use the instructions in this section to check the configuration after installation and change them to match the settings shown in Figure 5 8 if necessary Definition Single phase 60 Hz 120 240 VAC Parameter Unit s system voltage and frequency Three phase 50 Hz 230 400 VAC TRES Single phase 50 Hz 115 230 VAC Engine type 8 5 2 kW No J1939 communication Sleep mode enabled 48 hour power down in AUTO Communication setting J1939 communication enabled Sleep mode disabled no power down in AUTO Controller application code version 1 13 or higher Default setting for application code version 1 13 or higher Figure 5 8 Controller Configuration Parameters Follow the instructions in Figure 5 10 to enter the configuration mode while the engine is not running and then step through the following parameters Use the up and
85. 6 Remove the hose fitting from the natural gas outlet port in the fuel metering valve See Figure 6 35 7 Remove the plug from the LP port in the fuel metering valve See Figure 6 35 Clean the plug with a dry cloth or brush apply fresh pipe sealant and install the plug into the natural gas outlet port 8 Clean the hose fitting with a dry cloth or brush apply fresh pipe sealant to the threads and install the fitting into the LP Note Do not adjust the fuel metering valves 9 Slide the hose onto the hose fitting and secure it with the clamp 10 For 12 kW models only Connect the digital spark advance ignition DSAI leads together for natural gas Disconnect the leads for LP See Figure 6 37 1 DSAI leads connect for natural gas disconnect for LP Figure 6 37 Digital Spark Advance Ignition Leads 12kW only located in generator set air intake area Section 6 Component Testing and Adjustment 95 11 Connect and turn on the new fuel supply 12 Check that the generator set master switch is in the OFF position 13 Reconnect the generator set engine starting battery leads negative lead last 14 Reconnect power to the battery charger 15 Start the generator set by moving the generator set master switch to the RUN position 16 Check for leaks using a gas leak detector 17 Move the generator set master switch to the AUTO position To convert from LP vapor to natural gas follow the same
86. 6 5 Main Field Rotor to test the rotor If the ammeter reading is stable proceed to step 4 4 Check for AC output across the stator leads see Section 6 3 Stator Compare the readings to the AC output values shown in Section 1 Specifications If the readings vary considerably a faulty stator is likely Refer to Section 6 3 Stator for further information 5 If this test shows that the rotor and stator are in good condition check the wiring and fuses Check SCR module Section NO TAG Silicon Controlled Rectifier Module Check the controller settings and connections See Section 4 Controller Configuration and Adjustment 6 3 Stator The stator contains a series of coils of wire laid in laminated steel frame The stator leads supply AC voltage to the load and voltage regulator Before testing the stator inspect it for heat discoloration and visible damage to housing lead wires exposed coil windings and exposed areas of frame laminations Be sure the stator is securely fastened to the stator housing Note Disconnect all stator leads before performing all stator tests WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place TP 6196 10 09 High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high volta
87. 65A 0601 2 20 M4 0 70 x 12 5 0 80 x 12 5 0 80 16 M6 1 00 x 12 Appendix 129 Metric continued Part No Hex Nuts M934 03 50 M934 04 50 M934 04 B M934 05 50 M934 06 60 M934 06 64 M6923 06 80 M982 06 80 M934 08 60 M6923 08 80 M982 08 80 M934 10 60 M934 10 60F M6923 10 80 M6923 10 62 M982 10 80 M934 12 60 M934 12 60F M6923 12 80 M982 12 80 M982 14 60 M6923 16 80 M982 16 80 M934 18 80 M982 18 60 M934 20 80 M982 20 80 M934 22 60 M934 24 80 M982 24 60 M934 30 80 Washers Part No M125A 03 80 M125A 04 80 M125A 05 80 M125A 06 80 M125A 08 80 M125A 10 80 M125A 12 80 M125A 14 80 M125A 16 80 M125A 18 80 M125A 20 80 M125A 24 80 Dimensions 3 0 50 4 0 70 4 0 70 5 0 80 6 1 00 6 1 00 6 1 00 6 1 00 8 1 25 8 1 25 8 1 25 10 1 50 10 1 25 10 1 50 10 1 50 10 1 50 12 1 75 12 1 25 12 1 75 12 1 75 14 2 00 16 2 00 16 2 00 18 2 5 18 2 50 20 2 50 20 2 50 M22 2 50 M24 3 00 M24 3 00 30 3 50 3 2 4 3 5 3 6 4 8 4 10 5 13 0 15 0 17 0 19 0 21 0 25 0 7 0 9 0 10 0 12 0 16 0 20 0 24 0 28 0 30 0 34 0 37 0 44 0 Standard Standard Brass Standard Standard Std green Spiralock Elastic Stop Standard Spiralock Elastic Stop Standard Standard Spiralock Spiralock Elastic Stop Standard Standard Spiralock Elastic Stop El
88. 9 983 sl IMNHO 335 NOLLINOI LOANNOO LON Od Sv9 dl OL S9 193NNOO Sv9 OvZHO 1303 Ad dnON5 5 35 AINO 3AVA 1303 035 NOLLONAP 0 NI ANO Svo IVN HOdVA d Ad NI ENO00 804 983 N vS 43 9 64 034 6d 10 005 9 EI 1415 99 N18 15 on 9 64 134 4 64 55 689 ld e B e bad voz sf D 01 15 115 GION31OS 18 15 SS WOION H3lNVIS WS M3lJILO34 Q3TIOMINOO 15 YS davog 4431 AVY LOANNOO AINO M0193NNOO HOLIMS 553 10 MOT 401 Qnis 01 XO8 N3TIOHINOO 01 1 JOYLNOO NOILIN I NOI ANNOYS H3TIOMINOO 3AWA 1303 Ad asni 4 ANNOYS ANIONS 983 5 LNVIOOD 5 N3931 519 30010 89 192198 1 1 Avus wibivis 9
89. ADC controller controls the governor system operation See Section 8 Wiring Diagrams for governor connections 6 9 1 Operation The frequency of the alternator output is determined by the speed of the engine A two pole alternator must be driven at 3600 rpm to provide 60 Hertz A 50 Hz model must be driven at 3000 rpm Engine speed is maintained by an electronic governor system that consists of a magnetic pickup and electric actuator stepper motor The ADC controller controls the governor system The magnetic pick up which monitors the speed of the flywheel ring gear provides the speed reference signal to the ADC controller The controller provides regulated power to the bidirectional stepper motor actuator which is linked to the carburetor throttle arm At cranking speed a properly adjusted pick up should produce a minimum of 1 75 VAC The magnetic pick up air gap is factory set to 0 5 mm 0 020 in Failure or loss of the input speed signal from the magnetic pick up will result in erratic speed A setting on the ADC controller allows adjustment of the engine speed within the 50 60Hz range See Section 6 9 3 A gain adjustment may be required if an unstable hunting surging condition occurs Adjusting the gain may require readjustment of the engine speed See Section 6 9 3 84 Section 6 Component Testing and Adjustment 6 9 2 Initial Checks and Operation Test The factory sets the electronic governor Under normal cir
90. DC 2200 Controllers 49 Note Some versions of the controller mount from inside the controller compartment Others are front mounted 6 For inside mounted controllers a Remove 5 screws to remove the front panel on the air intake end of the enclosure Remove the plastic caps to access the 2 side screws See Figure 4 17 b Remove two screws to remove the cover from the controller compartment See Figure 4 18 c Disconnect wiring harness plugs P1 P15 and P16 from the ADC controller See Figure 4 19 d Loosen and remove four controller mounting screws at the front of the controller See Figure 4 20 Remove the controller from the compartment 1 P1 35 pin connector e Placethe new controller into position and install 2 P15 3 pin connector the four mounting screws Comment f Attach connectors P15 and P16 to the new controller g Replace the cover on the controller compartment h Replace the front panel on the air intake end of the enclosure 1 Controller mounting screws 4 ea Figure 4 20 Controller Mounting Screws inside mounted controller shown 1 Cover screws Figure 4 18 Controller Compartment Cover 50 Section 4 ADC 2100 and DC 2200 Controllers TP 6196 10 09 7 10 11 For front mounted controllers a Remove four mounting screws from the front of the controller b Carefully pull the controller forward angling it sothatthe P1 connector on the right side c
91. FOS UM 5031545 WO O2 H3 1HO 190241 r 6N ov SYM indi ov N INANI SVM BA 22 617 SNOUD3NNOO Gir 8 72 zoze 1 1 335 88 41 1 1 335 niei 1 asses 235 1 1 Bas W3T110H1NO2 0012 OOV S38 MY 21 98 VEN uns 13539 4340 Ld OOLZIOV viz 15 6 1 8 71 voz 13nd L tld lVBA _ 9 vld AVY HSV14 S bld 3AUVO3N v vld JOMINOO 31314415 6 014 1 AVIS Linvs NOWWOO 2 914 JOXLNOD Avi3H NAY 1 914 SNOIIO3NNOO vid ON L 1nv4 NOWWOO 9 ld ON AVI3M G ld ON Avia NOY v tld INVA NONNOO ld NONNOO l1nv4 NOWWOO eld NOWNOO AVI3H NOH 1 1d SNOILO3NNOO 19 3OVJH3INI AVTSY 8 IndNI Ov 6A IndNI Ov 2 91 11 Sir 5 Sif 99 LNdNI 9 XY 9 914 2 85 914 4 SANIN 0134 914 99 1ndNI ONIGNIM Xnv 914 1 0 HSV 2 914 9 5014 Gi3H 1 914 SNOILOSNNOO ONnOHD 4
92. HC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 123 KBus kg kg cm kgm kg m kHz kJ km kOhm KQ kPa kph kV kVA kVAR kW kWh kWm kWth LxWxH Ib Ibm ft3 LCB LCD Id shd LED Lph Lpm LOP LP LPG LS La LWL LWT m M m3 m hr 2 mil min misc MJ mJ mm kilo 1000 kelvin kiloampere kilobyte 219 bytes Kohler communication protocol kilogram kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilo
93. IS 31OW3H 80 14 IVBA 14 4 9 60 14 QNnONO 20 14 10 14 QNnONO 02 14 ANNOYS YOSNES 35155334 61 14 ANNOY 81 14 HOSNJS 11 14 QNnONO 91 14 HOLIMS SYNSS3Yd 10 81 14 100 HOVL vi id 110 T304 21 14 NMOGLNHS 21 14 7 NVO 11 14 NVO 01 14 HOSN3S dW3L 1 1002 6 14 HOIH 5 5 dW3L INYIOOO 8 14 AZ 1 14 9 14 Vi 5 14 91 bold 11094 NOAWOO ld 104100 82 14 100 AVI3H B3lNVIS l id SNOILOSNNOO id S3TIOHINOO 0012 207 Figure 8 8 Schematic Diagram Three Phase 12TRES w ADC RES Controller ADV 7623 Sheet TP 6196 10 09 116 Section 8 Wiring Diagrams 9 2 5 Avauovia 5 me awans 2 FRC ZH OS 082 SX 534 MA 90 MOlVIS 093121 Do T E B 3SVHd 33HHl 5485 5335 5 31ON 035 935 5 2 64 38N3S ov 1 130 035 Ol NMOGLNHS 3 1 64 3SN3S Ov E 235 OL 0384 mm 4 20 BA 01 MOlOVdVO Willd ZIG L
94. M Xnv SNISNIS HSU 01 14 Figure 8 6 Schematic Diagram Single Phase 12RESL RESM1 RESNT w DC RET Controller ADV 7351 D TP 6196 10 09 114 Section 8 Wiring Diagrams ZESL AQV ma 80 178 M ARM 6 88 0 m 3335 SNOLLO3NNO2 xm oe BHOLVYIN39 310N x 7035 670 cen arme 035 Mcr 3 1 64 3SN3S ov 935 01 03B4 N30Nn H3 O Egg 2 64 SNS ov 935 OL NMOGINHS Avi3Q 038 ZOVIIOA OV 5 iO3NNOOSIQ NYO zi 50018 YOLOW Y3dd3LS WLS ANNONO 91 194 zs MOLVIS 1915 a am dINAL 161000 11 14 TINTON LNVAS 5 MOSN3S dW3l 1 1000 81 14 M LHM GION310S 5 SS MNOLON 1 15 WS 1 014 YONY3A09 14 4 15 Q3TIOHINOO NOOlIIS NOS MOSN3S MA 5 1 3OVJH3lNI 014 VC MOT HOSN3S 9 14 6 8 193NNOO MOIND f NODD 40014 OILANOWN dW HOLIMS 553 10 MOI 401 GAL
95. ONIM XNY 9 5 35 HSV Aviad 935 S la 935 of 4 5 3BnSS3Nd 10 2 14 6 NMOGINHS Q3AVT30 6 114 GNNOYD 01 119 1304 8 114 IVA 1 19 035 Z NMOQ1nHS 2 14 5 7 HOIH MOSN3S MA HT MOT HOSN3S YA 9 14 2 4018 18415 8 14 1 9015 15 15 BLONZY 8 ldj v 1 ANNONO 91 14 Zzs j4 wey 2900 11 14 5 1 ZL Ld M ivan 01 14 EUN 401 HOLIMS JNBN 219 4 138 218 j IN e MW3dSNVHL NO SIOVINOO HOLIMS HVIS 310W3H 14 4 HINOLSND 1NO20 HOLIMS 18415 3NION3 NO Zi Ayauya 2 v Aun OL Figure 8 9 Schematic Diagram Three Phase 12TRES w ADC RES Controller ADV 7623 Sheet 4 Section 8 Wiring Diagrams 117 TP 6196 10 09 2 86566299 aul eum EL 5384 21 98 15 81 T _ WEEN wl Sau MY 21 48 mul HONG UD NOSIO TU 20K 09 NOUDINNOD 8 savana NY 09
96. Q0V 1335 SNOILO3NNOO MOIVH3N39 310N 99 2 99 9 08 di 8 9 4 Sti SM 105 983 SIN 766 as 189 282 o n 85 H a yao OT 1 1 M ss dvi f SNOILO3NNCO 914 H3lNVIS 1 918 drt 9 N 014 O 8 014 0 vi Z Old T 583 153 01 119 02 553 1 01 0 82 1 Nid SNOILOSNNOO 94 983 S19 RS TIE 11 14 81 18 JHM V SNOIIO3NNOO Sd 1415 LA vis BA 115 6 908 OL siouovavo aanu 1 0 0 10028 aaov 1335 SHI SNOILO3NNOO Alt 01 109 OL Ol 6 114 6 8 11 0 11 2 19 NOL 0 19 Nee 2 21 819 Vedd 1 Nid SNOILOANNOD 914 Zid 8 ZN 1 9 114 9N z vid 2 N g vid NOL 1 SNOILOSNNOO 914 77 HOLMS 4 3NVSBN3N
97. S 01 M3TIOHLNOO GY 7OMINOO PERSE BI SONOS ANNONO YFMOYLNOO 3NA TANA Ad f 30 35 LNY1009 510 IWLISIG 50 2 30010 035 o eus 38065384 30 z a i o Lino 89 NMOGINHS 03 130 401 3931 100 AV 5014 INYO quai TONDO SANIN 071314 VLOA 2 NOY 11 14 oo 1 b 103NNOO ION 00 5941 1ndNI ONONM XAY D 9 N OL S9 103NNOO SVO 9NSN3S 10 OrZHO 3dAL 1303 ONIWIL 6 114 GNNOYD 01 114 1304 Z dOLS IMVLS 6 14 335 1 dOIS 1NVIS SLON3Y 8 14 ONINIL HOLIMS NOLINOI 8 114 3NYHBW3A QCONA 1 18 Hailsvis RED 1 72 19 44 128 BLK NHT 2 14 6 1 50 AINO OFLHO L1 12 GND GND I g B3 W3 63
98. S SNNSS3Yd 10 MOT 401 GMS O1 N3TIOMINOO 01 M0103NNOO IOMINOO ONnOWO N3TIOMINOO 3NWA 1313 asn4 an 2018 3NION3 983 M3ON3S 3HniVN3dW3L INYIOOO 510 30011 2 unos 80 9 1 cin o gir o 66 cir o 16 cir ol 06 gir ol 68 8 vzd s vzd 24 z vzd 1 88 6 16 06 68 26 L SNOILOSNNOO 0 E0822 983 OL NOL 1963 SYM 983 5 0 22021 03009 ved 7 8 2 0 p SNOILO3NNOO Ir 1415 4 11 29 05 9 di 1915 1 dd y 91d 4 9 1 914 99 vis 99 9 91 134 99 IRA L 9 4 vis N 15 11 Nid SNOILOSNNOD Sid zov uos 134 99 10 05 ss 19 095 9 5 HOLMS M3JSNVHI NO_SLOVINOD S JNION3 LVL lt lt KONN S NNINH3 zov uos 99 uos dd VLL 18 11 21 11418 1 vo 24 917182 1715 v voi von 14 OvZ OZl SNOILOANNOO 5
99. You should read low resistance in both directions 8 See Figure 6 19 Connect the negative lead from the DC power source to the positive terminal on the SCR module Note The SCR module may be damaged if the power supply is connected incorrectly Be sure to connect the negative lead from the battery to the positive terminal on the SCR module TP 6196 10 09 1 12 VDC power source 2 12 VDC test lamp 3 SCR module 4 Jumper 5 100 500 ohm resister Figure 6 19 SCR Test 9 10 11 12 Connect the positive lead from the DC power source with the lamp in series to terminal AC1 on the SCR module The lamp should not glow Connect the jumper with the resistor in series from the positive lead of the DC power source to terminal G1 the SCR module The lamp should glow Repeat steps 9 and 10 with the positive lead and lamp connected to terminal AC2 on the SCR module and connecting the jumper with resister to terminal G2 If any of the above checks indicates a bad SCR module replace the module Be sure to apply the thermal compound supplied with the module replacement kit to the back of the new module Section 6 Component Testing and Adjustment 88 6 9 Electromechanical Governor System Electromechanical governor systems are used on models 8 5 12RES and 12TRES The governor system consists an electromechanical stepper motor actuator and a magnetic pickup The
100. a 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 4 8 To save changes To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET X in the runtime hours display above denotes any number from 0 to 9 Figure 4 10 Save Mode after configuring generator set parameters TP 6196 10 09 Section 4 ADC 2100 and DC 2200 Controllers 43 Output Voltage and Frequency Adjustment Mode Display Move the generator set master switch to the RUN position The generator set engine starts the controller display shows the engine runtime hours Hold Wait about 5 seconds until the display changes from runtime hours Or to the program version number x Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password The controller is now in the voltage coarse adjustment mode Press To raise or lower the voltage in
101. all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 8 Safety Precautions and Instructions 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 spi
102. and Adjustment 8 If the resistance test proves inconclusive use a megohmmeter to test the stator as described in the next step Note Because ohmmeter accuracy varies resistance readings approximate readings Take readings of the rotor and stator at room temperature Note Make sure that all stator leads are disconnected before running the megohmmeter test 9 Use a megohmmeter to determine whether the stator is shorted to ground a Apply 500 volts DC to any stator lead and the stator frame Perform the megohmmeter test following the instructions of the megohmmeter manufacturer b Repeat the test on the other stator leads until each coil is tested Note A reading of approximately 500 kOhms 1 2 megohm and higher indicates a good stator c Repair or replace the stator if any reading is less than approximately 500 kOhms A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground TP 6196 10 09 6 4 Main Field Rotor The two pole rotor creates the magnetic field needed to produce alternating current in the stator windings Before testing inspect the rotor for visible damage to pole shoes insulation exposed coil windings and slip ring surfaces Rotate the bearing to check for wear heat discoloration or noise Rotor Continuity and Resistance Tests A WARNING Hazardous voltage Moving parts Can cause severe injury or death Oper
103. and not bent or damaged Remove any dirt or debris from the air cleaner base Wipe the base carefully so that no dirt falls into the intake throat c Check the element cover for damage and fit Replace all damaged air cleaner components Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary d Install the paper element precleaner element cover element cover nut and air cleaner cover Secure the cover with the cover retaining knob finger tighten only e Check the element cover for damage and fit Replace all damaged air cleaner components Check the condition of the rubber seals and replace them if necessary 6 Enable the generator set a Reconnect the generator set engine starting battery negative lead last b Reconnect the power to the battery charger 2 5 Cooling System Fans in the engine and generator draw cooling air through the louvered openings in the sides and end of the sound enclosure The cooling air mixes with the engine exhaust and is discharged through the outlet end To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times See Figure 2 11 24 Section 2 Scheduled Maintenance Note Do not block the generator set cooling air inlet or mount other equipment above it Overheating and severe generator damage may occur PU 1 N
