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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside front cover Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Service Assistance . . .
Table of Contents, continued Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Fuel System WARNING Hazardous Noise CAUTION Explosive fuel vapors. Can cause severe injury or death. Hazardous noise. Can cause hearing loss. Use extreme care when handling, storing, and using fuels. Never operate the generator set without a muffler or with a faulty exhaust system. 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.
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 batterycharging alternator connections. (5) Attach the weld ground connection close to the weld location.
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. Notice NOTICE Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards.
Notes VI Safety Precautions and Instructions TPTPS-6331 5/04
Introduction This manual provides operation and maintenance instructions for model 8.5RES and 12RES generator sets equipped with the Kohlerr 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.
of operating hours for which the engine has been shown to meet CARB emission requirements. The following table provides the engine compliance period (in hours) associated with the category descriptor found on the certification label. Emission Compliance Period (hours) tp6195 Figure 3 Air Index Label, 8.5/12RES This engine/generator is certified to operate using natural gas or propane fuel. CARB Moderate, 125 Intermediate, 250 Extended, 500 Refer to the certification label for engine displacement.
Section 1 Features 1.1 Specifications 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 Generator Set Components 1 2 3 4 5 6 7 17 18 19 8 20 23 9 10 22 21 16 21 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13 Enclosure Muffler Oil check Oil fill Air cleaner Spark plug locations (both sides) ADC 2100 Generator set master switch (RUN\OFF/RESET\AUTO) Nameplate Line circuit breaker Engine starting battery location Oil drain hose Figure 1-1 2 14 12 11 ADV-6823-A 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Section 2 Operation 2.1 Prestart Checklist 2.2 Exercising Generator Set 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. Operate the generator set without load once each week for 20 minutes.
2.3.1 Controls and Indicators Auto (Automatic) Starting Figure 2-2 describes the controls and indicators located on the ADC 2100. The LED display indicates generator set status as shown in Figure 2-2. 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.
2.4 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 controller after a fault shutdown. The controller resets automatically after a battery voltage fault condition is corrected. The shutdown switches on the generator set automatically reset when the problem is corrected.
Code Fault Description Check HB High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running. This fault condition does not inhibit engine starting. Check the battery rating and condition. Check the battery charger operation. The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.
2.6 Battery Charger 1 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. INDICATOR Red: Red & Green: Green: 6 AMP AUTOMATIC BATTERY CHARGER CAUTION: To reduce the risk of elect rical shock, connect only to properly gr ounded outlet. INPUT: 115 VAC 50/60Hz @ 1.6A OUTPUT: 12 VDC @ 6 Amps MAX. BAT.: 180 Amp Hr. Max.
Notes 8 Section 2 Operation TP-6331 5/04
Section 3 Scheduled Maintenance WARNING 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. 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.
3.2 Service Schedule 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 3.3 Oil level X Crankcase breather hose X X 8 hours or before use Yearly or 500 hours Change oil X Yearly or 100 hours Replace filter X Yearly or 200 hours Cooling 3.6 Air ducts, louvers Exhaust Line X X Yearly 3.
3.3 Lubrication System 10W-30 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. 5W-20, 5W-30 60 80 100 °F --20 0 20 32 40 °C --30 --20 --10 0 10 20 30 40 Temperature Range Expected Before Next Oil Change Figure 3-1 3.3.
b. Clean the gasket sealing surface of the oil filter adapter. carefully bending the ground electrode. Figure 3-2 and Figure 3-3. See c. Apply a light 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. 1--514 Figure 3-2 Checking the Spark Plug Gap 3. Fill with oil. a.
traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry. 11. Reconnect the generator set engine starting battery, negative (--) lead last. 1 5. Saturate the precleaner with new engine oil. Squeeze out all of the excess oil. 6. Reinstall the precleaner over the paper element. 2 7. Reinstall the air cleaner cover. Secure the cover with the cover retaining knob. 3 8. Reconnect the power to the battery charger. 4 9.
3.6 Cooling System 3.8 Battery 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.
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.
3.10 Circuit Protection 3.11 Storage Procedure If the generator set circuit breaker trips or the fuses blow repeatedly, see Section 4, Troubleshooting, for possible causes. 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. 3.10.
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 plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the plugs. 3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders. 3.11.4 Exterior Preparation 3.11.5 Battery Perform battery storage last. 1.
Notes 18 Section 3 Scheduled Maintenance TP-6331 5/04
Section 4 Troubleshooting 4.1 Introduction 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. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/ dealer.
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. 4.5 Battery Charger Troubleshooting Use the battery charger’s LED indicators and the table in Figure 4-3 to troubleshoot battery charger operation problems. 4.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw. CEC cert.
ISO International Organization for Standardization J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (210 bytes) kg kilogram kg/cm2 kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 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 L liter LAN local area network L x W x H leng
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 TP-6331 5/04 E 2004 by Kohler Co. All rights reserved.
