Home

Kohler 05810334 Automobile Parts User Manual

1. 3 Years General Condition of Equipment Evidence of vibration leakage excessive noise temperature or deterioration X x x Weekly Interior of sound enclosure x x Quarterly Not necessary for maintenance free batteries Authorized distributor dealer only Action Replace as necessary Megger is a registered trademark of Biddle Instruments 10 Section 3 Scheduled Maintenance TP 6331 5 04 3 3 Lubrication System See Section 3 2 Service Schedule for oil change and oil filter replacement intervals See Section 1 5 Service Views for the oil drain oil check oil fill and oil filter locations For extended operation check the oil level every 8 hours Maintain the oil level at or near not over the full mark on the dipstick 3 3 1 Low Oil Pressure Shutdown The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below 24 1 kPa 13 8 kPa 3 5 psi 1 5 psi because of oil pump failure or other malfunction The shutdown feature does not protect against damage caused by operating with the oil level below the safe range it is not a low oil level shutdown Check the oil level regularly and add oil as needed 3 3 2 Oil Check The generator setis shipped with oil Before operating a new generator set check the engine oil in the crankcase See Section 1 5 Generator Set Components Verify that the oil level is at the F mark on the dipstic
2. Welding on the generator set Can cause severe electrical equipment damage Before welding on the generator set perform the following steps 1 Remove the battery cables negative lead first 2 Disconnect all engine electronic control module ECM connectors 3 Disconnect all generator set controller and voltage regulator circuit board connectors 4 Disconnect the engine battery charging alternator connections 5 Attach the weld ground connection close to the weld location Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and 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 bodi
3. 3 7 Exhaust System Remove all combustible materials from the exhaust location Combustible materials include building materials as well as natural surroundings Keep dry field grass foliage and combustible landscaping material a minimum of 1 5 m 5 ft from the exhaust outlet Periodically inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks leaks and corrosion Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace clamps and or hangers as needed e Check for and remove loose insulation in the exhaust duct e Check that the exhaust outlet is clear 14 Section 3 Scheduled Maintenance 3 8 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 Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Neve
4. AUTO position and remains active until the master switch is moved to the OFF RESET position or power to the controller is removed If the continuous power mode jumper has been disconnected the LED display is activated by a start or RUN command and turns off 48 hours after generator set shutdown See Section 2 5 The buttons on the controller keypad are used only for system configuration and adjustment The system configuration is factory set and should not require changes under normal operating conditions Contactan authorized distributor dealer or service technician if adjustments are required 2 3 2 Starting Generator Set The following procedures describe the actions required to start the generator set The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault Local Starting Move the generator set master switch to the RUN position to immediately start the generator set Control or Indicator LED display Description Runtime hours Auto Automatic Starting Move the generator set master switch to the AUTO position to allow startup by an automatic transfer switch ATS or remote start stop switch if equipped 2 3 3 Stopping Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the gener
5. ction 5002 a a sd kl ate wack AA EA EEEE AAEE i Service Assistance 2 c 22 jets sve cede a a wi ele ii Section t Features amina adrede cas 1 ET Specifications iire doler eine dnd bedded o anat ii 1 A Me id Ook eed hea eh i Et ete CTW iad 1 L3 Engien 20 cite ae ne the a a ete nape 23 Sc tedetn seca gh duik EI U E EA sts 1 1 4 Advanced Digital Control 00 cc eect eee 1 1 5 Generator Set Components 000 cece eee cette eet e eens 2 Section 2 Operation assi sssi srra tesa eves eee ee eee eee sete skeen teens eee a eee ee enews 3 2 1 PrestartCheckKliSt cuco ao iaa 3 2 2 Exercising Generator Set o oooooooccoconocr rr 3 2 3 Generator Set Operation oooooococooocn tee eee eens 3 2 3 1 Controls and Indicators 00 ccc eect nes 4 2 3 2 Starting Generator Set c e qirrani ee deee ta n ere ia aa eens 4 2 3 3 Stopping Generator Set 0 cece cece eens 4 2 4 Fatilt SAUTHOWMS uri par a aba GAA a Stale eden es 5 2 4 1 Resetting Controller after a Fault Shutdown 000000005 6 2 5 Continuous Power Mode 00 cece ee eee tence e eee eee eeee 6 2 6 Battery Charger cocoa a de ede be adn id 7 2 6 1 Battery Charger Operation 0 eee eects 7 Section 3 Scheduled Maintenance c cece cece eee eee ee eee eee 9 3 1 Routine Maintenance 0 tenets 9 3 2 Service Schedule o oococooocoooccr ete entree eeee 10 3 3 Lubri
6. digital spark advance module digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ibs ft min g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC in H20 in Hg in Ibs Inc ind int int ext 1 0 IP hex cap high cylinder head temperature heavy duty high exhaust temperature high engine temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink hou
7. MAINTENANCE rate of less than 1 5 amps Green ON stage 3 Your battery is now 90 charged and ready for use This float charging current will gradually decrease to as low as 0 1 amps as the battery reaches 100 charge It will now be kept at full charge without overcharging If the green LED stays on when your battery is known to be low refer to Section 4 5 in this manual Figure 2 7 Battery Charger LED Indicator Functions TP 6331 5 04 Section 2 Operation 7 Notes 8 Section 2 Operation TP 6331 5 04 A WARNING TAS x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hot engine and exhaust system Can cause severe injury or dea