104. ange the communication setting if necessary See Figure 4 7 To enter setting and step to SAVE Press To SAVE CHANGES 2 DISCARD CHANGES without saving Yes or flashes when the up down arrow is pressed then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET Note Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed X in the runtime hours display above denotes any number from 0 to 9 Figure 5 10 Configuration Mode system voltage frequency engine type and communication parameters TP 6196 10 09 Section 5 ADC RES and DC RET Controller 61 5 6 Voltage and Frequency Adjustments 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 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 Note The settings described in this section are not adjustable on the DC RET cotnroller The controller s adjustment mode a
105. are hardness grade 8 8 unless noted Part No Hex Head Bolts Partial Thread M931 05055 60 M931 06040 60 M931 06055 60 M931 06060 60 M931 06060 SS M931 06070 60 M931 06070 SS M931 06075 60 M931 06090 60 M931 06145 60 M931 06150 60 M931 08035 60 M931 08040 60 M931 08045 60 M931 08050 60 M931 08055 60 M931 08055 82 M931 08060 60 M931 08070 60 M931 08070 82 M931 08075 60 M931 08080 60 M931 08090 60 M931 08095 60 M931 08100 60 M931 08110 60 M931 08120 60 M931 08130 60 M931 081 40 60 M931 08150 60 M931 08200 60 M931 10040 82 M931 10040 60 M931 10045 60 M931 10050 60 M931 10050 82 M931 10055 60 M931 10060 60 M931 10065 60 M931 10070 60 M931 10080 60 M931 10080 82 M931 10090 60 M931 10090 82 M931 10100 60 M931 10110 60 M931 10120 60 M931 10130 60 M931 10140 60 M931 10180 60 M931 10235 60 M931 10260 60 M960 10330 60 M931 12045 60 M960 12050 60 M960 12050 82 M931 12050 60 M931 12050 82 M931 12055 60 M931 12060 60 M931 12060 82 M931 12065 60 M931 12075 60 M931 12080 60 M931 12090 60 M931 12100 60 M931 12110 60 This metric hex bolt s hardness is grade 10 9 TP 6196 10 09 Dimensions 5 0 80 x 55 M6 1 00 x 40 M6 1 00 x 55 M6 1 00 x 60 M6 1 00 x 60 M6 1 00 x 70 M6 1 00 x 70 M6 1 00 x 75 M6 1 00 x 90 M6 1 00 x 145 M6 1 00 x 150 M8 1 25 x 35 8 1 25 x 40 8 1 25 45 8 1 25 50 8 1 25 55 8 1 25 555
106. astic Stop Spiralock Elastic Stop Standard Elastic Stop Standard Elastic Stop Standard Standard Elastic Stop Standard Bolt Thick Screw M3 M4 5 6 8 10 12 14 30 M16 M18 30 M20 40 M24 This metric hex hardness is grade 8 130 Appendix TP 6196 10 09 6196 10 09 2004 2008 2009 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 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
107. ate the generator set only when all guards and electrical enclosures are in place High voltage test Hazardous voltage can cause severe injury or death Follow the instructions of the test equipment manufacturer when performing high voltage tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure 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 circuits Turn off the 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 Rotor Test Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first TP 6196 10 09 4 Remove the brush cover from the alternator end bracket 5 Check the rotor for continuity and resistance Raise the brushes from the slip rings while performing ohmmeter tests Measure the rotor resistance ohms between the two slip rings see Figure 6 9 See Section 1 6 Alternator Specifications for rotor resistance readin
108. aterials engine oil fuel filter etc in an environmentally safe manner 3 Fill with oil a Fill with oil See Section 2 2 3 for oil selection and Figure 2 3 for oil capacity b Replace the oil fill cap and dipstick 4 Check for leaks Checkthatthe generator set master switch is in the OFF position b Reconnect the generator set engine starting battery negative lead last c Reconnect the power to the battery charger 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 Oil Cooler Inspect and clean the oil cooler at the intervals shown in the Service Schedule The oil cooler must be kept free of debris 2 2 5 See Figure 2 2 and Figure 2 5 for the oil cooler location Clean the outside of the oil cooler with a brush or compressed air If itis necessary to clean the back of the oil cooler remove the two screws holding the oil cooler unit to the blower hosing Tilt the cooler and clean with brush or compressed air as shown in Figure 2 6 After cleaning reinstall the oil cooler and secure with the mounting screws 22 Section 2 Scheduled Maintenance 1 Oil filter 2 Oil cooler 24 590 01 A Figure 2 5 Oil Cooler Location 24 590 01 A Figure 2 6 Cleaning the Oil Cooler 2 3 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as nece
109. atic performance TP 6196 10 09 6 9 3 Hunting Surging 4 If the engine speed hunts or surges while the throttle is held steady check the carburetor Often hunting surging problems thought to be caused position and engine operation by the governor are actually caused by engine or carburetor problems Check engine speed stability a Check carburetor position Slotted mounting using the following procedure before testing the holes in the base of the carburetor determine governor the carburetor position which affects the throttle operation Verify that the carburetor is Ts Open the generator set line circuit breaker mounted as close to the governor actuator stepper motor as the mounting holes allow 2 Start the generator set b Refer to the engine service manual for other engine diagnostic and service information 3 Hold the throttle linkage steady while the engine is running See Figure 6 20 If the engine runs at a steady speed with no hunting or surging when the throttle is held steady then the hunting surging 6 9 4 Governor System Magnetic problems during operation are probably caused by Pickup Operation Test the governor Proceed to Section 6 9 4 If the engine continues to operate erratically after the previous checks test the governor system operation using the following procedure The procedure is summarized in the flowchart in Figure 6 21 1 Electronic governor stepper motor 2 Carburetor throttle linkage TP5632721 3
110. ation System 21 2 2 1 Low Oil Pressure Shutdown 21 2 22 OilLevel Check 21 2 2 8 Engine Oil Recommendation 21 2 2 4 Change Procedure 21 225 Oil COOLER gem aede cun cert dod dido Ne 22 2 9 Spark Plugs BG LER ag etuer 4 22 24 Air Cleaner Element and Precleaner 23 2 5 Cooling System cost pp p UM E 24 2 6 Exhaust Systemi ker ESS LOS Chea uq ee edes 24 27 ID E E E E 24 2 7 1 Cleaning Battery 25 2 7 2 25 28 Storage Procedure 26 2 8 1 Lubricating System 26 2 8 2 5 nd 26 2 8 3 Internal Engine Components Gas Gasoline Fueled Engines 26 284 beats heed tan e eases 26 2 8 5 Baltety s take ting dees seed dus 26 Section 3 Troubleshooting esasen rex RR ru E
111. ation for each generator model is set at the factory Changes in the controller configuration may required after controller replacement or other service Use the instructions in Section 5 5 4 to check the controller settings and change them if necessary 5 5 1 Controller Time Out The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure again from the beginning if the controller exits the configuration mode before the settings have been saved Changes in voltage and speed adjustments are also lost if they are not saved before the generator set shuts TP 6196 10 09 down The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup Be sure to save your changes immediately after making adjustments 5 5 2 Voltage and Frequency Adjustments Voltage and or frequency adjustments may be required after controller replacement or other service procedures See the instructions in Section 5 6 to adjust the generator set output voltage and frequency using the ADC RES 5 5 3 Controller Application Program Version Number The ADC RES application program version number is displayed on the LED screen during the key sequence to enter the configuration mode Hold the Select button and move the generator set master switch to the RUN position After about
112. below 54 Hz for more than 5 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Undervoltage Shutdown occurs if the voltage falls below 8096 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Check wiring and connections Check controller configuration system voltage and frequency parameter UU Check AC voltage and adjust if necessary Check the SCR module Replace if necessary and test voltage again Separately excite unit Check stator continuity Software Communication Fault 0 Indicates a software or communication problem within the ADC RES Replace the controller Engine S M Engine Service Manual O M Generator Set Operation Manual ADC RES only Figure 5 7 Fault Codes Shutdowns 58 Section 5 ADC RES and DC RET Controller TP 6196 10 09 5 5 Controller Configuration and Adjustment ADC RES Note The settings described in this section are not adjustable on the DC RET cotnroller The first step in troubleshooting the controller is to verify that the controller is correctly configured for the generator set The ADC RES controller s configuration modes allow setting of the engine type generator set configuration marine mobile or standby data input types and other parameters The controller configur
113. ce fuel lines and connections as necessary Figure 2 1 Service Schedule 20 Section 2 Scheduled Maintenance TP 6196 10 09 2 2 Lubrication System See Section 2 1 Service Schedule for oil change and oil filter replacement intervals See Figure 2 2 for the oil drain oil check oil fill and oil filter locations The engine has a positive pressure lubrication system and low oil pressure shutdown 4 Oil drain valve 5 Oil cooler 6 Oil filter 1 Dip stick location 2 Oil fill 3 Oil drain hose Figure 2 2 Lubrication System typical 2 2 1 Low Oil Pressure Shutdown The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below preset limits because of oil pump failure or other malfunction It does not protect against damage caused by operating with the oil level below the safe range it is not a low oil level shutdown 222 Oil Level Check Check the oil level regularly and add oil as needed to protect against running out of oil See Figure 2 2 for the dipstick and oil fill locations Do not check the oil level when the generator set is running Shut down the generator set and wait several minutes before checking the oil level TP 6196 10 09 2 2 3 Engine Oil Recommendation Use synthetic oil of API American Petroleum Institute Service Class SG or higher Synthetic oil causes fewer deposits o
114. clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment 6 11 1 Controller Fault Shutdown Functions Check the operation of the fault functions programmed inthe ADC controller by performing the following tests If the ADC controller does not operate as described check the controller configuration settings see Section 4 5 2 Also check the controller wiring and connections Overspeed Shutdown The overspeed setting is programmed into the ADC controller and is not adjustable Verify that the following controller configuration parameters are set correctly for your unit See Section 4 5 and Figure 4 7 for the settings e System voltage frequency parameter UU e Unit configuration parameter UC e Engine type parameter EC e Engine data input type parameter ED TP 6196 10 09 WARNING 024 Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system parts can cause severe injury or death Do
115. ct speed Check for blocked air inlets and exhaust outlets Low coolant level Not used on air cooled models Loss of coolant Not used on air cooled models Low oil pressure Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protective becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Check low oil pressure switch connections and operation Check the oil pump and lubrication system Overcrank Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest Check the fuel supply valves and pressure Check spark plug and battery See Troubleshooting Chart generator set cranks but does not start The generator set shuts down on an overcrank fault if no engine rotation is sensed Shuts down after 3 seconds of cranking or 1 second after the fault is detected Check mag pickup connections and operation Check for a locked rotor Overfrequency 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
116. cumstances the electronic governor requires no further adjustment Verify that the governor stepper motor moves smoothly and steadily during operation If the engine operates erratically check the following connections and conditions before adjusting the governor e Verify that the electrical connections are clean and tight e Check the magnetic pickup connections Poor connections may cause an erratic signal or an overspeed condition An erratic signal causes the generator set to govern poorly but not shut down e Verify thatthe battery connections are clean and tight e Check for dirt buildup on the magnetic pickup Metal filings or caked on dirt or grease decreases the output signal of the magnetic pickup e Check for a loose or worn stepper motor throttle shaft coupling Replace the shaft and bushing every 500 hours of engine operation e Check the carburetor for dirt grime or misadjustment Check for a loose mixer assembly e Check the idle adjustment screw The screw should not prevent the throttle plate from closing completely e Check the throttle linkage for any binding dirt damage or other visible problems e Check for electronic governor faults The fuel shutoff solenoid deenergizes and the generator set shuts down under the following conditions e Closed throttle Engine overspeed Broken fuel shutoff solenoid lead Broken stepper motor leads erratic performance Failed actuator linkage err
117. djustment 91 Overcrank Shutdown Disconnect the starter motor lead at the starter solenoid K20 terminal Move the controller master switch to the RUN position Observe that the generator set simulates cranking for 15 seconds and then rests for 15 seconds Check that the generator set shuts down after the third crank rest cycle High Engine Temperature Shutdown Connect a jumper wire across coolant temperature sensor CTS connections P1 8 and P1 9 Start the generator set Verify that the generator set shuts down approximately 5 seconds after the generator set comes up to speed Remove the jumper wire Start the generator set and run it for at least 30 seconds to verify that the generator set does not shut down 6 11 2 Fault Shutdown Switches Check the low oil pressure and high engine temperature shutdown switches on the engine by performing the following tests If the sensor does not function as described replace it WARNING Hazardous voltage Moving 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 hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Short circuits Hazardous voltage current can cau
118. drop The controller maintains generator output at the specified voltage under load until the generator engine speed drops to a preset level factory setting 57 5 Hz on 60 Hz models and 47 5 Hz on 50 Hz models Then the controller allows the generator voltage and current to drop The voltage current drop enables the engine to pick up the load When the generator speed returns to normal 60 Hz or 50 Hz as load is accepted the generator output also returns to normal See Section for more information about the volts Hz droop adjustment TP 6196 10 09 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 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 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 circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electricalleads or appliances whe
119. e sleep mode which causes the controller to power down after 48 hours of inactivity The generator set master switch must be in AUTO for the sleep mode to function The default setting for controllers with application code version 1 13 or higher is Cn01 communication on sleep mode off Controllers with earlier application code versions have communication disabled and the sleep mode enabled The Cn setting is not adjustable on these earlier versions KO ADVANCED DIGITAL CONTROL 1 Select button 2 Arrow buttons Figure 5 9 ADC RES Control TP 6196 10 09 Controller Configuration Mode 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 change the voltage frequency setting if necessary See Figure 4 7 To enter setting and step to the next parameter engine type Ec To change the engine type 8 5 12 kW if necessary To enter setting and step to the next parameter communication setting Cn To ch
120. e following table as a reference in troubleshooting individual problems Generator set faults are listed in groups and include likely causes and remedies The simplest most likely causes of the problem are listed first follow the recommendations in the order shown The reference column provides additional sources of information in this and related manuals regarding the problem and solution Possible Cause Weak or dead battery Problem Generator set does not Corrective Action Recharge or replace battery If battery is weak or dead check battery charger fuse power O M crank supply and operation Reference Generator Set Battery connections Check for reversed or poor battery connections Open circuit in engine controller connections Check for loose connections Check the wire harness continuity Section 6 15 Section 8 Blown fuse F3 controller Replace fuse if fuse blows again check circuit and components Section 6 13 Section 8 Blown fuse F2 relay Replace fuse Section 6 13 interface board RIB If fuse blows again disconnect the board leads one at a time to identify the cause of the blown fuse Lead 70A at the fuel valve Lead IGN at the ignition module Lead 71A at the starter relay Leads FP and FN at the rotor Section 8 ADV 6835 TP 6196 10 09 Repair or replace the component causing the blown fuse If fuse continues to blow and the previous st
