Kohler 05810334 Automobile Parts User Manual

Operation

Residential/Commercial Generator Sets

Models:

8.5RES

12RES

Controller:

Advanced Digital Control (ADC 2100)

TP-6331 5/04

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.

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

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inside front cover

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

Advanced Digital Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Generator Set Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Exercising Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1

Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2

Starting Generator Set

2.3.3

Stopping Generator Set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1

Resetting Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . .

2.5

Continuous Power Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1

Battery Charger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Routine Maintenance

3.2

Service Schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1

Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2

Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3

Engine Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4

Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Air Cleaner Element and Precleaner

3.5.1

Precleaner Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2

Paper Element Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6

Cooling System

3.7

Exhaust System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.1

Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.2

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.1

Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.2

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.3

Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.4

Exterior Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.5

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 i

TP-6331 5/04 Table of Contents

Table of Contents, continued

Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5

Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1

Table of Contents TP-6331 5/04

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.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.

The decals are shown throughout this publication to improve operator recognition.

Replace missing or damaged decals.

Safety Precautions and Instructions

Accidental Starting

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Battery

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

WARNING

Explosion.

Can cause severe injury or death.

Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.

Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

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) 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.

TP-6331 5/04 Safety Precautions and Instructions I

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.

Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.

Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.

Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits.

Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Disconnect the battery before generator set installation or maintenance.

Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash

Fire

WARNING

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. 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

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

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 generator 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 present in exhaust gases.

Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness

D Physical fatigue, weakness in joints and muscles

D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea

If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.

Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

II Safety Precautions and Instructions TPTPS-6331 5/04

Fuel System

WARNING

Hazardous Noise

CAUTION

WARNING

Explosive fuel vapors.

Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

The fuel system.

Explosive fuel vapors can cause severe injury or death.

Vaporized fuels are highly explosive.

Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.

Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not 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. A successful test depends on the ability of the solution to bubble.

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 Voltage/

Electrical Shock

DANGER

Hazardous voltage.

Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

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.

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.

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.

TP-6331 5/04 Safety Precautions and Instructions III

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.

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 bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility.

Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power.

Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

Heavy Equipment

damage.

the skid.

WARNING

Unbalanced weight.

Improper lifting can cause severe injury or death and equipment

Do not use lifting eyes.

Lift the generator set using lifting bars inserted through the lifting holes on

Hot Parts

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

Servicing the 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 injury or property damage. Install the heater before connecting it to power.

Operating the heater before installation can cause burns and component damage.

Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts.

Moving Parts

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.

WARNING

Rotating parts.

Can cause severe injury or death.

Operate the generator set only when all guards, screens, and covers are in place.

WARNING

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.

IV Safety Precautions and Instructions 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 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

Electrostatic discharge damage.

Electrostatic discharge (ESD) damages electronic circuit boards.

Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about

1 megohm), not a direct short, to ground.

246242

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 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 Kohler r 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 at the prescribed intervals.

Obtain service 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.

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.

tp6195

Figure 1 Emissions Label, 8.5RES Engine (CH20) tp6195

Figure 2 Emissions Label, 12 RES Engine (CH740)

TP-6331 5/04 Introduction i

tp6195

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 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.

CARB

Emission Compliance Period (hours)

Moderate,

125

Intermediate,

250

Extended,

500

Refer to the certification label for engine displacement.

The exhaust emission control system for the 8.5RES

(CH20) and 12RES (CH740) is EM.

Service Assistance

For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

Consult the Yellow Pages under the heading

Generators—Electric

Visit the Kohler Power Systems website at

KohlerPowerSystems.com

Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product

Call toll free in the US and Canada 1-800-544-2444

Outside the US and Canada, call the nearest regional office

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler Power Systems

ZI Senia 122

12, rue des Hauts Flouviers

94517 Thiais Cedex

France

Phone: (33) 1 41 735500

Fax: (33) 1 41 735501

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 264-6422

Fax: (65) 264-6455

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131 ii Service Assistance 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 t voltage regulation system, which provides instant response to load changes.

PowerBoost t ensures reliable motor starting and consistent voltage levels.

PowerBoost t 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, aircooled Kohler r engine.

The engine operates on clean-burning natural gas or propane (LP) vapor.

Engine features include:

Efficient overhead valve design and full pressure lubrication for maximum power, torque, and reliability under all operating conditions.

Dependable, maintenance-free electronic ignition.