8. following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA CCW CEC cert TP 6331 ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake m
9. free electronic ignition e Precision formulated cast iron construction of parts subjected to the most wear and tear e Field convertible multi fuel systems that allow fuel changeover from natural gas to LP vapor and vice versa while maintaining CARB emission certification e Digital spark advance module DSAM optimizes ignition timing for the selected fuel 12RES TP 6331 5 04 Section 1 Features 1 4 Advanced Digital Control The generator set is equipped with the Kohler Advanced Digital Control ADC 2100 Controller features include the following e Compact controller e integrally mounted to the generator set e LED display e Runtime hours e Crank cycle status e Diagnostics e LED display communicates faults High battery voltage High engine temperature Low battery voltage Low oil pressure Overcrank safety Overspeed Overfrequency Overvoltage Underfrequency Undervoltage e Membrane keypad for configuration and adjustment e Password protected user access to menus e Voltage gain and speed adjustment e System configuration system voltage phase and frequency settings battery voltage and generator set model e Master control switch Run Off Reset Auto e Remote two wire start stop capability e Superior electronics protection from corrosion and vibration e Potted electronics e Sealed connections e Digital isochronous governor to maintain steady state speed at all loads e Digital vo
10. ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble TP 6331 5 04 Hazardous Noise A CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Vo
11. leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6331 5 04 NOTICE Electrostatic discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits
12. reduced its output voltage below the normal level due to a DC overload or a DC short Remove the source of the overload or short Disconnect the battery charger s black NEGATIVE ring terminal from the battery Reapply AC power and the green LED only should now light Onboard DC systems are drawing more current than the battery charger can replace Turn off all DC equipment while charging Red and green LEDs stay on for more than 24 hours Onboard DC systems are drawing between 1 5 and 5 amps Turn off all DC equipment while charging One or more defective or damaged cells Load test the battery and replace if necessary Extremely low AC voltage at the battery charger Apply a higher AC voltage source or reduce the length of the extension cord Green LED stays on when the battery is known to be low Open DC output fuse Replace AGS 10 fuse Faulty or contaminated terminal connections Clean and tighten or repair all terminal connections One or more defective or damaged cells Load test the battery and replace if necessary Neither of the LEDs turn on when the AC power is applied No AC power available at the battery charger Connect AC power or reset the AC breaker on the main panel Component failure Figure 4 3 Battery Charger Troubleshooting 20 Section 4 Troubleshooting Replace battery charger TP 6331 5 04 Appendix A Abbreviations The
13. shutdown Check the oil level suddenly Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact the distributor dealer Controller fuse F3 blown Replace the fuse If the fuse blows again contact the distributor dealer Overspeed shutdown Reset the controller If the overspeed fault occurs again contact the distributor dealer Generator set master switch in the OFF RESET Move the switch to the correct position RUN or AUTO position Remote stop command received from a remote switch Check the remote switch position or ATS Engine malfunction Contact the distributor dealer Auxiliary winding fuse F1 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Figure 4 1 General Troubleshooting Chart TP 6331 5 04 Section 4 Troubleshooting 19 4 3 Fault Codes The Advanced Digital Control displays fault codes to aid in troubleshooting Fault codes descriptions and recommended actions are listed in Figure 2 3 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 4 1 4 4 Troubleshooting Figure 4 2 contains troubleshooting diagnostic and repair information for the Advanced Digital Control Problem Controller LED display is off Possible Cause No power to the controller Controller fuse F3 is blown Low or no ba
14. the spark plug to keep dirt and debris out of the engine 2 Remove the spark plug and check its condition Replace the spark plug if it is worn or if its reuse is questionable 3 Check the spark plug gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by 12 Section 3 Scheduled Maintenance carefully bending the ground electrode See Figure 3 2 and Figure 3 3 Figure 3 3 Adjusting the Spark Plug Gap 3 5 Air Cleaner Element and Precleaner The engine has a replaceable high density paper air cleaner element with an oiled foam precleaner See Figure 3 4 Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Note Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure 3 5 1 Precleaner Service Use the following procedure to wash and reoil the precleaner as indicated in the service schedule Wash and reoil the precleaner more often under extremely dusty or dirty conditions 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the power to the battery charger 3 Disconnect the battery negative lead first 4 Loosen the cover retaining knob and remove the cover Remove the precleaner from the paper element Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all TP 6331 5 04 traces of detergent are