121. e not reconnectable LO Neutral LO O Ground enD S L2 9 lo Factory two pole circuit breaker 4 3 Stator Leads 60 Hz 50 Hz 10 11 120 volt 110 volt LO L2 120 volt 110 volt L1 L2 240 volt 220 volt Figure 6 16 110 220 and 120 240 Volt 3 Wire Configurations Section 6 Component Testing and Adjustment 81 6 7 5 Voltage Connections 3 Phase Three phase generator sets are connected for 230 400 Volts 50 Hz See Figure 6 17 for the factory connections The generator sets are not reconnectable OPTIONAL DROOP COMP C METER SCALE a 9 7 0 LAMP JUMPER NOTES CURRENT TRANSFORMER DOT OR TOWARD GENERATOR CURRENT TRANSFORMERS NOT USED ON ALL SETS PHASE ROTATION A 1 12 Ls Figure 6 17 3 Phase Configuration 82 Section Component Testing and Adjustment 6 8 Silicon Controlled Rectifier Module The silicon controlled rectifier SCR module works with the ADC RES to regulate the output voltage The ADC RES monitors generator output voltage and adjusts the excitation current to the rotor through the SCR module The SCR module location is shown in Figure 4 1 The SCR module is powered through stator leads 55 and 66 connected to SCR terminals AC1 and 2 Leads G connected to terminals G1 and G2 provide the controller signal Leads FP and FN connected to the positive and negative SCR terminals provide e
122. e oil pressure is within the range specified in Section 1 Specifications before testing or replacing the LOP switch To test the LOP switch reinstall the switch and start the generator set If the unit shuts down disconnect lead 13 from the LOP Switch and resetthe controller Restartthe generator set and verify that it does not shut down A successful restart indicates a bad LOP switch Replace the switch TP 6196 10 09 6 12 Fuel Systems A WARNING 4 W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel supplier provides and maintains manual shut off valves and the primary regulator Verify that the fuel system capacity is adequate to supply the generator set plus all other gas appliances A factory installed secondary regulator and 12 VDC solenoid valve are located in the front inlet air compartment The controller energizes the fuel solenoid valve to open at startup and deenergizes the valve to close at shutdown The secondary fuel regulator reduces fuel pressure for delivery to the fuel metering valve The fuel flows from the fuel metering valve to the carburetor in a gaseous state The carburetor mixes the fuel with intake air for consumption by the engine Use a universal exhaust gas oxygen UEGO sensor check the fuel mixture after replacing the fuel regulator fuel mixer or silencer The engine should be warm when the fuel
123. e settings as instructed in Section 4 5 Note The controller will revert to the previous settings atthe next startup ifthe changes are not saved Stop the generator set TP 6196 10 09 6 7 3 Volts per Hertz Hz Adjustments Droop When the frequency falls below the cut in frequency see Figure 6 13 output voltage is reduced to relieve the engine The magnitude of the voltage reduction is set by the 3P parameter Monitor engine speed and output voltage as loads are applied e f there is excessive droop in engine speed little droop in voltage increase the value e f there is little engine speed droop but excessive voltage droop decrease the value e Readjust the voltage stability 2P and voltage 1P parameters after adjusting the setting if necessary See the instructions in Section NO TAG e Remember to save your settings Each step of 3P changes the amount of voltage droop approximately 0 596 of system voltage for each cycle Hz below the cut in frequency See Figure 6 15 Voltage Droop of System Voltage per 1 Hz Cycle Below Cut In Frequency 0 1 2 3 4 5 6 7 8 Figure 6 15 Voltage Droop Adjustments TP 6196 10 09 6 7 4 Voltage Connections Single Phase Single phase generator sets are available from the factory connected for 110 220 volt 50 Hz or 120 240 volt 60 Hz See Figure 6 16 for the factory connections These generator sets ar
124. eck the battery rating voltage warning 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system and condition for more than one minute when the engine is not running This fault Check the battery charger condition does not inhibit engine starting operation The fault condition clears when the battery voltage returns to a voltage Charge or replace the within the limits for more than 10 seconds battery ADC RES only Figure 5 6 Fault Codes Warnings TP 6196 10 09 Section 5 ADC RES and DC RET Controller 57 Auxiliary fault Description Indicates a shutdown initiated by the emergency stop switch or a tripped circuit breaker TRES models only Check the position of the emergency stop button TRES models only Refer to Section High engine temperature Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protective becomes active after the engine reaches the crank disconnect speed Check for blocked air inlets and exhaust outlets Low oil pressure Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protective becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if
125. enerator set does not start in three attempts the system shuts down on an overcrank fault When the engine comes up to speed the low oil pressure switch contacts open Note The controller circuit board prevents fault shutdowns during startup until the crank disconnect relay energizes The cyclic cranking cycle is programmed into the controller s application code and is not adjustable in the field The factory sets the cranking cycle for three cycles of 15 seconds on time and 15 seconds off time If the cranking cycle seems shorter than the factory setting check the engine starting battery 4 3 2 Starting Sequence Remote Start When the master switch is set to the AUTO position the generator set starts when the remote start switch or transfer switch engine start contacts close The start sequence proceeds as described in Section 4 3 1 Starting Sequence Master Switch Moved to RUN TP 6196 10 09 4 3 3 Running Sequence When the engine speed reaches 750 rpm the crank relay deenergizes and the crank LED 3 turns off When the output voltage on leads 11 and 44 reaches about 30 VAC the flash relay deenergizes and the flash LED 2 turns off 4 3 4 Stopping Sequence Master Switch Moved to OFF RESET Place the generator master switch in the OFF RESET position The run relay deenergizes and the run LED 1 turns off The generator set stops 4 3 5 Stopping Sequence Remote Stop When the remote start contacts open
126. engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Remove and replace the oil filter 5 Refill the crankcase with oil suited to the climate 6 Run the generator set for two minutes to distribute the clean oil 7 Stop the generator set 8 Check the oil level and adjust if needed 2 8 2 Fuel System Prepare the fuel system for storage as follows 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position 2 8 3 Internal Engine Components Gas Gasoline Fueled Engines If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows 1 While the engine is running spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops 26 Section 2 Scheduled Maintenance 2 Place the generator set master switch in the OFF RESET position If a fogging agent is not available perform the following 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the plugs 3 Togg
127. ep did not identify the cause check the continuity of leads FP and FN and the leads from the P14 connector Replace any bad leads Use a pin pusher to remove leads from the connector if necessary If replacing the leads does not solve the problem replace the RIB Section 8 ADV 6835 Section 4 8 or 5 7 Section 3 Troubleshooting 27 Troubleshooting Chart continued Problem Generator set does not crank continued Possible Cause Crank relay on relay interface board ADC 2100 Corrective Action Check connections to the RIB Check for 12VDC to the RIB on lead 71N Reference Section 4 8 or 5 7 Section 8 Check for a good ground connection lead 16N Section 8 Check crank relay K2 operation LED3 Replace the RIB if relay does not operate Section 4 8 or 5 7 Crank relay K3 on controller circuit board ADC RES Check connections to the controller Section 5 7 Section 8 Check for a good ground connection Section 8 Check LEDS to verify 12 VDC to relay If LEDS is not lit check for 12 VDC to the board If LEDS is lit but the relay does not operate replace the controller circuit board Section 5 7 Blown fuse F2 ADC RES Replace fuse Section 6 13 If fuse blows again disconnect the leads one at a time to identify the cause of the blown fuse e Lead 70C at the fuel valve e Lead IGN at the ignition module e Lead 71A atthe starter relay
128. er 4P to obtain a frequency reading of 60 Hz or 50 Hz on 50 Hz models See Section NO TAG Note Often hunting surging problems thought to be caused by the governor are actually caused by engine or carburetor problems If the generator set speed is unstable hunts or surges check for the cause using the procedure Section 6 9 3 before proceeding 5 Check stability with the generator set running and with no load applied If the generator set speed is unstable hunts or surges use the ADC controller to decrease the gain parameter 5P until the generator set becomes stable with no hunting or surging Observe the frequency reading 88 Section 6 Component Testing and Adjustment 10 Repeat steps 4 and 5 to obtain the rated frequency and stable operation Save the settings as instructed in Section 4 5 Note The controller will revert to the previous settings atthe next startup ifthe changes are not saved within one minute after the last change Apply rated load to the generator set and observe the frequency reading The no load and full load frequencies should be within 0 4 Hz of the rated generator frequency if not check that the carburetor throttle plate opens completely without sticking and check the carburetor adjustment If these procedures do not correct the problem replace the controller Check for hunting and surging at full load Use the controller to increase the gain parameter 5P until t
129. er Switch The generator set master switch is a three position RUN OFF RESET AUTO rocker switch See Figure 5 2 or Figure 5 3 for the master switch location See Section 6 15 for master switch connections 5 2 2 LED Display The LED display shows runtime hours fault codes application program version number or controller parameters during configuration and adjustment See Figure 5 4 54 Section 5 ADC RES and DC RET Controller DEFINITION Crank High GM57149 1 LED display 2 Generator set master switch RUN OFF RESET AUTO Figure 5 3 DC RET Controller The LED display is activated by a start or RUN command as follows e Move the master switch to RUN e With the master switch in AUTO send a remote start command close the remote start contact across leads 3 and 4 The LED display indicates generator set status as shown in Figure 5 5 When the generator set is running engine runtime hours are shown When the generator setis running the arrow keys on the ADC RES can be used to step through the other displays as described in Section 5 2 3 When the master switch is in AUTO the display turns off 48 hours after generator set shutdown TP 6196 10 09 Control or Indicator LED display Description Runtime hours Displays total generator set runtime hours while the generator set is running and when no other codes are displayed Metering display ADC RES only Displa
130. er adjusting the air gap check the voltage again as described in step 4 If the voltage does not measure 1 75 VAC minimum replace the magnetic pickup RED P1 29 LK P1 17 2 QCON1 MP Figure 6 22 Magnetic Pickup Leads Ignition module Air gap 0 5 mm 0 020 A 358000B C Top of flywheel ring gear tooth Lock nut Magnetic pickup Figure 6 23 Magnetic Pickup Air Gap 86 Section 6 Component Testing and Adjustment TP 6196 10 09 7 To test the controllers governing function disconnect the magnetic pickup leads and open the generator set circuit breaker PIN 3 BLK PIN 2 YEL 0 0 8 Manually move the throttle shaft governor stepper motor fully counterclockwise closed throttle PIN 5 GRN not used 9 Start the generator set The stepper motor should step clockwise to the wide open throttle position The stepper motor should remain in the clockwise PIN 4 PIN 1 PIN 6 BLUE RED WHT not used throttle fully open position If the stepper motor does not operate as described here proceed to the next steps to check the governor and stepper motor Figure 6 24 Actuator Coil Group 12 If there is power and a good ground connection to 10 Place the generator set master switch in the STOP the ADC controller and the stepper motor coil position Check the stepper motor connections to resistances are good but
131. ernal voltage source a 12 volt automotive battery Separately exciting the generator can identify faulty voltage regulation by the ADC controller or reveal a running fault in the rotor and or stator An external power source duplicates the role of the voltage regulator and excites the generator field rotor A generator component that appears to be in good condition while stationary may exhibit a running open or short circuit while moving Centrifugal forces acting on the windings during rotation cause a broken circuit to open or increasing temperatures cause the insulation to break down resulting in a running fault If this test shows that the rotor and stator are in good condition test the voltage regulation using the tests in Section 6 13 Section 6 Component Testing and Adjustment 73 Grounding electrical equipment Hazardous voltage 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 circuits Turn off the 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 Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and
132. ernor speed parameter 4P 10 Readjust the voltage stability gain parameter 2P if necessary 11 Readjust the voltage parameter 1P if necessary 12 Save settings See Figure 5 15 13 Stop the generator set 5 6 2 Frequency Adjustment The engine speed determines the generator output frequency 60 Hz units operate at 3600 rpm and 50 Hz units run at 3000 rpm Adjust the engine governor speed and gain to set the output frequency and stability using the following procedure Note Refer to the flowcharts in Figure 5 13 through Figure 5 15 during the following procedure Frequency Adjustment Procedure Note Refer to the flowcharts in Figure 5 13 through Figure 5 15 during the following procedure TP 6196 10 09 Attach a frequency meter to the AC output leads or an electrical outlet on the load side of the generator set Start and run the generator set until it reaches normal operating temperature at least 10 minutes Adjust electronic governor speed parameter 4P to obtain a frequency reading of 60 Hz or 50 Hz if appropriate Each step changes the engine speed about 3 6rpm which changes the output frequency about 0 06 Hz Check stability with the generator set running and with no load applied If the generator set speed is unstable hunts or surges adjust the governor stability gain parameter 5P until the generator set becomes stable with no hunting or surging Increasing the gain slows
133. et master switch is a three position RUN OFF RESET AUTO rocker switch The leads connecting to the master switch are labeled RUN VBAT and AUTO Check that the three pink connectors are connected to the terminals on the back of the switch as shown in Figure 4 14 Be careful not to reverse the RUN and AUTO leads 4 8 Relay Interface Board RIB The standard relay interface board RIB contains the K2 crank flash and K5 run relays Three LEDs indicate relay operation See Figure 4 15 Refer to the schematic diagram in Section 8 for the standard relay board connections The RIB is protected by a 10 amp fuse F2 located in the wiring harness If the fuse blows repeatedly disconnect the board loads one at a time to identify the cause of the blown fuse e Lead 70A at the fuel valve e Lead IGN at the ignition module e Lead 71A at the starter relay e Leads FP and FN at the rotor Repair or replace the component causing the blown fuse If fuse continues to blow and disconnecting components did not identify the cause remove the leads from the P14 connector using a pin pusher part 241918 large or 241919 small If replacing the leads does not solve the problem replace the RIB The individual relays are not replaceable If one or more relays are faulty replace the entire RIB To replace the RIB 1 Disconnect P14 and the brush leads FP and FN 2 Pull the board straight off the mounting stand offs 3 Snap the new b
134. ew is a trademark of Holo Krome Co Phillips screw is a registered trademark of Phillips Screw Company Sample Dimensions American Standard Screws Bolts Studs and Nuts Plain Washers 1 4 20 x 1 L Length In Inches Screws and Bolts 9 32 x 5 8 x 116 Thickness Threads Per Inch External Dimension Major Thread Diameter In Fractional Inches Or Screw Number Size Metric Screws Bolts Studs and Nuts Internal Dimension 8 1 25 x 20 Lock Washers Length In Millimeters Screws and Bolts 5 8 Distance Between Threads In Millimeters Internal Dimension Major Thread Diameter In Millimeters TP 6196 10 09 Appendix 127 1151 The Common Hardware List lists part numbers and dimensions for common hardware items American Standard Part No Dimensions Part No Dimensions PartNo Dimensions Hex Head Bolts Grade 5 Hex Head Bolts cont Hex Nuts X 465 17 1 4 20 x 38 X 6238 14 3 8 24 x 75 X 6009 1 1 8 Standard X 465 6 1 4 20 x 50 6238 16 3 8 24 1 25 465 2 1 4 20 x 62 6238 21 3 3 8 24 4 00 6210 3 6 32 Whiz X 465 16 1 4 20 x 75 X 6238 22 3 8 24 x 4 50 X 6210 4 8 32 Whiz X 465 18 1 4 20 x 88 X 6210 5 10 24 Whiz X 465 7 1 4 20 x 1 00 iib cae X 6210 1 10 32 Whiz X 6024 2 7 16 14 x 1 00 X 465 8 1 4 20 x 1 25 465 9 1 4 20 1 50 6024 8 7 16 14 1 25 6210