Precision-formulated cast iron construction of parts subjected to the most wear and tear.

Field-convertible multi-fuel systems that allow fuel changeover from natural gas to LP vapor (and vice-versa) while maintaining CARB emission certification.

Digital spark-advance module (DSAM) optimizes ignition timing for the selected fuel (12RES).

Section 1 Features

1.4 Advanced Digital Control

The generator set is equipped with the Kohler r

Advanced Digital Control (ADC 2100).

Controller features include the following:

Compact controller

Integrally mounted to the generator set

LED display:

Runtime hours

Crank cycle status

Diagnostics

LED display communicates faults:

High battery voltage

High engine temperature

Low battery voltage

Low oil pressure

Overcrank safety

Overspeed

Overfrequency

Overvoltage

Underfrequency

Undervoltage

Membrane keypad for configuration and adjustment

Password-protected user access to menus

Voltage, gain, and speed adjustment

System configuration (system voltage, phase, and frequency settings, battery voltage, and generator set model)

Master control switch: Run/Off-Reset/Auto

Remote two-wire start/stop capability

Superior electronics protection from corrosion and vibration

Potted electronics

Sealed connections

Digital isochronous governor to maintain steady-state speed at all loads

Digital voltage regulation:

±1.5% RMS no-load to full-load

Automatic start for programmed cranking cycle

TP-6331 5/04 Section 1 Features 1

1.5 Generator Set Components

1 2 3 4 5 6 7

15 14 13

1. Enclosure

2. Muffler

3. Oil check

4. Oil fill

5. Air cleaner

6. Spark plug locations (both sides)

7. ADC 2100

8. Generator set master switch (RUN\OFF/RESET\AUTO)

9. Nameplate

10. Line circuit breaker

11. Engine starting battery location

12. Oil drain hose

12 11

13. Oil drain valve

14. Oil filter

15. Alternator cooling air intake

16. Exhaust

17. DSAM leads

18. Multi-fuel block

19. Gas regulator assembly

20. Fuel solenoid valve

21. Air intake

22. Battery charger

23. Relay board

Figure 1-1 Generator Set Components

17 18 19

ADV-6823-A

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 air 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.

Check for corroded or broken metal parts and replace them as needed.

Check that the exhaust outlet is unobstructed.

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:op:001:002

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 operator.

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.

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

TP-6331 5/04 Section 2 Operation 3

2.3.1 Controls and Indicators

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.

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

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. Contact an 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.

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 generator 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.

Control or Indicator Item

LED display

Keypad

Description

Runtime hours

Software version number

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.

See TP-6196, Generator Set Service Manual. Contact an authorized distributor/dealer.

Select and arrow buttons

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 password-protected.

Generator set master switch

Three-position switch

Switch functions as the generator set operation and controller reset switch.

Figure 2-2 ADC 2100 Controls and Indicators

4 Section 2 Operation TP-6331 5/04

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. The high engine temperature switch automatically resets when the generator set cools. However, the fault does not clear until the controller is reset.

The controller displays a fault code but the generator set does not shut down under the conditions shown in

Figure 2-4.

Code

LCL

LOC

LOP

Fault

Auxiliary fault input shutdown

High engine temperature shutdown

Description

Not used.

Low coolant level Not used on air-cooled models.

Loss of coolant Not 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.

Overcrank 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

—

Check for blocked air inlets and exhaust outlets.

—

Check for leaks in the lubrication system.

Check the oil level and add oil if the level is low.

—

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

Overspeed shutdown

Overvoltage shutdown

Underfrequency shutdown

Undervoltage 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).

Shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than 0.3 seconds.

Shutdown occurs if the voltage exceeds 120% of the system nominal voltage for more than 2 seconds.

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).

Contact an authorized distributor/dealer for service if problem continues.

Reduce the load and restart the generator set.

Contact an authorized distributor/dealer for service if problem continues.

Shutdown occurs if the voltage falls below 80% of the nominal system voltage for more than 10 seconds.

Reduce the load and restart the generator set.

Contact an authorized distributor/dealer for service if problem continues.

Figure 2-3 ADC 2100 Fault Shutdown Codes

TP-6331 5/04 Section 2 Operation 5

Code

Fault

High battery voltage warning

Low battery voltage warning

Description

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.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.