15. using a trickle charger Follow the battery charger 3 Mask all areas to be used for electrical contact manufacturer s recommendations 2 Seal all openings in the engine with nonabsorbent adhesive tape TP 6331 5 04 Section 3 Scheduled Maintenance 17 Notes 18 Section 3 Scheduled Maintenance TP 6331 5 04 Section 4 Troubleshooting 4 1 Introduction dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help Use the following charts to diagnose and correct describe the problem and repairs or adjustments made common problems First check for simple causes such to the equipment as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of 4 2 Generator Set Troubleshooting common problems possible causes ofthe problem and recommended corrective actions Figure 4 1 contains generator set troubleshooting diagnostic and repair information Check for loose If the procedures in this manual do not explain how to connections before replacing parts correct the problem contact an authorized distributor Problem Possible Cause Corrective Action The generator set Battery weak or dead Check power to the battery charger does not crank Recharge or replace the battery Battery charger fuse blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Battery connections reversed or poor Check
16. 1 Emissions Label 8 5RES Engine CH20 IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH1 AND CALIFORNIA 2006 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY _KHXS 7252NA DISPL CC 725 MODEL NO SPEC NO SERIAL NO EMISSION COMPLIANCE PERIOD EPA CARB EXTENDED THIS ENGINE IS CERTIFIED TO OPERATE ON LPG NATURAL GAS REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS FOR SALES AND SERVICE IN US CANADA CALL Ors 1 800 544 2444 KohlerEngines com KOHLER ENGINES KOHLER CO KOHLER WISCONSIN USA Figure 2 Emissions Label 12 RES Engine CH740 Introduction i ENGINE AIR INDEX California Only 2 4 6 0 10 MOST CLEAN LEAST CLEAN O NOTE THE LOWER THE AIR INDEX THE LESS POLLUTION THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT FOR THE FOLLOWING USE MODERATE O INTERMEDIATE CHECK OWNER S MANUAL FOR FURTHER DETAILS THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY CAUTION CHECK OIL LEVEL BEFORE STARTING ENGINE EXTENDED 1p6195 Figure 3 Air Index Label 8 5 12RES This engine generator is certified to operate using natural gas or propane fuel The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number Service Assistance of operating hours for which the engine has been shown to meet CARB emission requirements The following table provides the engine c
17. 331 5 04 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 Refer to this section for general battery information and maintenance Also consult the battery manufacturer s instructions for battery maintenance All generator set models use a negative ground with al2 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator spec sheet for battery capacity recommendations for replacement purposes Wiring diagrams provide battery connection information See Figure 3 6 for typical battery connections Clean the battery and cables and tighten battery terminals using the service schedule recommendations To prevent corrosion maintain tight dry electrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the batte
18. A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building Never operate the g
19. An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground Safety Precautions and Instructions V Notes VI Safety Precautions and Instructions TPTPS 6331 5 04 This manual provides operation and maintenance instructions for model 8 5RES and 12RES generator sets equipped with the Kohlere Advanced Digital Control ADC 2100 This generator set is approved for use in stationary applications in locations served by a reliable utility power source Have the generator set installed by an authorized distributor dealer or service technician Refer to TP 6328 Installation Manual for installation instructions Information in this publication represents data available at the time of print The manufacturer may provide this manual for models not listed on the front cover Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe prescribed intervals Obtain serv
20. Operation Residential Commercial Generator Sets Models 8 5RES 12RES Controller Advanced Digital Control ADC 2100 NATIONALLY REGISTERED California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information 0 cece eee eee teen eee eee Inside front cover Safety Precautions and Instructions ccc cece eee eee eee eens l Introd
21. a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away 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 Il Safety Precautions and Instructions Engine Backfire Flash Fire A WARNING Lh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner
22. ator The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks Check the air inlets and outlets and remove any items restricting the air flow 2 3 Generator Set Operation Figure 2 1 illustrates the user interface on the Advanced Digital Control ADC 2100 generator set controller JTA KOHLER ADVANCED DIGITAL CONTROL CODE DEFINITION Auxillary Fault Binh ae cle Volt High Bai foltage High Engine Tom B Low Battery Vonage Low Coolant Level Loss of Coolant Low Oll Pressure over Granik ver Frequency Over Speed Over Voltage Under Frequency Under Voltage OFF RESET GM28707A C 1 LED display 2 Select button use for setup and adjustment only 3 Up and down arrow buttons use for setup and adjustment only 4 Generator set master switch Figure 2 1 ADC 2100 User Interface Section 2 Operation 3 2 3 1 Controls and Indicators Figure 2 2 describes the controls and indicators located onthe ADC 2100 The LED display indicates generator set status as shown in Figure 2 2 With the factory installed continuous power mode jumper in place the LED display is activated when the generator set master switch is moved to the RUN or