135. formation on the continuous power mode jumper Description High battery Fault code is displayed if the engine starting battery voltage voltage warning rises above 16 VDC for 12 VDC system or above 30 VDC for a 24 VDC system for more than one minute when the engine is not running This fault condition does not inhibit engine starting Check the battery rating and condition Check the battery charger operation The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Low battery Fault code is displayed if the engine starting battery voltage voltage warning falls below 8 VDC for a 12 VDC system or below 16 VDC for condition a 24 VDC system for more than one minute when the engine is not running This fault condition does not inhibit engine starting Check the battery rating and Check the battery charger operation Charge or replace the battery The fault condition clears when the battery voltage returns to 9 4 a voltage within the limits for more than 10 seconds Figure 4 5 Fault Warning Codes 38 Section 4 ADC 2100 and DC 2200 Controllers TP 6196 10 09 Auxiliary fault Description Not used on these models Refer to Section High engine temperature Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protective becomes active after the engine reaches crank disconne
136. formation to minimize disassembly time and indicates where special configurations exist which may require taking notes The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts 1 Remove the generator set from service and remove the generator set enclosure NNSNNNN a Remove the enclosure service side door See Figure 7 1 55 v 4 1 4 4 1 Screws 2 2 Plastic caps 2 ea remove to access screws 3 Screw 1 ea access from inside the enclosure Figure 7 2 Front Panel Mounting Screw Locations e Disconnect power to the battery charger f Disconnect the generator set engine starting battery negative lead first g Turn off the fuel supply to the generator set 1 4 Service side door 2 Roof locating pin 5 Front panel air intake end 3 Roof screws 4 ea 6 Rear panel exhaust end Figure 7 1 Generator Set Weather Housing TP 6196 10 09 Section 7 Disassembly Reassembly 101 From the inside of the enclosure remove 5 screws to remove the rear exhaust end panel See Figure 7 3 ONTO OO _ tp6196 1 Screws 5 ea Figure 7 3 Rear Panel Mounting Screw Locations viewed from inside the enclosure i From the inside of the enclosure remove the
137. ge tests on the rotor or stator An improper test procedure can damage equipment or lead to generator set failure Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Stator Continuity and Resistance Tests 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Disconnect all stator leads before performing all stator tests 5 To check for stator continuity set the ohmmeter on Rx 1 scale First set the ohmmeter zero by holding the red and black meter leads together and setting the ohmmeter reading to zero Then check the stator continuity by connecting the meter leads to the stator leads as shown in Figure 6 4 R14807 14 Figure 6 4 Testing Stator Windings Note For single phase models leads 1 2 3 and 4 are the generator output leads Leads 11 44 55 and 66 are the controller and SCR module sensing and supply leads Refer to the schematic in Figure 6 5 when performing the following steps TP 6196 10 09 Note For three phase models leads 1 12 are the generator output leads Leads V7 V8 V9 55 and 66 are the controller and SCR module sensing
138. gine service information and specifications not covered in this manual see the Engine Service Manual Section 1 Specifications 13 See the List of Related Materials in the Introduction Section 1 4 Engine Specifications Engine Specification Manufacturer 8 5 kW 12 kW 60 Hz 60 Hz Model Cycle Number of cylinders Compression ratio 8 5 1 9 0 1 Displacement cc cu in 624 38 0 725 44 0 Rated power propane fuel kw HP 11 5 15 4 17 6 23 6 Rpm 3600 Bore x stroke mm in 77 x 67 3 03 83 x 67 3 27 2 64 2 64 Valve material Steel Stellite Cylinder block material Aluminum w cast iron liners Cylinder head material Aluminum Piston rings 2 compression 1 oil Crankshaft material Heat treated ductile iron Main bearings number type 2 parent material Governor Electronic Lubrication system Full pressure Oil capacity w filter L qt 1 9 2 0 2 2 1 Oil pressure kPa psi 172 241 25 35 Fuel system LP gas or natural gas LP natural gas minimum supply pressure in H20 2 2 7 11 4 6 Battery voltage 12 VDC Battery ground Negative Spark plug gap mm in 0 51 0 020 0 76 0 030 Ignition system Smart Spark Capacitor Discharge Capacitor Discharge Starter motor Electric solenoid shift
139. gn Failure Mode and Effects Analysis 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 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 est E Stop etc exh ext fglass FHM fl oz flex freq ft Ib ft min ftp 9 gal gen genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute 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 HC HCHT HD HET hex Hg HH H
140. gs Ifthe resistance readings are low perform a megohmmeter test on rotor as described in the next step Note Because ohmmeter accuracy varies resistance readings are approximate Take readings at room temperature Figure 6 9 Rotor Resistance Check 6 Perform a megohmmeter test to determine whether the rotor is shorted to ground a Raise and secure the brushes away from the slip rings by inserting a retaining wire in the brush holder hole b Using a megohmmeter apply 500 volts DC to one rotor slip ring and the rotor poles or shaft Follow the instructions of the megohmmeter manufacturer when performing this test Note A reading of approximately 500 kOhms 1 2 megohm or higher indicates a good rotor Section 6 Component Testing and Adjustment 77 Repair or replace the rotor if the reading is less than approximately 500 kOhms A reading of less than 500 kOhms indicates deterioration of the winding insulation and possible current flow to ground d Following the test remove the retainer wire from the brush holder and check the brush positions on the slip rings See Section 6 6 Brushes e Reinstall the brush cover on the end bracket 6 5 Slip Rings Slip rings acquire a glossy brown finish in normal operation Do not attempt to maintain bright newly machined appearance on the slip rings Cleaning with a dry lint free cloth is usually sufficient Use very fine sandpaper 00 and apply light pressure
141. gs when the master switch is moved to the OFF RESET position Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 5 14 Output Voltage and Frequency Adjustments Continued TP 6196 10 09 Section 5 ADC RES and DC RET Controller 65 There 3 options when the display says SAVE Press To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 5 13 To save changes To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET Figure 5 15 Save Mode 5 7 Controller Relays The flash K2 fuel run crank relays are located on the controller s logic board An LED is associated with each relay See Figure 5 16 The LED indicates power to the corresponding relay If the LED is illuminated but the relay is not activated the relay is faulty The individual relays are not replaceable If one or more relays are faulty replace the logic board LED 4 lights to indicate a fault condition See Section 4 4 Faults The controller board is protected by a 10 amp fuse F2 located on the controller If the fuse blows repeatedly discon
142. handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground TP 6196 10 09 This manual provides troubleshooting and repair instructions for the generator set models listed on the front cover This manual may also be supplied for similar models not listed on the front cover Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe prescribed intervals Maintenance work must be performed by appropriately skiled and suitably trained maintenance personnel familiar with generator set operation and service For engine service procedures not covered in this manual refer to the Engine Service Manual TP 2428 TP 6196 10 09 Introduction List of Related Materials Separate manuals contain operation installation and par
143. he engine hunts and surges Then decrease the gain in small steps using the governor gain fine adjust parameter until the engine operation stabilizes Save the controller changes Remove the load and observe the frequency The frequency should return to the value stated in step 4 Gain adjustment may affect the generator set speed frequency the frequency has changed repeat step 4 Note Speed adjustments have no effect on gain adjustments It is not necessary to repeat the gain adjustments after adjusting the engine speed Check the overspeed shutdown operation when investigating a shutdown problem See Section 6 11 1 for the overspeed shutdown test procedure TP 6196 10 09 6 10 Mechanical Governor Mechanical governors are used on model 12RESL 12RESM1 and 12RESNT generator sets See Figure 6 25 This section includes governor adjustment procedures See the engine service manual for a description of mechanical governor design and operation if desired n A m ee 1 Mechanical governor assembly photo4991 Figure 6 25 Mechanical Governor Assembly Location TP 6196 10 09 Mechanical Governor Arm Adjustment Procedure Make this adjustment whenever the governor arm is loosened or removed from the cross shaft See Figure 6 26 and adjust as follows 1 Make sure the throttle linkage is connected to the governor arm and the throttle lever on the carburetor 2 Loosen the hex nut holding the g
144. he generator set only when all guards and electrical enclosures are in place TP 6196 10 09 Section 2 Scheduled Maintenance See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized distributor dealer perform generator set service Alternator Service Under normal operating conditions the generator set alternator does not require scheduled service Refer to the service schedule for items that require maintenance Engine Service Perform generator set engine service atthe intervals specified by the engine service literature Contact an authorized Kohler distributor dealer to obtain engine service literature All generator sets have emission certified engines The carburetors on emission certified engines are not adjustable Generator Set Service See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized Kohler distributor dealer perform all generator service Routine Maintenance Refer to the following generator Set service schedule the engine service schedule and the runtime hours displayed on the generator set controller to determine when to schedule routine maintenance Service the generator set more frequently if it is subject to extreme weather long operating hours or dusty or dirty conditions Service Sched
145. hiz nut or spiralock nut See Figure 2 3 Follow these SAE washer rules after determining exit hole type a Always use a washer between hardware anda slot Always use a washer under a nut see 2 above for exception Use a washer under a bolt when the female thread is fixed weld nut 4 Refer to Figure 2 which depicts the preceding hardware configuration possibilities EN 4 screw Entry hole types Standard nut and SAE washer Whiz nut or spiralock up to 1 2 in dia hardware Weld nuts above 1 2 in dia hardware Exit hole types Figure 2 Acceptable Hardware Combinations Appendix 125 Appendix General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Torque Aluminum Measurement Grade 2 Grade 8 Grade 2 5 8 32 10 24 10 32 1 4 20 1 4 28 5 16 18 5 16 24 3 8 16 3 8 24 7 16 14 7 16 20 Ib See Note 3 1 2 13 1 2 20 9 16 12 9 16 18 5 8 11 5 8 18 3 4 10 3 4 16 1 8 1 12 Metric Fasteners Torque Specifications Measured in Nm ft Ib Assembled into Aluminum Size mm Grade 5 8 Grade 8 8 Grade 10 9 Grade 5 8 or 8 8 Assembled into Cast Iron or Steel See Note 3 Notes 1 The torque values above are general guidelines Always use the to
146. 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 controller area network California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6196 10 09 cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept DFMEA dia DI EO DIN DIP DPDT DPST DS DVR E emer ECM EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper 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 Desi
147. ioned brush Figure 7 11 Brush Details e Remove the alternator overbolts and centering washers See Figure 7 10 f Using a soft faced hammer strike the side of the end bracket with medium force blows to remove the end bracket from the stator or remove the end bracket from the stator using a puller g Remove the leads connected to the end bracket from the convoluted conduit leading to GM29253B P controller Setthe end bracket assembly aside Brush cover screws Overbolt and centering washer 6 Check the brushes Alternator end bracket Brush holder a Remove the brush holder from the end bracket Brush retainer wire hole Thrubolt See Figure 7 10 Figure 7 10 Alternator End Bracket b Inspect the brushes Replace brushes when they are worn to half of their original size See d Raise the brushes in the brush holder and Figure 7 11 and Section 6 6 Brushes insert a small piece of wire into the brush holder 104 Section 7 Disassembly Reassembly TP 6196 10 09 7 Remove the stator and rotor a Remove the stator from the rotor b Loosen and remove the thrubolt Use a strap wrench on the rotor to keep the rotor from turning during loosening if necessary See Figure 7 12 c Remove the rotor assembly by striking the side of the rotor repeatedly with soft faced hammer to loosen it from the tapered crankshaft fitting See Figure 7 12 Rotate the rotor and strike it on alternate sides Set the rotor
148. is moved to the OFF RESET position Voltage frequency setting Uu Select the system voltage and frequency from the table in Figure 4 7 Note This parameter sets the nominal system voltage and frequency To adjust the output measured voltage and frequency see Section 4 5 3 Figure 4 11 and Figure 4 12 Unit configuration Uc This parameter sets the generator set type marine standby or mobile Engine configuration Ec The engine configuration must match the generator set engine type Single phase 60 Hz 120 VAC and frequency Uu01 Single phase 60 Hz 120 240 VAC Uu05 Single phase 50 Hz 115 VAC UuO6 Single phase 50 Hz 115 230 VAC Unit configuration UcO1 Standby Engine type 00 8 5 12RES Engine data input types Ed05 Digital low coolant level digital pressure analog temp with mag pickup Btl2 Battery voltage 12 VDC Communications Cnoo No CAN communications Factory settings Choose 50 or 60 hz setting for Uu as required for generator set frequency Figure 4 7 ADC 2100 Controller Configuration Parameters 40 Section 4 ADC 2100 and DC 2200 Controllers TP 6196 10 09 Advanced configuration mode Adnc The data input types battery voltage and communications setting can be changed in the advanced configuration mode Press the up arrow button when Adnc is displayed to enter the advanced configuration mode Engine data input t
149. ist of Related Materials for the document part number If the troubleshooting procedures in this section identify a bad part refer to the parts catalog for replacement part numbers See the List of Related Materials in the Introduction for the parts catalog number 3 2 Initial Checks When troubleshooting always check for simple problems first Check for the following common problems before replacing parts e Loose connections or damaged wiring e Dead battery e Fault shutdown Check for a fault code on the controller display Section 4 4 describes the warning and shutdown fault codes Troubleshooting Chart Section 3 Troubleshooting e Blown fuses Fuses in the wiring harness protect the controller SCR module and relay interface board A battery charger fuse is located in the positive battery lead Always check and replace the fuses before replacing other components e Incorrect controller settings Always check the controller configuration settings before replacing the controller Section 4 5 contains the instructions for checking and changing the controller configuration e Inadequate fuel supply Check for damaged primary or secondary fuel regulators loose connections to the fuel solenoid valve a damaged or closed fuel shutoff valve an empty LP fuel tank or other problems with the fuel supply Check the fuel supply pressure to the generator set See Section 6 12 Fuel Systems 3 3 Troubleshooting Chart Use th
150. k air cleaner Section 2 5 Section 2 4 Generator overloaded Reduce load Spark plug s Replace and plug s Section 2 3 Spark plug wire s Replace spark plug wires Engine S M DSAI leads incorrectly connected or disconnected 12kW only Connect for natural gas Disconnect for LP Section 6 12 5 Insufficient fuel pressure Check fuel pressure at carburetor outlet Section 6 12 Fuel line restriction Check fuel pipe size Section 6 12 Fuel regulator Check function of fuel regulator Section 6 12 Engine not running at rated rpm Check controller settings for unit configuration UC and engine type EC Adjust governor speed Section 4 5 or Section 5 5 Section 6 9 or 6 10 Engine power loss Refer to the engine service manual for troubleshooting and repair instructions Engine S M Lacks power continued Governor malfunction or misadjustment Test readjust governor Section 6 9 or 6 10 Ignition system 30 Section 3 Troubleshooting Test and or replace Engine S M TP 6196 10 09 Troubleshooting Chart continued Problem Overheats Possible Cause Inadequate cooling Corrective Action Inspect cooling system for air intake obstructions Reference Section 2 5 Fuel mixture adjustment incorrect Readjust fuel mixture Note Adjusting the fuel mixture may void the emission certification
151. lacing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion ca
152. le the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders 2 8 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 2 8 5 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to 2 7 Battery for the battery cleaning procedure 4 Place the battery in a cool dry location 5 Connect the battery to a float equalize battery charger or charge it monthly with a trickle battery charger Refer to the battery charger manufacturer s recommendations Maintain a full charge to extend battery life TP 6196 10 09 3 1 Introduction Corrective action and testing in many cases requires knowledge of electrical systems and electronic circuits Have an authorized distributor dealer or trained service technician perform testing and service Refer to the engine service manual for engine service information See L