Fault code is displayed if the engine starting battery voltage falls below 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.

The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.

Figure 2-4 ADC 2100 Fault Warning Codes

Check

Check the battery rating and condition.

Check the battery charger operation.

Check the battery rating and condition.

Check the battery charger operation.

Charge or replace the battery.

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.

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.

6 Section 2 Operation 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 charger 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.

INDICATOR

Red:

Red & Green:

Green:

VOLTS= 11.8--14.0

AMPS= 5.0--6.0

VOLTS= 14.0--14.5

AMPS= 1.5--5.0

VOLTS= 13.0--13.6

AMPS= 0.1--1.5

6 AMP AUTOMATIC

BATTERY CHARGER 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.

DATE:

Allowable Battery Types: Lead Acid a

C nd Gel Cell

2608KH

1. LED indicators

2. AC power cord

3. Fuse

4. Battery leads, 12 VDC

Figure 2-5 6-Amp Float/Equalize Battery Charger

Figure 2-6 Charging Method

Display

Red ON

Green OFF

Red ON

Green ON

Red OFF

Green ON

Operating Condition

When the red LED is on, it indicates the battery is discharged and the battery charger is recharging at the BULK rate

(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.

When both the green and the red LEDs are on, the battery charger is charging at an ABSORPTION rate of between 1.5 and

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.

When the green LED is on, the battery charger is charging at a FLOAT or MAINTENANCE rate of less than 1.5 amps

(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

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator 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.

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

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.

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.

TP-6331 5/04 Section 3 Scheduled Maintenance 9

3.2 Service Schedule

System Component or Procedure

Fuel

Flexible lines and connections

Main tank supply level

Fuel piping

Lubrication

Oil level

Crankcase breather hose

Change oil

Replace filter

Cooling

Air ducts, louvers

Exhaust Line

Leakage

Insulation, fire hazards

Obstructions or combustible materials near exhaust outlet

DC Electrical System

Battery charger operation, charge rate (if equipped)

Remove corrosion, clean and dry battery and rack

Clean and tighten battery terminals and inspect boots

Battery electrolyte level and specific gravity *

AC Electrical System

Tighten control and power wiring connections

Remote control system, if equipped

Visible wear or damage

Wire abrasions where subject to motion

Wire-cable insulation condition

Engine and Mounting

Visible wear or damage

Air cleaner and precleaner service

Spark plugs

Replace stepper motor coupling and bushing

Generator

Visible wear or damage

Exercise generator set

Brushes and collector ring

Measure and record resistance readings of windings with insulation tester (Megger r, with

SCR assembly or rectifier and load leads disconnected) *

General Condition of Equipment

Evidence of vibration, leakage, excessive noise, temperature, or deterioration

Interior of sound enclosure

* Not necessary for maintenance-free batteries.

See

Section

Procedure

Visually

Inspect Check Change Clean Test

3.3

3.6

3.7

3.8

3.5

3.4

2.1

2.2

D Authorized distributor/dealer only

X Action

R Replace as necessary

Monthly

Yearly

Monthly

Quarterly

Six Months

3 Years or 500 hours

Frequency

Quarterly

Weekly

Yearly

8 hours or before use

Yearly or 500 hours

Yearly or 100 hours

Yearly or 200 hours

Yearly

Weekly

Yearly

Weekly

Yearly or 100 hours

Yearly or 300 hours

500 hours

Quarterly

Weekly

Yearly

3 Years

Weekly

Quarterly

Megger r 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 set is 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 dipstick. 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.

5W-20, 5W-30

10W-30

°F

°C

--20

--30 --20

--10

20 32

100

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. Allow time 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 retaining clip.

2. Replace the oil filter.

a. Remove the oil filter by rotating it counterclockwise with an oil filter wrench.

TP-6331 5/04 Section 3 Scheduled Maintenance 11

b. Clean the gasket sealing surface of the oil filter adapter.

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.

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 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 3-2 Checking the Spark Plug Gap

1--514

1--511

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 eliminated. Squeeze out excess water (do not wring). Allow the precleaner 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.

2. Disconnect the power to the battery charger.

3. Disconnect the generator set engine starting battery, negative (--) lead first.

4. Loosen the cover retaining knob and remove the 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, bent, 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

11. Reconnect the generator set engine starting battery, negative (--) lead last.

1. Cover knob

2. Air cleaner cover

3. Element cover nut

4. Element cover

5. Foam precleaner

6. Air cleaner element

7. Air cleaner base

Figure 3-4 Air Cleaner Components

586536

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.