23. ator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Automatic Stopping With the generator set master switch in the AUTO position and an ATS or other automatic device connected to controller leads 3 and 4 1 The ATS or other device disconnects the load from the generator set 2 If the ATS is equipped with an engine cooldown time delay the generator set continues to run for a preset engine cooldown time Note There is no engine cooldown time delay on the ADC controller 3 The ATS or other device opens the connection between controller leads 3 and 4 The generator set shuts down Displays total generator set runtime hours while the generator set is running and when no other codes are displayed Crank indication Displays CC_1 CC_2 or CC_3 to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 2 4 Software version number See TP 6196 Generator Set Service Manual Contact an authorized distributor dealer Select and arrow buttons Keypad The keypad is used for controller setup and adjustment only Have setup and adjustments performed only by an authorized distributor dealer The setup and adjustment functions are pas
24. cation System kretas rerea a a ee etm a beeen 11 3 3 1 Low Oil Pressure Shutdown 000s 11 3392 Oil Check iutiteVnin ia din Vt a a ed Oded 11 3 3 3 Engine Oil Recommendation ooooccccccccccco 11 3 3 4 Oil Change Procedure 0 cece ete nes 11 34 Spark PUGS deee Teet faded alent datas td da 12 3 5 Air Cleaner Element and Precleaner 0 cee eee teens 12 3 5 1 Precleaner Service asco hatte tbat dads ak ated t Mii selon 12 3 5 2 Paper Element Service 000 c cece cee eee eens 13 3 6 Cooling System soa en e ea rr 14 3 77 Exhaust System iscs 0 cee trenie ee eatin eee ae en A eee eee ee 14 3 87 Bale iii AA tana ane aaa Ne bas 14 3 9 Battery Charger asistir die dose tlt dto lt 15 3 10 Circuit Protection sssaaa anaana rr 16 3 10 1 Line Circuit Breaker 0 0 eect eens 16 S10 2 BUSES cites hi a a dit ts 16 3 11 Storage Procedure xiii ave dew Siw Sede idee Ce eed dew ied 16 3 11 1 Lubricating System 0 cect eens 16 g E Fuel SVstem x 1sc isk fa sendin pe sie ata ciel cba Man Se a ea anae 16 3 11 3 Cylinder Lubrication 00 ccc 17 3 11 4 Exterior Preparation seris ninar eene noie ei raa en a A ia a 17 SiS Ballena e ce e ais aN A a e e ara 17 TP 6331 5 04 Table of Contents Table of Contents continued Section 4 Troubleshooting iii inde weeee ees E a EE O E 19 AT A o A a E a Senet a 19 4 2 Generator S
25. dia 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 6331 5 04 1 1 Specifications The generator set specification sheets provide specific generator and engine information Refer to the spec sheet for data not supplied in this manual Consult the generator set service manual engine operation manual and engine service manual for additional specifications Obtain copies of the latest spec sheets manuals diagrams and drawings from your local distributor dealer 1 2 Generator The generator uses Kohler s unique PowerBoost voltage regulation system which provides instant response to load changes PowerBoost ensures reliable motor starting and consistent voltage levels PowerBoost utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage 1 3 Engine The generator set has a four cycle twin cylinder air cooled Kohler engine The engine operates on clean burning natural gas or propane LP vapor Engine features include e Efficient overhead valve design and full pressure lubrication for maximum power torque and reliability under all operating conditions e Dependable maintenance
26. ean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified 5 04 cfh cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DSAM DVR E emer EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD cubic feet per hour cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch
27. eliminated Squeeze out 11 Reconnect the generator set engine starting excess water do not wring Allow the precleaner battery negative lead last to air dry 5 Saturate the precleaner with new engine oil Squeeze out all of the excess oil 6 Reinstall the precleaner over the paper element 7 Reinstall the air cleaner cover Secure the cover with the cover retaining knob 8 Reconnect the power to the battery charger 9 Reconnect the generator set engine starting battery negative lead last 3 5 2 Paper Element Service Use the following procedure to replace the paper element at the intervals specified in the service schedule Replace the paper element more often under extremely dusty or dirty conditions 1 Place the generator set master switch in the OFF RESET position 4 Cover knob 2 Air cleaner cover 2 Disconnect the power to the battery charger 3 Element cover nut 4 Element cover 3 Disconnect the generator set engine starting 3 Foam precleaner 6 Air cleaner element battery negative lead first 7 Ar leaner base 4 Loosen the cover retaining knob and remove the Figure 3 4 Air Cleaner Components cover 5 Remove the element cover nut element cover and the paper element with precleaner 6 Remove the precleaner from the paper element Note Do not wash the paper element or clean it with pressurized air as this will damage the element 7 Replace the element if it is dirty ben
28. enerator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air TPTPS 6331 5 04 Fuel System A WARNING j 4 W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may
29. ervoltage shutdown Shutdown occurs if the voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service if problem continues Underfrequency shutdown Shutdown occurs when the governed frequency falls blow 90 of the nominal system frequency for more than 5 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Undervoltage shutdown Shutdown occurs if the voltage falls below 80 of the nominal system voltage for more than 10 seconds Figure 2 3 ADC 2100 Fault Shutdown Codes TP 6331 5 04 Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Section 2 Operation 5 Check Check the battery rating and condition Fault Description High battery Fault code is displayed if the engine starting battery voltage rises voltage warning above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running This fault condition does not inhibit engine starting a Chal gor operation The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds Low battery voltage warning Fault code is displayed if