153. lears the opening in the mounting plate c Disconnect plugs P1 P15 and P16 from the ADC controller See Figure 4 19 d Attach plugs P1 P15 and P16 to the new controller e Placethe new controller into position and install the four mounting screws Verify that the generator set master switch is in the OFF position Reconnect the engine starting battery negative lead last Reconnect power to the battery charger Replace the roof and tighten the four roof screws TP 6196 10 09 12 13 14 15 16 Follow the instructions in Section 4 5 2 to change the new controller s configuration settings to match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings Use a voltmeter to check the output voltage Follow the instructions in Sections 4 5 3 Voltage and Frequency Adjustments and 6 7 2 Voltage Adjustment to adjust the output voltage and stability Check the output frequency Follow the instructions in Sections 4 5 3 Voltage and Frequency Adjustments and 6 9 5 Frequency Adjustment to adjust the output frequency and stability Place the generator set master switch the AUTO position if an ATS or remote start stop switch is used Replace the enclosure door Section 4 ADC 2100 and DC 2200 Controllers 51 5 52 Section 4 ADC 2100 and DC 2200 Controllers TP 6196 10 09 Secti
154. ler pins P7 1 and P7 2 maintains power to the controller at all times Controllers are shipped with the jumper connected for continuous power See Figure 4 14 Note The controller is powered by the generator set engine starting battery The 8 5 and 12 RES generator sets are equipped with factory installed battery chargers to prevent battery discharge The P7 connector has either 2 or 3 pins Disconnecting the jumper or moving the jumper to pins P7 2 and P7 3 allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position A remote start signal from a transfer switch or a remote start stop switch connected to controller leads 3 and 4 or moving the generator set master switch to the RUN position turns the controller back on Use the following procedure to disconnect the jumper if desired Engine wiring harness connector plug P1 Continuous power mode jumper location P7 J15 connector J16 connector Generator set master switch AUTO VBAT RUN 1 2 3 4 5 6 T 8 Figure 4 14 ADC 2100 back cover removed TP 6196 10 09 Procedure to disconnect the continuous power mode jumper optional Note For most applications it is not necessary to disconnect the continuous power mode jumper 1 Prevent the generator set from starting a Move the generator set master switch to the OFF RESET position b Disconnect po
155. lled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line 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 Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaustfumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a building through windows air intake vents or other openings Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide 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 Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision Stomachache vomiting
156. llows adjustment of the output voltage and frequency if necessary Have adjustments performed by an authorized distributor dealer or service technician A digital multimeter that measures voltage and frequency is required for these adjustments The generator set must be running during voltage and frequency adjustments Use a digital multimeter to check the output voltage and frequency Refer to Sections 6 7 2 Voltage Adjustment and 6 9 5 Frequency Adjustment for instructions to measure the output voltage and frequency Use the ADC controller to adjust the output voltage and engine speed frequency if necessary while the generator set is running See Figure 5 9 The flowcharts in Figure 5 13 through Figure 5 15 outline the adjustment procedures Note Be sure to save your changes as instructed in Figure 5 15 before exiting configuration mode Changes in voltage and frequency are lost if not saved before the generator set shuts down The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup if the changes have not been saved 62 Section 5 ADC RES and DC RET Controller 5 6 1 Voltage Adjustment Note Refer to the flowcharts in Figure 5 18 through Figure 5 15 during the following procedure Voltage Adjustment Procedure 1 With the generator set off connect a digital multimeter to the output leads or an electrical outlet on the load side of the
157. m Operating Voltage 250 VAC 60 VDC Maximum Switching Capacity 440 VA 75 W AUX RUN NC Auxiliary run relay normally closed contact Open when generator set is running AUX RUN COM Auxiliary run relay common AUX RUN NO Auxiliary run relay normally open contact Closed when generator set is running Note Use maximum 14 AWG wire for TB1 connections Figure 5 21 TB1 Customer Connections 68 Section 5 ADC RES and DC RET Controller TP 6196 10 09 5 8 2 Relay Board Replacement Procedure WARNING S 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 Movethe 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 6196 10 09 Access the controller junction box to l
158. meters 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 load shed light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level 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 MQ milliohm MOhm MOV MPa mpg mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean time between failure 124 Appendix MTBO mtg MTU MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA oz pF PF ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH RHM rly mean time between overhauls mounting Motoren und Turbinen U
159. mixture is checked See Section 6 12 6 for instructions to check the fuel mixture Refer to the troubleshooting instructions in Section Troubleshooting to identify generator set operation problems that may be caused by an inadequate fuel supply incorrect adjustments or damaged fuel system components Then use the instructions in this section to check fuel system components 6 12 1 Gas Piping Verify that the gas pipe size meets the size specifications in Figure 6 32 Measure the pipe length from the gas utility pressure regulator to the end of the pipe where it connects to the fuel inlet of the generator Add 2 4m 8ft for each bend in the pipe Compare the total length with the chart in Figure 6 32 If the piping is longer than the maximum length shown in the chart replace it with a larger pipe size Bleed the air from the gas lines after installation TP 6196 10 09 Figure 6 33 lists the maximum gas flow rates for each model 8 5RES 12RES Natural Natural Gas Gas Pipe Length Figure 6 32 Maximum Gas Pipe Length Gas Flow Rate Btu hr Natural Gas LP 132000 180000 270000 Generator Set Model 8 5kW 12kW 202000 Figure 6 33 Maximum Natural Gas Flow Rate 6 12 2 Fuel Solenoid Valve A solenoid valve upstream of the regulator and the flexible fuel connector provides automatic fuel on off control The engine starting battery powers the solenoid valve and the engi
160. n Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble LP liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi 621 kPa Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble TP 6196 10 09 Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Moving Parts 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 WARNING x 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 inte
161. n cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Use a 12 volt battery with a minimum rating of 525 cold cranking amps at 18 C 0 F The generator set uses a negative ground with a 12 volt engine electrical system Make sure that the battery is correctly connected and the terminals are tight See Figure 2 12 Note The generator set will not start and circuit board damage may result if the battery is connected in reverse TP 6196 10 09 7 1 Q x E EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 2 12 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Clean the battery and cables and tighten battery terminals using the service schedule recommendations Clean the battery by wiping it with a damp cloth Keep the electrical connections dry and tight Consult the battery manufacture
162. n standing in water or on wet ground because these conditions increase the risk of electrocution Voltage Adjustment Procedure 1 Connect a digital voltmeter from one side of the circuit breaker to the LO terminal inside the controller assembly See Figure 6 12 3 phase models connect the voltmeter from LO to L1 L2 or L3 on the circuit breaker See Figure 6 14 Set the meter to measure voltage 2 Start the generator set 3 Follow the controller instructions in Section 4 5 to enter the adjustment mode and increase voltage or decrease voltage parameter 1P until the output reaches the desired voltage See Figure 6 11 Voltage Approximate Measurement Voltage VAC L LO 120 L L 240 Models 1 phase 60 Hz 1 phase 50 Hz 3 phase 50 Hz Figure 6 11 Voltage Measurement Section 6 Component Testing and Adjustment 79 See Detail Controller Box Detail 1 Controller box location 2 Line circuit breaker 3 Load connection terminal LO Figure 6 12 Circuit Breaker and LO Terminal Location 4 Follow the controller instructions to step to the voltage
163. n the engine intake valves and pistons because it oxidizes and thickens less than other oils See Figure 2 3 and Figure 2 4 7 8 5kW 1 9 2 0 12kW 2 0 2 1 Figure 2 3 Oil Capacity with Filter C 30 20 10 0 10 20 30 40 80 100 F 20 0 20 32 40 60 Temperature Range Expected Before Next Oil Change Figure 2 4 Engine Oil Selection 2 2 4 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 b Disconnect the power to the battery charger c Disconnect the generator set engine starting battery negative lead first d Remove the oil drain hose from its retaining clip See Figure 2 2 Remove the cap from the oil drain hose and lower the hose into an oil collection container e Open the oil drain valve on the engine Remove the dipstick and oil fill cap f Allowtime for the engine oil to drain completely g Close the oil drain valve h Replace the cap on the oil drain hose Replace the oil drain hose in its retaining clip Section 2 Scheduled Maintenance 21 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Apply a light coat of clean oil to the rubber seal of the new oil filter c Install the new oil filter following the instructions provided with the filter Note Dispose of all waste m
164. 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 notimprove within minutes of breathing fresh air Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels TP 6196 10 09 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 Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosio
165. ne starting controls open the valve when the engine cranks or runs Gas Valve Operation Test Procedure 1 Disconnect the positive battery lead from the gas valve terminal 2 Apply 12 VDC to the gas valve terminal and listen for an audible click indicating that the valve actuates 3 Replace the gas valve if it does not actuate in step 2 6 12 3 Fuel Regulators The typical gaseous fuel system uses two regulators The primary regulator reduces the line pressure to an allowable inlet pressure for the secondary regulator The fuel supplier provides and maintains the primary regulator The secondary regulator is factory installed on the generator set and is designed for a maximum inlet pressure of 2 7 kPa 6 2 2 280 mm 11 in water column Note Do not attemptto adjust the fuel mixture or engine speed by adjusting the regulators Section 6 Component Testing and Adjustment 93 The fuel lock off prevents fuel flow when the engine is not operating See Figure 6 35 Do not try to adjust the fuel pressure fuel mixture or engine speed using the fuel lock off Checking the Fuel Pressure Use a gauge or manometer to check the fuel pressure at the secondary regulator inlet See Figure 6 35 Measure the fuel pressure with the generator set running at rated load Verify that the fuel pressure is within the range shown in Figure 6 34 Contact the fuel supplier if the inlet pressure is not within the specified range
166. nect the board loads one at a time to identify the cause of the blown fuse e Lead 70C at the fuel valve e Lead IGN at the ignition module e Lead 71A at the starter relay e Leads FP and FN at the rotor Repair or replace the component causing the blown fuse If fuse continues to blow and disconnecting components did not identify the cause remove the leads from the P14 connector using a pusher If replacing the leads does not solve the problem replace the controller logic board 66 Section 5 ADC RES and DC RET Controller 1 LED1 Flash K1 2 LED2 Fuel 2 3 LED3 Crank 4 LED4 Fault 5 LED5 SP2 6 LED6 SP1 Figure 5 16 Relays and LEDs on Controller Logic Board TP 6196 10 09 5 8 Optional Relay Board The generator set may be equipped with an optional relay board which contains the K1 common fault relay and K4 auxiliary run relay See Figure 5 17 for the relay board location inside the controller junction box 1 Relay board
167. ng can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Hot Parts WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the 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 enough to cause severe burns Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts 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
168. ng premature wear and failure 1 Cover knob 2 Air cleaner cover 3 Element cover nut 4 Element cover 5 Foam precleaner 6 Air cleaner element 7 Air cleaner base Figure 2 10 Air Cleaner Components Air Cleaner Service Procedure 1 Disable the generator set a Place the generator set master switch in the OFF RESET position b Disconnect the power to the battery charger c Disconnect the generator set engine starting battery negative lead first 2 Remove the foam precleaner and paper element a Loosen the air cleaner cover retaining knob and remove the cover b Remove the element cover nut element cover and paper element with precleaner c Remove the precleaner from the paper element 3 Wash and oil the foam precleaner a Wash the precleaner in warm soapy water Section 2 Scheduled Maintenance 23 Rinse the precleaner with warm water until the water runs clear c Squeeze out excess water and allow the precleaner to air dry Note Do not wring twist the precleaner or dry it with compressed air d Saturate the precleaner with new engine oil Squeeze out the excess oil 4 Replace the paper element if it is dirty bent or damaged Note Do not wash the paper element or clean it with compressed air as both will damage the element 5 Reinstall the air cleaner a Install the precleaner over the paper element b Check the air cleaner base Make sure it is secure
169. nion 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 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 rms rnd ROM rot rpm RS RTU RTV SAE scfm SCR 5 sec 51 SI EO sil
170. nnect the engine removal See Figure 7 20 and refer to Step 1 of the exhaust muffler to the engine at the flanges Do disassembly instructions not final tighten the mounting hardware a Install the non service side housing panel c Secure the muffler mounting tab to the heat shield with M8 hardware b Install the alternator end housing panel d Torque the nuts securing the engine muffler c Install the generator set housing roof flange to the engine to 24 Nm 216 in Ib BUR 4 tp6196 1 Roof 4 Mounting pad 2 Service side door 5 Rear panel alternator end 3 Front panel air intake end Engine exhaust muffler Muffler bolts Heat shield Flange connection Heat shield bolts Figure 7 20 Generator Set Enclosure Figure 7 19 Exhaust System TP 6196 10 09 Section 7 Disassembly Reassembly 107 12 Return the generator set to operation a Check that the generator set master switch is in the OFF position b Reconnect the generator set engine starting battery negative lead last c Reconnect power to the battery charger if equipped 108 Section 7 Disassembly Reassembly 13 14 15 Turn on the fuel supply Move the generator set master switch to the RUN position and check for leaks with the engine running Move the generator set master switch to the OFF RESET position Move the switch to the AUTO position if an automatic transfer switch or remote start stop switch is used Rein
171. ntroller settings as required Reference Section 4 5 or 5 5 Check for power to the controller at lead PF1 Check replace fuse F3 Check battery Section 8 Check controller fuse F3 Replace controller fuse Section 8 Check controller wiring and connections Tighten connections and or replace wiring Replace SCR module and recheck voltage Replace the SCR module Section 6 8 Perform all tests listed under high output voltage Replace the controller only if previous steps do not solve the problem Section 4 9 or 5 9 SCR module Check wiring and connections to the SCR module Tighten connections and or replace wiring to the SCR module Section 6 8 Test the SCR module using the procedure in Section 6 8 Replace the SCR module and recheck voltage Section 6 8 Check auxiliary winding fuse F1 lead 55 Replace auxiliary winding fuse F1 lead 55 Section 8 ADC RES controller only TP 6196 10 09 Section 3 Troubleshooting 33 5 34 Section 3 Troubleshooting TP 6196 10 09 Section 4 ADC 2100 DC 2200 Controllers 4 1 Introduction This section covers operation configuration adjustment and replacement of the ADC 2100 and DC 2200 controller See Section 3 for troubleshooting procedures See Figure 4 1 for the locations of the controller and related components Section 4 2 describes the controller keypad and displa
