Operation Residential/Commercial Generator Sets Models: 8.
California Proposition 65 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.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 3.10 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.3 Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.
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.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment.
Hazardous Noise CAUTION 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.
Hot Parts WARNING 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. 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.
Introduction This manual provides operation and maintenance instructions for residential/commercial generator sets equipped with ADC-RES controls. The generator set models covered by this manual are listed on the front cover. This generator set is approved for use in stationary applications in locations served by a reliable utility power source. Have the generator set installed by an authorized distributor/dealer or service technician. Refer to TP-6514, Installation Manual, for installation instructions.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KohlerPower.com. D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. D Call toll free in the US and Canada 1-800-544-2444.
Section 1 Specifications 1.1 Introduction 1.4 Advanced Digital Control 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.
1.5 Service Views for Maintenance 1 2 3 4 5 6 17 7 8 16 18 19 20 21 22 23 9 10 15 25 24 ADV-7466- 24 14 13 12 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Muffler Oil check Oil fill Air cleaner Fuses RS-232 connector (for application program updates) Controller user interface (see Figure 2-1) Generator set master switch (RUN-OFF/RESET-AUTO) Line circuit breaker (single-phase models)* Field-connection terminal block location (single-phase models)* 11. Spark plug locations (both sides) 12.
8 Control detail, top view 12 9 11 10 1 2 3 4 5 6 7 See control detail 18 19 20 21 22 23 24 29 28 27 25 17 25 ADV-7341A-B 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
2 1 3 GM66010 1. Emergency stop switch 2. Field-connection terminal block and circuit breakers 3.
Section 2 Operation 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. 2.3 ADC-RES Controls and Indicators Figure 2-1 illustrates the ADC-RES user interface and other items on the generator set junction box. Figure 2-2 describes the ADC-RES controls and indicators. Air Cleaner.
Control or Indicator Item Description LED display Runtime hours Displays total generator set runtime hours while the generator set is running and when no other codes are displayed. Metering display Displays 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.
2.4 Controller Power Auto (Automatic) Starting The ADC-RES is powered by the generator set engine starting battery. 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. Close a contact across engine start leads 3 and 4 to signal the controller to start the generator set. Note: The generator sets are equipped with factoryinstalled battery chargers to prevent battery discharge.
Emergency Stopping (TRES Models Only) 2.5.3 Push the red emergency stop switch for immediate generator set shutdown in the case of an emergency. See Figure 2-4 for the emergency stop switch location. The emergency stop switch shuts down the generator set immediately. The controller display shows AF (auxiliary fault) when the emergency stop button is activated. Use the generator set master switch for normal shutdowns.
2.6 Faults 2.6.1 Shutdowns Under the fault shutdown conditions listed in Figure 2-5, the generator set shuts down automatically 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 2.6.3 to reset the controller after a fault shutdown. The shutdown switches on the generator set will automatically reset when the problem is corrected.
Code Fault Description Check AF Indicates a shutdown initiated by pushing the emergency stop switch. (TRES models only) Check the position of the emergency stop button. (TRES models only) Auxiliary fault input shutdown Not used on RES models. HE High engine temperature shutdown Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds. This function becomes active after the engine reaches the crank disconnect speed.
Battery Charger Operation 2.7 Battery Charger 2.7.1 RES Battery Charger RES model generator sets are 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 2-6 illustrates the battery charger. Figure 2-7 illustrates the three-stage charging method. Red and green LEDs indicate charger operation.
2.7.2 TRES Battery Charger Three-phase model TRES generator sets are equipped with a 2.5-amp battery charger to maintain the engine starting battery. Utility power must be supplied to the generator set for the battery charger. 2 The battery charger is located in or near the controller junction box. See Figure 2-9 for the battery charger location. A green LED on the side of the battery charger indicates battery charger operation. See Figure 2-10. 1 3 Two internal fuses protect the battery charger.
Section 3 Scheduled Maintenance 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.