30. et Troubleshooting 000 cece cette eee eee 19 43 Fault Godes ei sila san ra da a 20 4 4 Troubleshooting 0 00 cece cect teen eee eee 20 4 5 Battery Charger Troubleshooting cece cece eee eeeeeeee 20 Appendix A Abbreviations 00 00600 ttn nett teen eee A 1 Table of Contents TP 6331 5 04 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in promi
31. harger uses an AGS 10 inline fuse The fuse is located in the battery lead See Figure 2 5 2 6 1 Battery Charger Operation Figure 2 6 illustrates the three stage charging method Red and green LEDs indicate charger operation The chart in Figure 2 7 describes the LED indicator operation during each stage of the charging process 1 LED indicators 2 AC power cord 3 Fuse 4 Battery leads 12 VDC Figure 2 5 6 Amp Float Equalize Battery Charger Float Green Output Voltage To Battery VDC Figure 2 6 Charging Method Display Operating Condition Red ON When the red LED is on it indicates the battery is discharged and the battery charger is recharging at the BULK rate Green OFF stage 1 This charging rate is 6 amps While the red LED is on the voltage measured with the battery charger on will be 11 8 14 volts If the red LED stays on for more than 24 hours refer to Section 4 5 in this manual Red ON When both the green and the red LEDs are on the battery charger is charging at an ABSORPTION rate of between 1 5 and Green ON 5 amps stage 2 This mode of charging gradually tops off your battery and reduces harmful sulfating While both LEDs are on the voltage measured with the battery charger on should be approximately 14 0 14 5 VDC If both LEDs stay on longer than 24 hours refer to Section 4 5 in this manual Red OFF When the green LED is on the battery charger is charging at a FLOAT or
32. ice from an authorized service distributor dealer to keep equipment in top condition Nameplate The following illustration shows a typical generator set nameplate Copy the model serial and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual See Section 1 5 Service Views for the nameplate location KOHLER KOHLER CO KOHLER WI USA MODEL SERIAL SPEC SERVICE DUTY HZ RPM GEN MODEL INSULATION NEMA CLASS KW VARIES WITH BTU CONTENT OF FUEL BATT V J TP 6331 5 04 Introduction EPA and California Emission Certification An engine or generator set with the following identification labels is certified to meet Small Off Road Engine emission standards for EPA CARB All model 8 5RES and 12RES generator sets with multi fuel systems are emission certified IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH1 AND CALIFORNIA 2006 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY _KHXS 7252NA DISPL CC 624 MODEL NO SPEC NO SERIAL NO EMISSION COMPLIANCE PERIOD EPA CARB EXTENDED THIS ENGINE IS CERTIFIED TO OPERATE ON LPG NATURAL GAS REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS E SALES AND SERVICE IN US CANADA C 1 800 544 2444 KohlerEngines com KOHLER engimes KOHLER CO KOHLER WISCONSIN USA Figure
33. ilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 lb of bicarbonate of soda baking soda toa container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions l Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of
34. jury 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 Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place A WARNING A Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware TPTPS 6331 5 04 Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test
35. k Add oil that has a viscosity appropriate for the climate See Section 3 3 3 Engine Oil Recommendation Do not check the oil level when the generator set is running Shut down the generator set and wait several minutes before checking the oil level 3 3 3 Engine Oil Recommendation Use API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner Select the viscosity based on the air temperature at the time of operation See Figure 3 1 TP 6331 5 04 5W 20 5W 30 F 20 0 20 3240 60 80 100 C 30 20 10 0 10 20 30 40 Temperature Range Expected Before Next Oil Change Figure 3 1 Engine Oil Selection 3 3 4 Oil Change Procedure Drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position b Disconnect the power to the battery charger c Disconnect the generator set engine starting battery negative lead first d Remove the housing side panel e Remove the oil drain hose from its retaining clip Remove the cap from the oil drain hose and lower the hose into an oil collection container f Open the oil drain valve on the engine g Allowtime for the engine oil to drain completely h Close the oil drain valve i Replace the cap on the oil drain hose Replace the oil drain hose in its retai
36. l oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference RH round head RHM round head machine screw rly relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S Sec second SI Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s sq square sq cm square centimeter sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine coo
37. ldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency WwW watt WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6331 5 04 TP 6331 5 04 O 2004 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
38. ltage Electrical Shock A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply A CAUTION Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Safety Precautions and Instructions Ill
39. ltage regulation 1 5 RMS no load to full load e Automatic start for programmed cranking cycle Section 1 Features 1 1 5 Generator Set Components N 05 o pa o a oa al ol ll ol al ll A ADV 6823 A Enclosure Oil drain valve Muffler Oil filter Oil check Alternator cooling air intake Oil fill Exhaust Air cleaner DSAM leads Spark plug locations both sides Multi fuel block ADC 2100 Gas regulator assembly Generator set master switch RUN OFF RESET AUTO Fuel solenoid valve Nameplate Air intake Line circuit breaker Battery charger Engine starting battery location Relay board Oil drain hose OANDARWAN Figure 1 1 Generator Set Components 2 Section 1 Features TP 6331 5 04 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed ai