172. nts Parameter 2P KT To enter volts Hz adjustment mode Parameter 3P To raise or lower the volts Hz 00 low 09 high lt Continued on Figure 5 14 Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 5 13 Output Voltage and Frequency Adjustments 64 Section 5 ADC RES and DC RET Controller TP 6196 10 09 Continued from Figure 5 13 Display Press To enter engine governor speed coarse adjustment mode Parameter 4P To raise or lower the engine speed in large increments lt el To enter engine governor speed fine adjustment mode Parameter 4P To raise or lower the engine speed in smaller increments lt enter engine governor stability gain coarse adjustment mode Parameter 5P To raise or lower the engine governor stability gain in large increments To enter engine governor stability gain fine adjustment mode Parameter 5P To raise or lower the engine governor stability gain in smaller increments lt enter SAVE mode Go to Figure 5 15 Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settin
173. o 7 Nm 60 in Ib 106 Section 7 Disassembly Reassembly tp6196 1 Alternator assembly overbolts 2 Rotor thrubolt 3 Vibromount plate Figure 7 16 Generator Set Right Side typical 6 Reinstall the end bracket components a Install the brush holder onto the end bracket Verify that the brushes are not sticking in the holder Verify that the brushes are centered on the slip rings If required insert spacers between the mounting surface and brush holder to center the brushes on the slip rings See Figure 7 17 See Section 6 6 Brushes for information Reinstall the brush cover onto the alternator end bracket Verify that the brush leads are not pinched between the brush cover and end bracket 1 Brush holder 2 Brushes 3 Slip rings Figure 7 17 Brush Positioning TP 6196 10 09 7 Reinstall the alternator air inlet duct Orient the 8 Install the exhaust shield See Figure 7 18 duct as shown in Figure 7 18 ALTERNATOR AIR INLET DUCT DETAIL GM29253C U 1 Alternator air inlet duct 2 Mounting screws 3 ea 3 Exhaust shield Figure 7 18 Alternator Air Inlet Duct 9 Install the exhaust system See Figure 7 19 10 Reconnect the alternator leads inside the controller box See the wiring diagrams in Section 8 for a Install the heat shield onto the alternator connections exhaust support using M8 hardware 11 Reinstall the enclosure panels in reverse order of b Using new gaskets co
174. oard onto the stand offs and reconnect P14 and the brush leads 48 Section 4 ADC 2100 and DC 2200 Controllers The generator set may be equipped with an optional RIB which contains the K4 auxiliary run relay and K1 common fault relay in addition to the standard relays The optional relay board kit includes a wiring harness for connection of customer equipment to the K1 and K4 relays See Figure 4 16 for optional relay connections RUY UJ 6 4 4 E 3 1 T 22 y R GM29779 A K1 common fault relay optional K2 crank relay standard flash relay standard K4 auxiliary run relay optional 5 run relay standard P14 engine harness connection standard P13 connection to optional relay harness optional Figure 4 15 Relay Board Harness Lead Connector Number Pin Number Connection Common fault normally open Common fault common Common fault normally closed Run relay normally open Run relay common Run relay normally closed Figure 4 16 Optional Common Fault and Run Relay Board Harness Connections TP 6196 10 09 4 9 Controller Replacement If the troubleshooting procedures in Section 3 identify a bad controller use the procedure in this section for controller replacement Always check the controller configuration fuse wiring and connections before replacing the controller For output voltage
175. ocate the relay board See Figure 5 17 Disconnectrelay board harness connector P3 from connector P14 on the relay board Pull the faulty relay board off the four mounting standoffs inside the junction box Press the new relay board onto the four standoffs Connect three pin connector of the relay board harness GM52639 to P14 on relay board GM51403 See Figure 5 18 and Figure 5 20 Verify that the relay board harness is securely connected to P11 on the control board See Figure 5 19 and Figure 5 20 Verify that the relay board harness is securely connected to the engine harness See Figure 5 20 Section 5 ADC RES and DC RET Controller 69 5 9 Controller Replacement If the troubleshooting procedures in Section 3 identify a bad controller use the procedure in this section for controller replacement Always check the controller configuration fuse wiring and connections before replacing the controller For output voltage problems replace the SCR module and check the operation again before replacing the controller After replacing the controller verify that the new controller s configuration settings match the generator set system voltage frequency and unit configuration Refer to Section 4 5 for instructions to check the controller configuration and to change the settings if necessary After the controller configuration has been checked and set to match the generator set use a voltmeter to check
176. ocation Refer to the generator set Parts Catalog for the fuel metering valve part number 96 Section 6 Component Testing and Adjustment Only trained authorized service technicians may adjust the new fuel metering valve The adjustment procedure requires a digital volt meter DVM UEGO oxygen sensor service kit GM29385 and load bank capable of the rated kW for the fuel being used Always use an oxygen sensor when adjusting the fuel metering valves Observe the following safety precautions while performing the procedure A WARNING omi 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 Fuel Mixture Check Fuel Metering Valve Adjustment Procedure 1 Place the generator set master switch in the OFF position 2 Disconnect power to the battery charger 3 Remove the oxygen sensor plug from the exhaust manifold and install the oxygen sensor See Figure 6 38 for location Sawa GM29253 1 Oxygen sensor mounting location Figure 6 38 Oxygen Sensor Mounting Location TP 6196 10 09 10 Connect the oxygen sensor to the engine starting battery control module and voltmeter as
177. on 5 ADC RES DC RET Controller 5 1 Introduction See Figure 5 1 for the controller location This section covers operation configuration adjustment and replacement of the ADC RES and DC RET controllers See Section 3 for troubleshooting procedures GROUND STUD DETAIL 2 PLACES Front View Controller display Keypad ADC RES only see Figure 5 2 Generator set master switch RUN OFF RESET AUTO Line circuit breaker load connection Fuses F1 F2 and Serial port for communication connection remove plug to access Figure 5 1 Controller Components TP 6196 10 09 Logic board Optional relay board location LO stud Ground stud Start relay SCR module Section 5 ADC RES and DC RET Controller 53 5 2 Controls and Display The ADC RES controller has an LED display and a three button keypad See Figure 5 2 The DC RET controller has an LED display See Figure 5 3 three position generator set master switch is mounted on the controller junction box DEFINITION Crank Cycle High Battery Voltage High Engine Temp Low Battery V a AN 721 250 2501 OUTPUT POWER BREAKER 1 LED display 2 Select button use for setup and adjustment only 3 Up and down arrow buttons use for setup and adjustment only 4 Generator set master switch RUN OFF RESET AUTO Figure 5 2 ADC RES Controller 5 2 1 Mast
178. on RIB Check fuse F2 and troubleshoot RIB Section 4 8 Flash relay on controller board ADC RES Check fuse F2 Check flash LED1 on controller board If LED1 indicates power to but relay does not operate replace controller circuit board Section 5 7 Noisy operation Exhaust system leaks Check and replace as necessary Section 2 6 Engine not running smoothly See Generator set operates erratically in this table Broken or damaged vibromount s Check and replace as necessary Section 7 Loose or vibrating sheet metal housing Retighten screws replace rivets Exhaust piping or air inlets outlets not securely installed Inspect for loose parts and secure if necessary Section 2 6 Excessive engine generator vibration 32 Section Troubleshooting Check rotor crankshaft bearing etc disassembly of engine and or alternator may be required Section 7 Engine S M TP 6196 10 09 3 4 Controller Troubleshooting Refer to the controller troubleshooting table in this section when troubleshooting procedures in Section 3 3 indicate a possible controller problem Always check the ADC RES controller configuration settings before replacing the controller installation manual contains the instructions for checking and changing the controller configuration Possible Cause Controller Check controller settings Corrective Action Adjust co
179. onal RUN Position components A zero reading on the ohmmeter indicates continuity No ohmmeter reading indicates very high T resistance an open circuit A measurement that g 2 varies significantly from the value shown in the table indicates faulty component replace faulty components Note Disconnect the generator set battery before performing continuity checks to prevent damage to the ohmmeter Master Switch in AUTO Position Figure 6 44 Generator Set Master Switch Continuity Checks Generator Set Ohmmeter Ohmmeter Master Switch Ohmmeter Readings for Component Connections Scale Position Operative Components Generator set RUN and VBAT see RUN Zero ohms continuity Any other reading master switch Figure 6 44 indicates a bad switch OFF RESET reading open circuit Any other reading indicates a bad switch AUTO and VBAT AUTO Zero ohms continuity Any other reading see Figure 6 44 indicates a bad switch OFF RESET reading open circuit Any other reading indicates a bad switch P1 wiring P1 27 and ground OFF RESET Zero ohms continuity Any other reading harness indicates a poor ground connection P15 1 and P15 3 OFF RESET Zero ohms continuity If no continuity stator leads 11 and 44 check wiring P16 3 and P16 6 stator OFF RESET Zero ohms continuity If no continuity leads 55 and 66 check fuse F1 and wiring Controller fuse P1 24 and batte
180. ontroller parameters during configuration and adjustment See Figure 4 4 FOU to pem CONTROL CODE DEFINITION Auxillary Fault Crank Cy rem Under Voltage 7 OFF RESET GM28707A C 1 LED display 2 Select button use for setup and adjustment only 3 Up and down arrow buttons use for setup and adjustment only 4 Generator set master switch Figure 4 2 ADC 2100 Controller DEFINITION Crank Cycle High Engine Temp Low Battery Voltage Low Oil Pressure Over Crank Over Speed Under Frequency seh OFF RESET GM39579 1 LED display 2 Generator set master switch Figure 4 3 DC 2200 Controller 36 Section 4 ADC 2100 and DC 2200 Controllers Controller Display Crank indication Description Displays CC_1 CC_2 or CC_3 to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Runtime hours Displays total generator set runtime hours when no other code is displayed Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 4 4 System parameters Displays 2 letter codes or 4 digit alphanumeric codes during system configuration or adjustment See Section 4 5 Application program version number ADC 2100 Displays the version number of the controller s application program before entering the configuration or
181. ontroller see Section 2 Operation in the operation manual Environmental Specifications Operating temperature 20 to 70 C Storage temperature 60 to 70 C Humidity 0 95 condensing Power requirements 12 or 24 VDC 250 mA 12 VDC 125 mA 24 VDC Voltage Current 1 3 Engine Features The generator sets are equipped with four cycle twin cylinder air cooled Kohler engines Some of the engine features include TP 6196 10 09 Section 1 Specifications One side serviceability of air cleaner carburetor oil fill dipstick and oil drain e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions e Electronic governor to ensure AC power output is maintained at desired frequency Overspeed shutdown to prevent governed frequency from exceeding 70 Hz on 60 Hz models 60 Hz on 50 Hz models e Low oil pressure cutout to prevent failure e Dependable maintenance free electronic ignition e Digital Spark Advance Ignition DSAI optimizes engine timing for natural gas or LP fuel 12 kW models only e Parts subject to the most wear and tear made from precision formulated cast iron e Hydraulic valve adjusters to eliminate the need for valve adjustments Field convertible fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintaining CARB certification For en
182. or recognition Replace missing or damaged decals TP 6196 10 09 Accidental Starting A WARNING Pa or Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop Switch or engine start command from a remote computer Battery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles clothing Battery acid may cause blindness and burn skin 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
183. or overloading on the load side before resetting the circuit breaker Reference Alternator or control system Perform separate excitation procedure to isolate the problem to the alternator or the control system Then troubleshoot the alternator or control system components as follows Section 6 2 Aux winding fuse F1 blown Check fuse F1 and replace if blown If fuse blows again check stator Section 6 3 SCR module Check auxiliary winding fuse F1 Replace SCR module and test voltage Section 6 13 Section 6 8 Controller Check controller settings Check wiring and connections Before replacing controller replace SCR module and check voltage Section 4 5 Section 6 8 Open wiring terminal or pin in buildup circuit or SCR module circuit Check continuity Sections 6 13 Section 8 Brushes Inspect brushes and replace if worn Section 6 6 Check for brushes sticking in brush holder or broken brush spring Section 6 6 Rotor connections Check for open circuit in rotor connection circuit leads FN and FP to SCR and RIB Section 8 Rotor slip rings dirty or corroded Check slip ring condition Section 6 4 Rotor open grounded or shorted windings Check voltage and continuity Section 6 4 Stator open grounded or shorted windings Check voltage and continuity Section 6 3 Flash relay K3 on RIB ADC 2100 Check flash LED
184. ors the generator output voltage through leads 11 and 44 single phase or leads V7 V8 and V9 three phase and adjusts the DC current from the SCR module to the rotor to meet load requirements See Figure 6 1 ADC Controller 1 Fuse 2 Power lead 55 3 Excitation to rotor 4 Brushes 5 Slip rings 6 Main field rotor 7 Stator windings 8 Sensing leads 11 44 Figure 6 1 Single Phase Generator Schematic TP 6196 10 09 6 2 Separate Excitation To determine the cause of no or low AC output refer to the troubleshooting flow chart in Figure 6 2 Before beginning the test procedures read all safety precautions at the beginning of this manual Many of the test procedures include additional safety precautions No Generator Output Separate Excitation Output within Specifications Check Wiring Fuses SCR Module and Controller Erratic or No Output Check Rotor Check Stator TP563273 Figure 6 2 Generator Troubleshooting Check the condition of the alternator fuse before performing the separate excitation procedure The inline fuse is located in lead 55 of the wiring harness or on the junction box panel near the cotnroller See Figure 6 1 If the fuse is not blown use the following procedure to separately excite the generator using an ext
185. overnor lever to the cross shaft 3 Move the governor lever toward the carburetor as far as it will move wide open throttle and hold in this position 4 Insert a nail into the hole in the cross shaft and rotate the shaft counterclockwise as far as it will turn Tighten the hex nut securely and then remove the nail photo5005 1 Hex nut 2 Cross shaft 3 Governor lever 4 Throttle linkage passes under air cleaner Figure 6 26 Governor Arm Adjustment Section 6 Component Testing and Adjustment 89 Mechanical Governor Sensitivity Adjustment Note Often hunting surging problems thought to be caused by the governor are actually caused by engine or carburetor problems If the generator set speed is unstable hunts or surges check for the cause using the procedure in Section 6 9 3 before proceeding Governor sensitivity is adjusted by repositioning the governor spring in the holes of the governor lever If speed surging occurs with a change in engine load decrease the governor sensitivity If a drop in speed occurs when normal load is applied increase the governor sensitivity See Figure 6 27 and adjust as follows 1 To increase the sensitivity move the spring closer to the governor cross shaft 2 To decrease the sensitivity move the spring away from the governor cross shaft nas 1 Governor lever 2 Cross shaft Figure 6 27 Governor Sensitivity Adjustment 90 Section Component
186. pickup gap and operation Section 6 9 4 Check for locked rotor Section 6 4 Starts hard Low battery voltage Check battery voltage and battery charger connections power supply and operation Generator Set O M Air cleaner clogged Replace element Section 2 4 Fuel mixture adjustment incorrect Adjust fuel valve Section 6 12 DSAI leads incorrectly connected or disconnected 12kW only Connect for natural gas Disconnect for LP Section 6 12 5 Spark plug s Replace or regap spark plug s Section 2 3 Spark plug wire s Check spark plug wires and connections Replace spark plug wires Engine S M Ignition components spark control or ignition module Test replace ignition components Engine S M Insufficient fuel pressure Check fuel pressure Section 6 12 3 Worn piston rings valves Check compression Engine S M Starts but shuts down Fault shutdown Check for a fault shutdown code on the controller s LED display Correct the fault and then move the generator set master switch to OFF RESET to reset the controller Section 4 4 or 5 4 Section 6 11 Stops suddenly Fault shutdown Check for a fault shutdown code on the controller s LED display Correct the fault and then move the generator set master switch to OFF RESET to reset the controller Section 4 4 or 5 4 Section 6 11 No fuel Turn on fuel supply