3.1.1 Service Schedule, 8.5/12 kW Models Procedure System Component or Procedure Fuel See Section Visually Inspect Check Change Clean Test Flexible lines and connections X Main tank supply level Quarterly X Fuel piping Lubrication R Frequency Weekly X Yearly 3.2 Oil level X Crankcase breather hose 8 hours or before use X X Yearly or 500 hours Change oil X Yearly or 100 hours Replace filter X Yearly or 200 hours Cooling 3.5 Air ducts, louvers Exhaust Line X X Yearly 3.
3.1.2 Service Schedule, 18 kW Models Procedure System Component or Procedure Fuel See Section Visually Inspect Check Flexible lines and connections X Main tank supply level Clean Test R Frequency Quarterly X Fuel piping Lubrication Change Weekly X Yearly 3.2 Oil level X 8 hours or before each use Change oil X Yearly or 150 hours Replace filter X Yearly or 150 hours Crankcase breather hose X Oil cooler X Cooling X X Yearly 3.
3.2 Lubrication System 3.2.3 See the service schedules in Section 3.1 for oil change and oil filter replacement intervals. See the service views in Section 1.5 for the oil drain, oil check, oil fill, and oil filter locations. Use 5W-30 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. 3.2.1 3.2.
3. Fill with oil. 3.2.5 a. Fill the engine to the F mark on the dipstick. The engine oil capacity is shown in Figure 3-2. See Section 3.2.3, Engine Oil Recommendation, for oil selection. Generator Set Oil Capacity, L (qt.) 8.5/12RES8.5/12RES 1.9 (2.0) 18RES18RES 2.8 (3.0) Figure 3-2 Engine Oil Capacity Oil Cooler, 18 kW Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris. See Figure 3-3 for the oil cooler location.
3.3 Spark Plugs 3.4 Air Cleaner Service Reset the spark plug gap or replace the plugs with new plugs as necessary. 3.4.1 1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine. Air Cleaner, 8.5/12RES The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See Figure 3-7. 2. Remove the spark plug and check its condition. Replace the spark plug if it is worn or if its reuse is questionable. 1 3.
2. Disconnect the power to the battery charger. Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary. 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 traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry. 9.
Paper Element Service 3.5 Cooling System Replace the paper element at the intervals indicated in the service schedule. See Section 3.1.2 for the service schedule. See Figure 3-8 for the air cleaner components. 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 3-9.
Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance. 3.7 Battery 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.
3.9 Circuit Protection 3.9.2 If the generator set circuit breaker trips or the fuses blow repeatedly, see Section 4, Troubleshooting, for possible causes. Three panel-mounted fuses protect the alternator and electrical controls. See Section 1.5 for fuse locations. Another 10-amp fuse protects the battery charger. 3.9.1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load.
3.10 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. 3.10.1 Lubricating System 1. Operate the generator set until it reaches operating temperature, or about 15 minutes. 3.10.3 Cylinder Lubrication 1. Remove the spark plugs. 2. Pour one tablespoon of engine oil into each spark plug hole.
Notes 34 Section 3 Scheduled Maintenance TP-6515 1/11
Section 4 Troubleshooting 4.1 Introduction 4.2 Controller Troubleshooting Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions. Figure 4-1 contains troubleshooting, diagnostic, and repair information for the ADC-RES controller.
Problem The generator set does not crank. Possible Cause Corrective Action Fault shutdown Check for a fault code on the controller display. See Section 2.6. Battery weak or dead Check power to the battery charger. 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 Fuse F2 blown Check the connections. Replace the fuse.
4.4 Battery Charger Troubleshooting Use the battery charger’s LED indicators and the table in Figure 4-3 or Figure 4-4 to troubleshoot battery charger operation problems. Problem Cause Solution Red LED stays on for more than 24 hours One or more inoperative or damaged cells. Load test the battery and replace, if necessary Battery charger has 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.
Notes 38 Section 4 Troubleshooting TP-6515 1/11
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. APU AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CAT5 CB CC cc CCA ccw. CEC cert.
kg/cm2 kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ 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 kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
Notes
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KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com TP-6515 1/11e E 2007, 2008, 2009, 2011 by Kohler Co. All rights reserved.