40. ly 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 IV Safety Precautions and Instructions Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Lift the generator set using lifting bars inserted through the lifting holes on the skid Hot Parts A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the generator Hot parts can cause severe injury or death Avoid touching the generator set field or exciter armature When shorted the generator set field and exciter armature become hot enough to cause severe burns Servicing the exhaust system Hot parts 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 in
41. man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour A 2 Appendix MS m sec MTBF MTBO mig MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns oc OD OEM OF opt OS OSHA OV oz P Pp PC PCB pF PF ph Y PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI military standard meters per second mean time between failure mean time between overhauls mounting megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National 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 optiona
42. nent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6331 5 04 Accidental Starting A WARNING FAS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command froma remote computer Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well vent
43. ning clip 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench Section 3 Scheduled Maintenance 11 b Clean the gasket sealing surface of the oil filter adapter c Apply alight coat of clean oil to the rubber seal of the new oil filter d Install the new oil filter following the instructions provided with the filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner 3 Fill with oil a Remove the oil fill cap and fill the engine to the F mark on the dipstick The engine oil capacity is 1 9 L 2 0 qt See Section 3 3 3 Engine Oil Recommendation for oil selection b Reinstall the dipstick and the oil fill cap c Check that the generator set master switch is in the OFF position d Reconnect the generator set engine starting battery negative lead last e Reconnect the power to the battery charger f Start and run the generator set for a minute to allow the oil pressure to reach the operating range g Stop the generator set wait 1 minute and then recheck the oil level Add oil to bring the level up to the F mark on the dipstick 4 Check for leaks a Check for oil leaks b Fix leaks and recheck the oil level c Reinstall the housing side panel 3 4 Spark Plugs Reset the spark plug gap or replace the plugs with new plugs as necessary 1 Clean the area around the base of
44. ompliance period in hours associated with the category descriptor found on the certification label Emission Compliance Period hours Moderate Intermediate Extended Refer to the certification label for engine displacement The exhaust emission control system for the 8 5RES CH20 and 12RES CH740 is EM For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KohlerPowerSystems com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems ZI Senia 122 12 rue des Hauts Flouviers 94517 Thiais Cedex France Phone 33 1 41 735500 Fax 33 141 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 264 6422 Fax 65 264 6455 ii Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka In
45. onds 7 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Note The controller s LED display remains off until an engine start command is received Opening and closing a remote start stop contact also resets the controller 2 5 Continuous Power Mode The ADC 2100 is powered by the generator set engine starting battery A jumper on the back of the controller maintains power to the controller at all times Controllers are shipped with the jumper connected Note The 8 5 and 12 RES generator sets are equipped with factory installed battery chargers to prevent battery discharge Disconnecting the jumper allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position A remote start signal from a transfer switch or a remote start stop switch connected to controller leads 3 and 4 or moving the generator set master switch to the RUN position turns the controller back on Contact an authorized distributor dealer to disconnect the jumper if necessary TP 6331 5 04 2 6 Battery Charger The generator set is equipped with a 6 amp float equalize battery charger to maintain the engine starting battery The charger s power cord must be connected to a 120 VAC power source Figure 2 5 illustrates the battery charger The battery c
46. ot used on air cooled models Low oil pressure shutdown Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protective becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank shutdown Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest The generator set also shuts down if no engine rotation is sensed during cranking Shuts down 1 second after the fault is detected Check the fuel supply spark plug and battery Check for loose connections Contact an authorized distributor dealer for service if problem continues Overfrequency shutdown Shutdown occurs when the governed frequency exceeds 110 of the system s frequency setpoint for more than 5 seconds This protective becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service if problem continues Overspeed shutdown Shutdown occurs if the engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service if problem continues Ov
47. r add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases TP 6
48. r cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Exhaust System Check for exhaust leaks and blockages Check the muffler and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks leaks and corrosion e Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set x 0p 001 002 TP 6331 5 04 Section 2 Operation 2 2 Exercising Generator Set Operate the generator set without load once each week for 20 minutes If the generator set does not have a programmed exercise mode or an automatic transfer switch ATS with an exercise option exercise the unit in the presence of an oper