187. problems replace the SCR module and check the operation again before replacing the controller After replacing the controller verify that the new controller s configuration settings match the generator set system voltage and frequency unit configuration engine type engine data input types battery voltage and communications settings Refer to Section 4 5 for instructions to check the controller configuration and to change the settings if necessary After the controller configuration has been checked and set to match the generator set use a voltmeter to check the generator set output voltage and frequency If the output voltage or frequency needs adjustment use the Voltage and Frequency Adjustment Procedure Section 6 7 2 and the controller voltage and speed adjustment instructions in Section 4 5 3 Also see the Frequency Adjustment Procedure in Section 6 9 5 TP 6196 10 09 ADC 2100 Controller Replacement Procedure 1 Remove the enclosure service side door See Figure 4 17 2 Place the generator set master switch in the OFF position 3 Remove 4 roof screws Lift the roof up and off See Figure 4 17 4 Disconnect power to the battery charger 5 Disconnect the generator set engine starting battery negative lead first amp POWER SYSTEMS BAR Roof Roof locating pin Roof screws 4 ea Service side door Front panel Figure 4 17 Enclosure Roof and Door Section 4 ADC 2100 and
188. r s instructions for battery care and maintenance 2 7 4 Cleaning Battery To prevent dirt and grime buildup occasionally wipe the battery with a damp cloth To prevent corrosion maintain tight dry electrical connections at the battery terminals remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water Do not allow the cleaning solution to enter the battery s cells After cleaning flush the battery and cables with clean water and wipe them with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease 2 7 2 Battery Charger Generator sets are equipped with a factory installed battery charger to keep the starting battery fully charged Observe the battery polarity when connecting the battery charger Check the battery charger fuse and power supply See the generator set operation manual for information about battery charger operation and troubleshooting Section 2 Scheduled Maintenance 25 2 8 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system internal engine component storage 2 8 4 Lubricating System Prepare the
189. raise or lower the engine governor stability gain in large increments To enter engine governor stability gain fine adjustment mode To raise or lower the engine governor stability gain in smaller increments lt To enter SAVE mode Go to Figure 4 13 SAV Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Shaded boxes show which character in the controller display changes for each adjustment X in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 4 12 Output Voltage and Frequency Adjustments Continued TP 6196 10 09 Section 4 ADC 2100 and DC 2200 Controllers 45 There 3 options when the display says SAVE Press To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 4 8 To save changes To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET Figure 4 13 Save Mode after generator set and engine adjustments 4 6 Continuous Po
190. rconnection of standby normal sources of supply CAUTION C j 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 circuits 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 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 Safety Precautions and Instructions 9 High voltage test Hazardous voltage can cause severe injury or
191. rque values specified in the service manuals and or assembly drawings when they differ from the above torque values 2 The torque values above are based on new plated threads Increase torque values by 15 if non plated threads are used 3 Hardware threaded into aluminum must have either two diameters of thread engagement or a 30 or more reduction in the torque to prevent stripped threads 4 Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90 of the yield strength and a friction coefficient of 0 125 126 Appendix TP 6196 10 09 Appendix D Common Hardware Identification Screw Bolts Studs Ns Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head with Washer or Elastic Grade 5 Flat Head FHM Square Grade 8 Grade 8 9 Hex Socket Round Head RHM Cap or Acorn Head Metric Number stamped on Hex Socket Head Cap or Washers hardware 5 8 shown Allen Head Cap Washer Styles Hex Socket Head or Allen Head Shoulder Bolt Plain e Sheet Metal Screw Split Lock or Spring Stud Spring or Wave Drive Styles External Tooth Lock Hex Internal Tooth Lock Hex and Slotted Internal External Tooth Lock Phillips Slotted Hex Socket Allen head scr
192. rter relay Negative battery connection DSAM ground screw Figure 1 3 Generator Set Service View 12 kW Model with ADC 2100 Controller TP 6196 10 09 WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer WARNING Efe 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 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate t
193. ry OFF RESET Zero ohms continuity If no continuity is and wiring positive found check fuse F3 and wiring Auxiliary winding P16 3 and stator lead 55 OFF RESET ohms continuity If no continuity is fuse 20 amp fuse found check for an open circuit and or a blown fuse Low oil pressure Lead 13 and ground R x 100 OFF RESET Zero ohms continuity No continuity LOP switch engine block indicates a bad switch and or wiring Temperature P1 8 and P1 9 R x 1000 OFF RESET 1180 2500 ohms depending on engine sensor CTS temperature Zero ohms or an open circuit indicates bad wiring or a bad switch See Section 6 11 2 Fault Shutdown Switches Figure 6 45 Continuity Checks TP 6196 10 09 Section 6 Component Testing and Adjustment 99 5 100 Section Component Testing Adjustment TP 6196 10 09 Section 7 Disassembly Reassembly This section provides instructions for the disassembly b Place the generator set master switch in the and reassembly of the generator set alternator Before OFF position beginning the generator disassembly or reassembly procedure carefully read all safety precautions at the c Remove 4 roof screws Lift the roof up and off beginning of this manual See Figure 7 1 d Remove 5 screws to remove the front panel 7 1 Disassembly Remove the plastic caps to access the 2 side screws See Figure 7 2 The disassembly procedure provides important in
194. save your changes immediately after making adjustments 4 5 2 Controller Configuration The controller configuration is factory set and should not normally require changes in the field However the controller configuration may need to be checked or Parameter Definition Unit s system voltage changed during generator set service or controller replacement The controller s configuration mode allows adjustment of the system parameters listed in this section The system voltage and frequency and unit configuration and engine type are factory set for each type of generator set and engine and should not require changes unless the controller is replaced The controller s advanced configuration mode allows the user to set the data input type for engine senders toggle the battery voltage between 12 and 24 volts and change the controller communications setting for optional meters not offered for standby models Check these settings after controller replacement and change them if necessary to match the settings shown in Figure 4 7 Follow the instructions in Figure 4 8 to enter the configuration mode while the engine is not running and then step through the following parameters Use the up A and down arrow buttons to select the appropriate setting for the application Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch
195. se severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Temperature Sensor CTS The coolant temperature sensor CTS is used to monitor engine temperature for the high engine temperature fault shutdown HE See Section 1 7 92 Section Component Testing and Adjustment Service View for the coolant temperature sensor location Set the generator set master switch to the OFF position and allow the generator set to cool Disconnect the CTS and use an ohmmeter to measure the resistance across the sensor The sensor resistance varies with temperature and should be within the values shown in Figure 6 30 If the resistance is very low indicated a short circuit or very high indicating an open circuit replace the CTS Note The HET switch is located in the engine oil pan Drain the engine oil before removing the switch Temperature C F Resistance Ohms 30 86 2100 2500 100 212 180 200 Figure 6 30 Coolant Temperature Sensor Resistance Readings Low Oil Pressure LOP Switch The low oil pressure LOP switch is located under the engine air cleaner See Figure 6 31 1 Oil pressure switch Figure 6 31 Oil Pressure Switch Location under air cleaner Remove the LOP switch and install an oil pressure gauge to verify that the engin
196. sformer TP 6196 10 09 Appendix Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made Bolt Screw Length When bolt screw length is not given use Figure 1 as a guide As a general rule a minimum length of one thread beyond the nut and a maximum length of 1 2 the bolt screw diameter beyond the nut is the preferred method Washers and Nuts Use split lock washers as a bolt locking device where specified Use SAE flat washers with whiz nuts spiralock nuts or standard nuts and preloading torque of the bolt in all other applications See Appendix C General Torque Specifications and other torque specifications in the service literature Preferred Nut Bolt Clearance 1 1 2 of bolt diameter 2 Min 1 full thread beyond top of nut 3 Below top of nut Figure 1 Acceptable Bolt Lengths TP 6196 10 09 Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nut and SAE washer Hardware 1 2 inch or less in diameter can take a properly torqued w
197. ssary Spark Plug Maintenance Procedure 1 Clean the area around the base of the spark plug to keep dirt and debris out of the engine 2 Remove the spark plug and check its condition Replace the spark plug if it is worn or if its reuse is questionable TP 6196 10 09 3 Check the spark plug gap using a wire feeler gauge See Figure 2 7 for the recommended gap Adjust the gap by carefully bending the ground electrode See Figure 2 8 and Figure 2 9 4 Install the spark plug and tighten it according to the torque specification in Section 1 5 8 5 kW 12 kW 0 51 mm 0 020 in 0 76 mm 0 030 in Figure 2 7 Spark Plug Gap Figure 2 9 Adjusting the Spark Plug Gap 2 4 Air Cleaner Element and Precleaner The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 2 10 Refer to Section 1 7 Service View for the air cleaner location Wash and oil the precleaner and replace the paper element at the intervals shown in the service schedule Figure 2 1 Service the air cleaner more often if the generator set operates under dusty or dirty conditions Refer to Maintenance and Service Parts the Introduction section of this manual for replacement part numbers Keep the area around the air cleaner housing free of dirt and debris TP 6196 10 09 Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causi
198. stall the generator set housing service side door TP 6196 10 09 Section 8 Wiring Diagrams At the time of print this manual applied to the models with controllers shown in Figure 8 1 The schematics and wiring diagram drawing numbers and page numbers are listed in the table below The drawings are arranged in numerical order on the following pages Schematic Point to Point Wiring Diagram Model No Controller Drawing Number Drawing Number Page ADV 6835A 8 5RES ADC 2100 GM29358 ADV 6835B 8 5RES ADC RES ADV 7592 GM66285 ADV 6835A 12RES ADC 2100 GM29358 ADV 6835B 12RES ADC RES ADV 7592 GM66285 12RESL ADV 7296A DC 2200 GM49761 12RESM1 ADV 7296B 12RESL 12RESM1 ADV 7351 GM52471 12RESNT 12TRES nope GM63546 ADC RES Sheet 3 50 Hz Sheet 4 sheet 3 Figure 8 1 Wiring Diagrams and Schematics TP 6196 10 09 Section 8 Wiring Diagrams 109 i 2 GE89 AGY 2 1 NOVEN 777 534 21 88 5 GEE NOUN 87 30530 0 SLO TY 31403 NODIS CIS 108 ISO 09 ANON SIKL VST 92086 TION SNAISAS HAMOA OD 3NION3 YOLON 344315 WLS MOlVIS 191 45 LYWWS 955 GIONSIOS 5 SS AVI3N N3lMVIS MS
199. stem voltage frequency and unit configuration b Use a voltmeter to check the output voltage Follow the instructions in Sections 4 5 3 Voltage and Frequency Adjustments and 6 7 2 Voltage Adjustment to adjust the output voltage and stability GM57149 c Check the output frequency Follow the 1 User interface membrane instructions in Sections 4 5 3 Voltage and 2 Controller logic board location Frequency Adjustments and 6 9 5 Frequency Figure 5 25 Controller PN to adjust the output frequency and stability 20 Place the generator set master switch in the AUTO position if an ATS or remote start stop switch is used 21 Replace the service door TP 6196 10 09 Section 5 ADC RES and DC RET Controller 71 5 72 Section 5 ADC RES and DC RET Controller TP 6196 10 09 Section 6 Component Testing and Adjustment 6 1 Theory of Operation These generator sets utilize a rotating field alternator to produce AC voltage Upon activation of the generator master switch DC current from the battery magnetizes the rotor field When the magnetized rotor rotates within the stator windings an electrical voltage develops within the stator As engine speed and generator output increase the SCR module feeds rectified stator output current to the rotor through the brushes slip rings to increase the strength of the rotor field As the rotor field increases in strength generator output also increases The ADC controller monit
200. sure and pipe size for the generator set plus all other gas appliances Section 6 12 3 Fuel regulator valve Check regulator valve operation Section 6 12 4 Spark plugs or spark plug connections Check spark plug wires and connections Replace or clean and regap spark plugs Section 2 3 Loose connection or open circuit 28 Section 3 Troubleshooting Check for loose or open connection at the fuel valve lead 70A and at the engine spark control module leads IGN and 70 Check controller engine wiring continuity Section 8 TP 6196 10 09 Troubleshooting Chart continued Problem Cranks but Possible Cause Air cleaner clogged Corrective Action Clean or replace Reference Section 2 4 does not start continued Magnetic pickup Check for 1 75 volts or higher from the magnetic pickup during cranking A lower signal will cause the stepper motor to open and close during cranking Section 6 9 4 Incorrect controller configuration Check for correct controller configuration settings Section4 5 or 5 5 Ignition system spark control or ignition coil Test and or replace components Engine S M Digital spark advance ignition DSAI connections 12kW only Connect for natural gas Disconnect for LP Check for loose connections Section 6 12 5 No engine rotation sensed check for an overcrank fault shutdown Check mag pickup connections mag
201. t battery boots and replace if necessary Yearly Tighten DC electrical connections Yearly AC Electrical System General inspection Quarterly Wire abrasions where subject to motion Six Months Tighten control and power wiring connections Yearly Wire cable insulation breakdown 3 yr or 500 hr Engine and Mounting General inspection Weekly Air cleaner and precleaner service Yearly or 100 hr Spark plugs Yearly Replace spark plugs 500 hr Stepper motor coupling and bushing 3 yr or 500 hr Generator Compartment condition Weekly Inspect brushes and collector ring Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier and load leads disconnected 3 yr Run exercise generator set Weekly Remote control operation Monthly General Condition Of Equipment Any condition of vibration leakage excessive noise high temperature or deterioration X X Weekly Interior of enclosure X Quarterly Replace X Action O M Generator Set Operation Manual E Follow procedures and frequencies indicated in the engine manufacturer s maintenance manual If not indicated follow this service schedule Some items may not apply to all generator sets Service more frequently if operated in dusty areas Repla
202. that may appear in this publication A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP alt ANSI AO APDC API approx AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BDC BHP blk blk htr BMEP bps br Btu min cal CAN CARB CB 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 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
203. the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer 1 DSAI connector location 2 Fuel metering valve 3 Fuel inlet 1 2 in NPT female Figure 6 36 Generator Set Fuel System Location Air Inlet Side TP 6196 10 09 1 Place the generator set master switch in the OFF position 2 Disconnect the power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Turn off the fuel supply 5 Remove the hose clamp and fuel hose from the hose fitting in the fuel metering valve See Figure 6 35
204. the level is low Check low oil pressure switch connections and operation Check the oil pump and lubrication system Overcrank Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest Check the fuel supply valves and pressure Check spark plug and battery See Troubleshooting Chart generator set cranks but does not start Locked rotor The generator set shuts down on an overcrank fault if no engine rotation is sensed Shuts down 3 seconds after the fault is detected Check mag pickup connections and operation Check for a locked rotor Overfrequency 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 Check system frequency setting parameter UU on controller Measure output frequency and adjust if necessary Check governor system condition and operation Overspeed Shutdown occurs if the engine speed exceeds 11096 of the normal running speed for more than 0 3 seconds Check governor settings and operation Overvoltage Shutdown occurs if the voltage exceeds 12096 of the system nominal voltage for more than 2 seconds Check AC voltage Check wiring and connections Underfrequency Shutdown occurs when the governed frequency falls