1. Exhaust outlet

2. Alternator air intake (both sides)

3. Engine air intake

Figure 3-5 Cooling Air Intake and Exhaust

3 tp6195

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.

Check for loose, corroded, or missing clamps and hangers. Tighten or replace clamps and/or hangers as needed.

Check for and remove loose insulation in the exhaust duct.

Check that the exhaust outlet is clear.

3.8 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. 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) 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 it is charging. Do not dispose of a battery in a fire.

To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded 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.

14 Section 3 Scheduled Maintenance TP-6331 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 a12-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.

connections.

See Figure 3-6 for typical battery

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 battery 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.

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 factorywired. Figure 3-7 illustrates the battery charger.

Periodically tighten all connections.

No other maintenance on the battery charger is required.

INDICATOR

Red:

Red & Green:

Green:

VOLTS= 14.0--14.5

AMPS= 1.5--5.0

VOLTS= 13.0--13.6

AMPS= 0.1--1.5

6 AMP AUTOMATIC

BATTERY CHARGER 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.

DATE:

Allowable Battery Types: Lead Acid a

BATTERY CHARGER

53AB nd Gel Cell

2608KH

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

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 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 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.

Model

8.5RES

12RES

Circuit Breaker

Rating, Amps

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.

Fuse

Auxiliary winding

Relay interface board

Controller

Battery charger

Label

Part

Number Location

292937 Lead 55

223316 Lead PF2

—

223316 Lead PF1

AGS 10 Battery charger DC lead. See Section 2.6.

Figure 3-9 Fuses

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 about 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.

16 Section 3 Scheduled Maintenance TP-6331 5/04

3.11.3 Cylinder Lubrication

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

1. Clean the exterior surface of the generator set.

2. Seal all openings in the engine with nonabsorbent adhesive tape.

3. Mask all areas to be used for electrical contact.

4. Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion.

3.11.5 Battery

Perform battery storage last.

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the battery, negative (--) lead first.

3. Clean the battery. Refer to Section NO TAG for the cleaning procedure.

4. Place the battery in a warm, dry location.

5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger.

Follow the battery charger manufacturer’s recommendations.

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

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. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to the equipment.

4.2 Generator Set Troubleshooting

Figure 4-1 contains generator set troubleshooting, diagnostic, and repair information.

Check for loose connections before replacing parts.

Problem

The generator set does not crank.

Possible Cause

Battery weak or dead

Battery charger fuse blown

Battery connections reversed or poor

Controller fuse (F3) blown

Relay interface board fuse (F2) blown k b d start, starts hard, lacks

Generator set master switch in the OFF position

Air cleaner clogged

Battery weak or dead

Battery connection poor

Spark plug wire connection loose

Low oil pressure shutdown

Fuel pressure insufficient

Engine malfunction

AC circuit breaker in the OFF position

AC circuit breaker tripping because of overload

AC circuit breaker tripping because of short circuit

Auxiliary winding fuse (F1) blown

Corrective Action

Check power to the battery charger.

Recharge or replace the battery.

Replace the fuse. Contact an authorized distributor/dealer for service if fuse blows repeatedly.

Check the connections.

Replace the fuse. Contact an authorized distributor/dealer for service if fuse blows repeatedly.

Move the master switch to the RUN position.

Clean and/or replace the air cleaner.

Check power to the battery charger.

Recharge or replace the battery.

Clean and tighten the battery connections.

Check the spark plug wires.

Check the oil level.

Check the fuel supply and valves.

Contact the distributor/dealer.

Place the circuit breaker in the ON position.

Reduce the load on the generator set.

Contact an authorized distributor/dealer for service.

Replace the fuse. Contact an authorized distributor/dealer for service if fuse blows repeatedly.

Reduce the load.

Low output or excessive drop in voltage.

Generator set overloaded dd l

Low oil pressure shutdown

Out of fuel

Overcrank shutdown

Controller fuse (F3) blown

Overspeed shutdown

Check the oil level.

Check fuel supply.

Reset the controller. If the overcrank fault occurs again, contact the distributor/dealer.

Replace the fuse. If the fuse blows again, contact the distributor/dealer.