49. ry and cables with a solution of baking soda and water 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 EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 6 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection TP 6331 5 04 3 9 Battery Charger The generator set is equipped with a 6 amp float equalize battery charger to maintain the engine starting battery The charger s DC leads are factory wired Figure 3 7 illustrates the battery charger Periodically tighten all connections No other maintenance on the battery charger is required a SN 5 Y 4 Y 1 I mg l DA NS NZ iil n J 1 LED indicators 2 Mounting flanges 3 AC power cord 4 Fuse 5 Battery leads 12 VDC Figure 3 7 6 Amp Float Equalize Battery Charger Section 3 Scheduled Maintenance 15 3 10 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly see Section 4 Troubleshooting for possible causes 3 10 1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between
50. sing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe Appendix A 1 International Organization for Standardization J joule JIS Japanese Industry Standard k kilo 1000 K kelvin kA kiloampere KB kilobyte 210 bytes kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds lbm ft pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 108 when used with SI units male ms cubic meter m min cubic meters per minute mA milliampere
51. sword protected Generator set master Three position switch switch Figure 2 2 ADC 2100 Controls and Indicators 4 Section 2 Operation Switch functions as the generator set operation and controller reset switch TP 6331 5 04 The shutdown switches on the generator set automatically reset when the problem is corrected The high engine temperature switch automatically resets when the generator set cools However the fault does not clear until the controller is reset 2 4 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2 3 and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 4 1 to reset the The controller displays a fault code but the generator set does not shut down under the conditions shown in controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected Auxiliary fault input shutdown Figure 2 4 Description Not used High engine temperature shutdown Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protective becomes active after the engine reaches the crank disconnect speed Check for blocked air inlets and exhaust outlets Low coolant level Not used on air cooled models Loss of coolant N
52. t or damaged 8 Check the air cleaner base Make sure it is secure and not bent or damaged Also check the element cover for damage and fit Replace all damaged air cleaner components Remove any loose dirt or debris from the air cleaner base Wipe the base carefully so that no dirt drops into the intake throat Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary 9 Reinstall the paper element precleaner element cover element cover nut and the air cleaner cover Secure the cover with the cover retaining knob 10 Reconnect the power to the battery charger TP 6331 5 04 Section 3 Scheduled Maintenance 13 3 6 Cooling System The engine fan draws cooling air through the openings in the sides and end near the battery The alternator fan draws cooling air through openings on the side walls of the enclosure The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet See Figure 3 5 To prevent generator set damage caused by overheating keep the housing cooling inlets and outlets clean and unobstructed at all times Note Do not block the generator set cooling air inlets or mount other equipment above them Overheating and severe generator damage may occur OLER POWER SYSTEMS 1 N ee 2 1 Exhaust outlet tp6195 2 Alternator air intake both sides 3 Engine air intake Figure 3 5 Cooling Air Intake and Exhaust
53. t 15 minutes 2 Stop the generator set 3 While the engine is still warm drain the engine lubrication oil from the engine crankcase 4 Refill the engine crankcase with oil See Section 3 3 3 for oil recommendations 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the generator set 3 11 2 Fuel System 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position TP 6331 5 04 3 11 3 Cylinder Lubrication 4 Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark 3 11 5 Battery plug hole Install the spark plugs and ground the spark plug leads Do not connect the leads to the Perform battery storage last plugs 1 Place the generator set master switch in the 3 Toggle the generator set master switch to crank the OFF RESET position engine two or three revolutions to lubricate the cylinders 2 Disconnect the battery negative lead first 3 Clean the battery Refer to Section NO TAG for the 3 11 4 Exterior Preparation cleaning procedure 1 Clean the exterior surface of the generator set 4 Place the battery in a warm dry location 5 Connect the battery to a float equalize battery charger or charge the battery monthly
54. tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose Yearly or 500 hours Change oil Yearly or 100 hours Replace filter Yearly or 200 hours Cooling Air ducts louvers Yearly Exhaust Line Leakage Weekly Insulation fire hazards Yearly Obstructions or combustible materials near exhaust Weekly outlet DC Electrical System Battery charger operation charge rate if equipped Monthly Remove corrosion clean and dry battery and rack Yearly Clean and tighten battery terminals and inspect Yearly boots Battery electrolyte level and specific gravity Yearly AC Electrical System Tighten control and power wiring connections Yearly Remote control system if equipped Monthly Visible wear or damage Quarterly Wire abrasions where subject to motion Six Months Wire cable insulation condition 3 Years or 500 hours Engine and Mounting Visible wear or damage Weekly Air cleaner and precleaner service Yearly or 100 hours Spark plugs Yearly or 300 hours Replace stepper motor coupling and bushing 500 hours Generator Visible wear or damage Quarterly Exercise generator set Weekly 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