205. the stepper motor does the controller Leads 1A 1B 2A and 2B to pins not operate as described in step 9 the problem is P1 4 P1 5 P1 6 and P1 7 Check the pins and with the ADC controller Check controller connections at plugs 46 and See the wiring connections fuses wiring and settings Refer to diagrams in Section 8 the troubleshooting procedures in Section 3 11 Check the stepper motor coil resistance across pins 2 and 3 and across pins 1 and 4 Only two stepper motor leads of each coil group are used BLK YEL and RED WHT See Figure 6 24 The resistance per half coil is 38 5 ohms If one of the coils has a significantly higher resistance or is shorted replace the stepper motor TP 6196 10 09 Section 6 Component Testing and Adjustment 87 6 9 5 Frequency Adjustment The engine speed determines the generator output frequency 60 Hz units operate at 3600 rpm and 50 Hz units run at 3000 rpm Adjust the engine governor to change the output frequency using the following procedure Note Engine governor speed frequency and gain adjustments are made using the ADC controller See Section 4 5 3 for instructions Frequency Adjustment Procedure 1 Open the generator set line circuit breaker 2 Attach a frequency meter to the AC output leads 3 Start and run the generator set until it reaches normal operating temperature at least 10 minutes 4 Use the ADC controller to adjust the electronic governor speed paramet
206. to remove roughness Do not use emery or carborundum paper or cloth Clean all carbon dust from the generator after sanding the slip rings If the rings are black or pitted remove the rotor and use a lathe to remove some of the slip ring surface material 6 6 Brushes The brushes transfer current from the SCR module to the slip rings The brushes should last the life of the generator Abrasive dust on the slip rings however shortens the life of the brushes Excessive arcing at the brushes could damage the SCR module and the controller Weak springs damaged slip rings sticking brushes a loose brush holder or poor brush contact causes arcing The brushes must be free to move within the holder and be held in contact with the slip rings by the springs When correctly positioned spring pressure on the brush surface causes the brush to wear evenly The entire brush must ride on the ring or arcing occurs and causes burned rings or voltage regulator failure Figure 6 10 shows the correct positioning of the brushes Add or remove shims as necessary to center the brushes on the slip rings Replace the brushes if they show uneven wear or are worn to one half their original length 78 Section Component Testing and Adjustment Check the resistance through the brushes Resistance through the brushes should be low 0 1 0 2 ohms without meter lead resistance GM29253B P Side View 1 2
207. ts information not provided in this manual Separate engine operation and service manuals are also available The following table lists the available manual part numbers Part Document Description Number Operation Installation Manual 8 5 12RES TP 6195 Installation Manual 8 5 12RES w ADC 2100 TP 6328 Operation Manual 8 5 12RES w ADC 2100 TP 6331 Installation Manual 12RESL RESM1 w DC 2200 Operation Manual 12RESL RESM1 w DC 2200 Installation Manual 8 5 12RES 12TRES w ADC RES Operation Manual 8 5 12RES 12TRES w ADC RES Installation Manual 12RESL RESM1 w DC RET Operation Manual 12RESL RESM1 w DC RET Parts Catalog 8 5 12RES Parts Catalog 12RESL RESM1 TP 6398 TP 6397 TP 6514 TP 6515 TP 6516 TP 6517 TP 5868 TP 6399 TP 2428 Engine Service Manual Replaced by TP 6328 and TP 6331 May 2004 Routine Service Parts See the Parts Catalog for a list of common replacement parts Introduction 11 Service Assistance For professional advice generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler KohlerPower com Power Systems website Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in
208. uency Adjustments 41 4 5 4 Controller Application Program 41 4 6 Continuous Power Mode Jumper 46 47 Master SWIC sen eda e pti ee REG Allee Shani aga ade ae 48 4 8 Relay Interface Board 48 4 9 Controller Replacement 49 Section 5 ADC RES DC RET Controller 53 5 T rtroductlon s sax la Sas aries 53 5 2 Controls and Display 54 5 2 1 Master SWIG sanp Raced 54 522 ee RE DERE ERE BUS MERE RANA 54 5 2 8 E 55 5 3 Sequence of Operation 56 5 3 1 Starting Sequence Master Switch Moved to RUN 56 5 8 2 Starting Sequence Remote 5 56 5 3 3 Running Sequence 56 5 3 4 Stopping Sequence Master Switch Moved to OFF RESET 56 5 3 5 Stopping Sequence Remote Stop 56 5 3 6 Standby cere ex XA gon d ed 56 biu Sleep M d 22205 ie eee ath a amu 56 524 TT 57 5 4 1
209. ule Perform maintenance on each item in the service schedule at the designated interval for the life of the generator set Tools Tools and instruments used to perform some maintenance items are not generally available to the generator set owner Therefore have service performed by an authorized distributor dealer 2 1 Service Schedule Perform the items listed in the service schedule at the designated intervals for the life of the generator set For example an item serviced every 100 hours or 3 months must also be serviced after 200 hours or 6 months 300 hours or 9 months etc Section 2 Scheduled Maintenance 19 Lubrication Refer to Section Action Inspect Check Change Interval Oil level 8 hr or before use Crankcase breather hose Yearly or 500 hr Change oil Yearly or 100 hr Replace filter s Yearly or 200 hr Oil cooler Yearly or 100 hr Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Cooling Air ducts and louvers in enclosure Yearly Exhaust System Leakage Weekly Obstructions or combustible materials near exhaust outlet Weekly DC Electrical System Battery charger operation Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals Yearly Inspec
210. ure 5 5 After 10 seconds the display returns to engine runtime hours Use the configuration and adjustment menus to change controller settings and adjust the generator set output A password key sequence is required to enter the configuration and adjustment menus Section 4 5 contains the instructions to enter the configuration and adjustment menus and change the settings using the controller keypad The DC RET controller is not equipped with a keypad DC RET controllers are factory set and not adjustable TP 6196 10 09 Switch functions as the generator set operation and controller reset switch Engine Runtime XXX X hours Y Output Voltage VAC Output Frequency Hz Battery Voltage VDC Notes Generator set master switch in AUTO Step through using up or down arrow buttons After 10 seconds display returns to runtime hours Figure 5 5 Generator Set Status Displays ADC RES only Section 5 ADC RES and DC RET Controller 55 5 3 Sequence of Operation The following sections describe the controller sequence of operation during generator start run stop and fault shutdown modes Use this as a starting point for controller and relay board fault identification Refer to the wiring diagrams in Section 8 to assist in the troubleshooting procedure 5 3 1 Starting Sequence Master Switch Moved to RUN When the master switch is moved to the RUN position there is a
211. used at this time P1 P10 Figure 5 24 Controller Logic Board Connections TP 6196 10 09 7 Check that the replacement board is positioned so User Interface Membrane Replacement that the display shows through the opening in the cover plate and then press the board onto the 9 Disconnect the membrane ribbon cable from standoffs Check that all corners are securely connector P8 on the logic board WIBunted SEE Figure 5525 10 Carefully remove the membrane from the junction 8 Reconnect all cables and harnesses to the board box cover See the wiring diagram in Section 8 for 11 Remove the protective backing to expose the connections adhesive on the new membrane Note Connector P12 on the logic board is not 12 Thread the new membrane s ribbon cable through used at this time the small rectangular opening in the cover Line up the membrane window with the larger rectangular opening 13 Press the membrane firmly into place 14 Connect the ribbon cable to the P8 connector on the logic board 15 Verify that the generator set master switch is in the OFF position 16 Reconnect the engine starting battery negative lead last 17 Reconnect power to the battery charger 18 Replace the front panel 19 Check settings and adjustments for the ADC RES controller only a Follow the instructions in Section 5 5 4 to change the new controller s configuration settings to match the generator set sy
212. version number is displayed on controller powerup Figure 4 6 Fault Shutdown Codes TP 6196 10 09 Section 4 ADC 2100 and DC 2200 Controllers 39 4 5 ADC 2100 Controller Configuration and Adjustment Note The settings described in this section are not adjustable on the DC 2200 cotnroller The first step in troubleshooting the controller is to verify that the controller is correctly configured for the generator set The controller s configuration modes allow setting of the engine type generator set configuration marine mobile or standby data input types and other parameters The controller configuration for each generator model is set at the factory Changes in the controller configuration may be required after controller replacement or other service Use the instructions in the following section to check the controller settings and change them if necessary 4 5 1 Controller Time Out The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure again from the beginning if the controller exits the configuration mode before the settings have been saved Changes in voltage and speed adjustments are also lost if they are not saved before the generator set shuts down The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup Be sure to
213. wer Mode Jumper Generator sets with serial numbers below 2051415 were built with controllers equipped with the continuous power mode jumper See TT 1364 ADC 2100 Controller Replacement for additional information WARNING D KS S 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 46 Section 4 ADC 2100 and DC 2200 Controllers 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 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 Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment TP 6196 10 09 Ajumper across control
214. wer to the battery charger c Disconnect the generator set engine starting battery negative lead first 2 Remove the controller from the generator set housing a Disconnect the engine wiring harness connector P1 plug 35 pin from the controller Disconnect the J15 and J16 connectors See Figure 4 14 b Remove the controller from the generator set housing in order to access the back of the controller 3 Remove the controller s back cover to access the jumper Notethe labels on the three leads connected to the generator set master switch for reconnection later Disconnect the leads at the pink connectors See Figure 4 14 b Remove the cover screws and remove the controller s back cover See Figure 4 14 4 Locate the P7 connector near the top of the controller See Figure 4 14 Remove the jumper from pins 1 and 2 of the P7 connector If the P7 connector has three pins connect the jumper across pins 2 and 3 for storage 5 Replace the controller s back cover and secure the cover screws 6 Reconnect the three pink connectors to the generator set master switch as shown Figure 4 14 7 Reconnect the J15 and J16 connectors 8 Reconnect the generator set engine starting battery negative lead last 9 Reconnect power to the battery charger 10 Place the generator set master switch in the AUTO position Section 4 ADC 2100 and DC 2200 Controllers 47 4 7 Master Switch The generator s
215. witch or a remote start stop switch connected to controller leads 3 and 4 reactivates the controller Moving the generator set master switch to the RUN position also activates the controller TP 6196 10 09 5 4 Faults Always identify correct the cause of fault shutdown before restarting the generator set Refer to Section 3 Troubleshooting for instructions to identify 5 4 1 Warnings and correct the cause of the fault The fault conditions listed in Figure 5 6 will cause the Move the generator set master switch to the OFF controller to display a fault code but will not shut down g RESET position to reset the controller after a fault the generator set shutdown Then move the switch to the AUTO or RUN position 542 Shutdowns Under the fault conditions listed in Figure 5 7 the controller displays a fault code and the generator set shuts down Description High battery Fault code is displayed if the engine starting battery voltage rises Check the battery rating voltage warning above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC and condition system for more than one minute when the engine is not running This Check the battery charger fault condition does not inhibit engine starting operation The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Low battery Fault code is displayed if the engine starting battery voltage falls below Ch
216. xcitation current to the rotor See Figure 6 18 and the wiring diagrams in Section 8 The SCR module is protected by a 20 amp fuse F1 in lead 55 on the controller Check the fuse and replace it if blown In the case of output voltage problems check the controller configuration and settings Then test the SCR module using the following procedure Note If it is necessary to replace the SCR module be sure to apply thermal compound to the back of the module to prevent overheating Thermal compound is provided with the SCR module replacement kit Figure 6 18 Silicon Controlled Rectifier SCR Module TP 6196 10 09 SCR Module Test Procedure Required equipment e Ohmmeter e 12 volt test lamp or voltmeter e 12 volt DC power source e 100 500 ohm resistor e Jumper 1 Set the ohmmeter to the R x 1 scale 2 Connect the ohmmeter from to on the SCR module You should read high resistance in one direction and low resistance in the other reverse the leads 3 Connect the ohmmeter from AC1 to onthe SCR module You should read high resistance in both directions 4 Connect the ohmmeter from AC1 to on the SCR module You should read high resistance in one direction and low resistance in the other 5 Repeat steps 3 and 4 for AC2 6 Connect the ohmmeter from G1 to on the SCR module You should read low resistance in both directions 7 Repeat step 6 for G2
217. y Section 4 3 describes the sequence of operation and faults are described in Section 4 4 Controller configuration and adjustment are covered in Section 4 5 A silicon controlled rectifier SCR module works with the controller to regulate the output voltage See Section 6 8 A relay interface board RIB is used with the ADC controller Section 4 8 describes the standard and optional RIBs 1 Controller 2 SCR module 3 Ground stud 4 LO stud Figure 4 1 Advanced Digital Control ADC 2100 TP 6196 10 09 5 Relay interface board RIB 6 Line circuit breaker load connection 7 Engine harness to controller connection 8 Generator set master switch Section 4 ADC 2100 and DC 2200 Controllers 35 4 2 Controller Display and Keypad The ADC 2100 controller has an LED display and a three button keypad See Figure 4 2 The DC 2200 controller has a display but no keypad See Figure 4 3 The LED display shows runtime hours fault codes application program version number or c
218. ypes Ed This setting defines the type of senders used on the generator set engine Battery voltage Bt This setting toggles between 12 and 24 VDC for the engine starting battery voltage Communications setting Cn This setting allows the user to set the controller for communication with optional meters which are available for marine and mobile units only 4 5 3 Voltage and Frequency Adjustments The flowchart in Figure 4 12 outlines the procedures for using the ADC controller to adjust the output voltage and engine speed frequency Voltage and or frequency adjustments be required after controller replacement or other service procedures TP 6196 10 09 The generator set must be running during these adjustments Use a multimeter to measure the generator set output voltage and frequency during adjustments Refer to Sections 6 7 2 Voltage Adjustment and 6 9 5 Frequency Adjustment for instructions to measure the output voltage and frequency Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position 4 5 4 Controller Application Program The ADC 2100 application program version number is displayed on the LED screen during the key sequence to enter the configuration mode Hold the Select button and move the generator set master switch to the RUN position After about 5 seconds the application
219. ys AC voltage output frequency and battery voltage Press the up or down arrow when runtime hours are displayed to step through these displays 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 Software version number ADC RES The software version number v is displayed when entering configuration mode See the installation manual DC RET The software version number v is displayed during the first 2 seconds of the crank cycle Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 4 4 Select and arrow buttons Keypad ADC RES only Use the arrow buttons to step through the data displays See Section 5 2 3 The keypad is also used for controller setup and adjustment The setup and adjustment functions are password protected Have setup and adjustments performed only by an authorized distributor dealer Generator set master switch Three position switch Figure 5 4 Controls and Indicators 5 2 3 Keypad The three button keypad is a feature of the ADC RES controller The keypad is used to check system status change controller settings and adjust the generator set output voltage and frequency When the generator set is running press the up and down arrow buttons to step through system status displays as shown in Fig

8.5RES 12RES 12RESL 12RESM1 12RESNT 12TRES Service

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