Reset the controller. If the overspeed fault occurs again, contact the distributor/dealer.

Move the switch to the correct position (RUN or AUTO).

Generator set master switch in the OFF/RESET position

Remote stop command received from a remote switch or ATS

Engine malfunction

Auxiliary winding fuse (F1) blown

Check the remote switch position.

Contact the distributor/dealer.

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.

4.5 Battery Charger

Troubleshooting

Use the battery charger’s LED indicators and the table in

Figure 4-3 to troubleshoot battery charger operation problems.

4.4 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:

Continuous power mode jumper is disconnected and the generator set has not run for 48 hours or longer.

Controller fuse (F3) is blown.

Low or no battery voltage.

Generator set master switch is in the OFF/RESET position.

Generator set master switch in AUTO but no start command has been received since last controller reset.

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.

Move generator set master switch to the AUTO or RUN position.

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.

Figure 4-2 ADC 2100 Troubleshooting Chart

Problem

24 hours

Red and green h th th to be low

Neither of the

Cause

One or more defective or damaged cells.

Battery charger has reduced its output voltage below the normal level due to a DC overload or a DC short.

Solution

Load test the battery and replace, if necessary

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.

Turn off all DC equipment while charging.

Onboard DC systems are drawing more current than the battery charger can replace.

Onboard DC systems are drawing between 1.5 and

5 amps.

One or more defective or damaged cells.

Extremely low AC voltage at the battery charger.

Turn off all DC equipment while charging.

Open DC output fuse.

Faulty or contaminated terminal connections.

One or more defective or damaged cells.

No AC power available at the battery charger.

Load test the battery and replace, if necessary

Apply a higher AC voltage source or reduce the length of the extension cord.

Replace AGS-10 fuse.

Clean and tighten or repair all terminal connections.

Load test the battery and replace, if necessary.

Connect AC power or reset the AC breaker on the main panel.

when the AC power is applied

Component failure.

Figure 4-3 Battery Charger Troubleshooting

Replace battery charger.

20 Section 4 Troubleshooting TP-6331 5/04

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere

ABDC after bottom dead center

A/D alternating current analog to digital

ADC adj.

ADV

AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature

AISI

ALOP alt.

American Iron and Steel

Institute anticipatory low oil pressure alternator

ANSI aluminum

American National Standards

Institute

(formerly American Standards

Association, ASA) anticipatory only AO

API American Petroleum Institute approx.

approximate, approximately

ASE

ASME assy.

ASTM as required, as requested as supplied, as stated, as suggested

American Society of Engineers

American Society of

Mechanical Engineers assembly

ATDC

ATS auto.

aux.

A/V avg.

American Society for Testing

Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average

AVR

AWG

AWM bat.

BBDC

BCA

BCI

BDC

BHP blk.

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) blk. htr.

block heater

BMEP brake mean effective pressure bps br.

bits per second brass

BTDC

Btu before top dead center

British thermal unit

Btu/min.

British thermal units per minute

C Celsius, centigrade cal.

CARB

CB cc calorie

California Air Resources Board circuit breaker cubic centimeter

CCA ccw.

CEC cert.

cold cranking amps counterclockwise

Canadian Electrical Code certificate, certification, certified cfh cfm

CID

CL cm

CMOS cubic feet per hour cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogen.

com cogeneration communications (port) coml commercial

Coml/Rec Commercial/Recreational conn.

cont.

CPVC crit.

CRT

CSA connection continued chlorinated polyvinyl chloride critical cathode ray tube

Canadian Standards

Association

Cu cu. in.

cw.

CWC cyl.

D/A

DAC current transformer copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter dB dBA

DCR deg.,

° dept.

dia.

DI/EO

DIN decibel decibel (A weighted) direct current direct current resistance degree

DIP

DPDT

DPST

DS e.g.

EGSA

EIA

EI/EO

EMI emiss.

eng.

EPA 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

DSAM

DVR digital spark-advance module digital voltage regulator

E, emer.

emergency (power source)

EDI

EFR 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

EPS

ESD

Environmental Protection

Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge

TP-6331 5/04 est.

estimated

E-Stop emergency stop etc.

exh.

ext.

F et cetera (and so forth) exhaust external

Fahrenheit, female fglass.

FHM fl. oz.

flex.

fiberglass flat head machine (screw) fluid ounce flexible freq.

FS ft.

ft. lbs.

frequency full scale foot, feet foot pounds (torque) ft./min.

feet per minute g gram ga.

gal.

gen.

genset

GFI gauge (meters, wire size) gallon generator generator set ground fault interrupter

GND, gov.

gph gpm ground governor gallons per hour gallons per minute gr.

GRD grade, gross equipment ground gr. wt.

gross weight

H x W x D height by width by depth

HCHT

HET hex cap high cylinder head temperature heavy duty high exhaust temperature, high engine temperature hex

HHC

HP hr.

HS hsg.

HVAC hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature HWT

IEC hertz (cycles per second) integrated circuit inside diameter, identification

International Electrotechnical

Commission

IEEE

IMS in.

Institute of Electrical and

Electronics Engineers improved motor starting inch in. H

2 in. Hg

O inches of water inches of mercury in. lbs.

inch pounds

Inc.

ind.

incorporated industrial int.

internal int./ext.

internal/external

I/O

IP input/output iron pipe

Appendix A-1

ISO

JIS k

K kA

KB kg kg/cm

International Organization for

Standardization joule

Japanese Industry Standard kilo (1000) kelvin kiloampere kilobyte (2 kilogram

10 bytes) kgm kg/m

3 kHz kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kJ kilojoule km kilometer kOhm, k

Ω kilo-ohm kPa kilopascal kph kV kVA kVAR kW kWh kWm

L kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical liter

LAN local area network

L x W x H length by width by height lb.

lbm/ft

3 pound, pounds pounds mass per cubic feet

LCB

LCD line circuit breaker liquid crystal display ld. shd.

load shed

LED light emitting diode

Lph

Lpm

LOP

LPG liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas

L wa

LWL left side sound power level, A weighted

LWT low water level low water temperature m

M meter, milli (1/1000) mega (10

6 when used with SI m

3 m

3 units), male cubic meter

/min.

cubic meters per minute mA man.

max.

MCM

MCCB milliampere manual maximum megabyte (2

20 bytes) one thousand circular mils molded-case circuit breaker meggar megohmmeter

MHz megahertz mi.

mil min.

misc.

mile one one-thousandth of an inch minimum, minute miscellaneous

MJ mJ megajoule millijoule mm millimeter mOhm, m

Ω milliohm

MOhm, M

Ω megohm

MOV

MPa metal oxide varistor megapascal mpg mph miles per gallon miles per hour

A-2 Appendix

MS m/sec.

MTBF

MTBO military standard meters per second mean time between failure mean time between overhauls mtg.

MW mounting megawatt mW

µF milliwatt microfarad

N, norm.

normal (power source)

NA not available, not applicable nat. gas natural gas

NBS

National Bureau of Standards normally closed

NEC

NEMA

National Electrical Code

National Electrical

Manufacturers Association psi pt.

PTC

PTO

PVC qt.

qty.

OV oz.

p., pp.

PCB pF

PF ph.,

∅

PHC

NFPA

National Fire Protection

Association newton meter normally open no., nos.

number, numbers

NPS National Pipe, Straight

NPSC

NPT

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

NPTF

NR ns

OEM

OF opt.

OSHA

National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option, optional oversize, overspeed

Occupational Safety and Health

Administration overvoltage ounce page, pages personal computer

PHH

PHM

PLC

PMG pot ppm

PROM 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 rad.

RAM

RDO ref.

radiator, radius random access memory relay driver output reference rem.

remote

Res/Coml Residential/Commercial

RFI radio frequency interference

VAR

VDC

VFD

VGA

VHF

WCR w/ w/o wt.

xfmr

UHF

UNC

UNF univ.

VAC

RHM rly.

rms rnd.

ROM rot.

rpm

RTV

SAE scfm

SCR s, sec.

SI round head round head machine (screw) relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units

TDOE

TDON temp.

term.

TIF

TIR tol.

turbo.

typ.

SI/EO sil.

SPDT side in/end out silencer serial number single--pole, double--throw

SPST single--pole, single--throw spec, specs specification(s) sq.

square sq. cm sq. in.

SS std.

stl.

tach.

TDC

TDEC

TDEN

TDES

TDNE square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency

Underwriter’s Laboratories, Inc.

unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer

TP-6331 5/04

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

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