55. th Do not work on the generator set until it cools TP 6331 5 04 Section 3 Scheduled Maintenance 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 rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set 3 1 Routine Maintenance Refer to the following service schedule and the runtime hours displayed on the ADC 2100 display to schedule routine maintenance Have an authorized distributor dealer service the generator set at the designated intervals in the service schedule for the life of the generator set Service units subject to extreme weather long operating hours or dusty or dirty conditions more frequently Contact an authorized distributor dealer for parts Section 3 Scheduled Maintenance 9 3 2 Service Schedule Procedure See Visually System Component or Procedure Section Inspect Check Change Frequency Fuel Flexible lines and connections Quarterly Main
56. the connections Controller fuse F3 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Relay interface board fuse F2 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Generator set master switch in the OFF position Move the master switch to the RUN position The generator set Air cleaner clogged Clean and or replace the air cleaner cranks but does not start starts hard lacks power or operates erratically Battery connection poor Clean and tighten the battery connections Battery weak or dead Check power to the battery charger Recharge or replace the battery Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check the oil level Fuel pressure insufficient Check the fuel supply and valves Engine malfunction Contact the distributor dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC circuit breaker tripping because of overload Reduce the load on the generator set AC circuit breaker tripping because of short circuit Contact an authorized distributor dealer for service Auxiliary winding fuse F1 blown Replace the fuse Contact an authorized distributor dealer for service if fuse blows repeatedly Low output or Generator set overloaded Reduce the load excessive drop in voltage Generator set stops Low oil pressure
57. the engine starting battery voltage falls below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 10 seconds when the engine is not running This fault condition does not inhibit engine starting Check the battery rating and condition Check the battery charger operation Charge or replace the battery The fault condition clears when the battery voltage returns to a Figure 2 4 ADC 2100 Fault Warning Codes 2 4 1 Resetting Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Move the generator set master switch to OFF RESET 2 Disconnect the generator set from the load using the line circuit breaker or ATS See the safety precautions at the beginning of this section before proceeding 3 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this section before proceeding Refer to Section 4 Troubleshooting 4 Start the generator set by moving the generator set master switch to RUN Test operate the generator set to verify that the cause of the shutdown has been corrected 5 Move the generator set master switch to OFF RESET 6 Reconnect the generator set to the load using the line circuit breaker or ATS 6 Section 2 Operation voltage within the limits for more than 10 sec
58. the generator and the load The line circuit breaker location is shown in Figure 1 1 See Figure 3 8 for the circuit breaker ratings If the circuit breaker trips reduce the load and switch the breaker back to the ON position With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load Circuit Breaker Rating Amps 8 5RES Figure 3 8 Line Circuit Breakers 3 10 2 Fuses The engine harness contains two 10 amp and one 20 amp inline fuses See Figure 3 9 Another 10 amp fuse protects the battery charger Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Section 4 Troubleshooting for conditions that may indicate a blown fuse Replace blown fuses with identical replacement parts Location Auxiliary winding 292937 Lead 55 Relay interface 223316 Lead PF2 board Controller 223316 Lead PF1 Battery charger AGS 10 Battery charger DC lead See Section 2 6 Figure 3 9 Fuses 16 Section 3 Scheduled Maintenance 3 11 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer Follow the engine manufacturer s recommendations for storage if available Note Run the generator set monthly whenever possible 3 11 1 Lubricating System 1 Operate the generator set until it reaches operating temperature or abou
59. ttery voltage Continuous power mode jumper is disconnected and the generator set has not run for 48 hours or longer 4 5 Battery Charger Troubleshooting Use the battery charger s LED indicators and the table in Figure 4 3 to troubleshoot battery charger operation problems Corrective Action Controller display will automatically activate when a remote start command is received or the generator set master switch is moved to the RUN position See Section 2 5 Connect the jumper to maintain continuous power to the controller if desired Replace the fuse If the fuse blows again contact the distributor dealer Check connections Check generator set battery and battery charger See Figure 4 1 position Generator set master switch is in the OFF RESET Move generator set master switch to the AUTO or RUN position reset Figure 4 2 ADC 2100 Troubleshooting Chart Problem Red LED stays on for more than 24 hours One or more defective or damaged cells Generator set master switch in AUTO but no start command has been received since last controller No action required see Section 2 3 1 Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position Use the remote switch to start generator set and activate the controller display if desired Solution Load test the battery and replace if necessary Battery charger has

Kohler 05810334 Automobile Parts User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents