Kohler RES 8.5, RES 12, RES 17, RES 18, TRES 12, 18 Generator Set Operation Manual

Below you will find brief information for Generator set RES 8.5, Generator set RES 12, Generator set RES 17, Generator set RES 18, Generator set TRES 12, Generator set TRES 18. This manual provide instructions to ensure proper equipment operation and to avoid bodily injury. It contains all necessary information for installing, operating, and maintaining these generator sets. It also includes safety precautions and instructions.

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Operation

Residential/Commercial Generator Sets

Models:

8.5/12/17/18RES

12/18TRES

Controller:

Advanced Digital Control ADC-RES

TP-6515 1/11f

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

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

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

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

Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

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

1.2

Generator

1.3

Engine

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

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

1.4

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

1.5

Service Views for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

2.1

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

2.2

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

2.3

ADC-RES Controls and Indicators

2.3.1

LED Display

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

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

2.3.2

Controller Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3

Generator Set Master Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1

Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2

Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

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

2.5.1

Starting Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2

Stopping Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.3

Resetting Emergency Stop Switch (TRES Models only)

2.6

Faults

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

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

2.6.1

Shutdowns

2.6.2

Warnings

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

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

2.6.3

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

2.7

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

2.7.1

RES Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.2

TRES Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

3.1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1

Service Schedule, 8.5/12 kW Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2

Service Schedule, 17/18 kW Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

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

3.2.1

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

3.2.2

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

3.2.3

Engine Oil Recommendation

3.2.4

Oil Change Procedure

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

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

3.2.5

Oil Cooler, 17/18 kW

3.3

Spark Plugs

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

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

3.4

Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1

Air Cleaner, 8.5/12RES

3.4.2

Air Cleaner, 17/18RES

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

3.5

Cooling System

3.6

Exhaust System

3.7

Battery

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

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

3.8

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

TP-6515 1/11 Table of Contents

Table of Contents, continued

3.9

Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.1

Line Circuit Breaker

3.9.2

Fuses

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

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

3.10 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.1

Lubricating System

3.10.2

Fuel System

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

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

3.10.3

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

3.10.4

Exterior Preparation

3.10.5

Battery

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

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

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

4.1

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

4.2

Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3

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

4.4

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

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

Table of Contents TP-6515 1/11

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

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. 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.

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

TP-6515 1/11 Safety Precautions and Instructions 5

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 is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

Light-headedness, dizziness

Physical fatigue, weakness in joints and muscles

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

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.

Fuel System

WARNING

Explosive fuel vapors.

Can cause severe injury or death.

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

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.

6 Safety Precautions and Instructions TP-6515 1/11

Hazardous Noise

CAUTION

Hazardous noise.

Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can

cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than

105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/

Moving Parts

WARNING

Hazardous voltage.

Moving parts.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

WARNING

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. Ensure you comply with all applicable codes and standards.

Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

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.

Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).

Have a qualified electrician install the battery(ies).

Short circuits.

Hazardous voltage/current can cause severe

injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility.

Hazardous backfeed voltage can

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

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

WARNING

Airborne particles.

Can cause severe injury or blindness.

Wear protective goggles and clothing when using power tools, hand tools, or compressed air.

Heavy Equipment

WARNING

Unbalanced weight.

Improper lifting can cause severe injury or death and equipment damage.

Do not use lifting eyes.

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

TP-6515 1/11 Safety Precautions and Instructions 7

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 exhaust system. Hot parts can cause severe injury or

death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

Servicing the engine heater. Hot parts can cause minor personal

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

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

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

Notice

NOTICE

Canadian installations only.

For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with

Canadian Electrical Code, Part 1.

8 Safety Precautions and Instructions TP-6515 1/11

This manual provides operation and maintenance instructions for residential/commercial generator sets equipped with ADC-RES controls. The generator set models covered by this manual are listed on the front cover.

This generator set is approved for use in stationary applications in locations served by a reliable utility power source. Have the generator set installed by an authorized distributor/dealer or service technician.

Refer to TP-6514, Installation Manual, for installation instructions.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service 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 for the nameplate location.

Introduction

Emission Information

The Kohlerr Model CH640 engine used on the model

8.5RES generator set, CH740 engine used on the

12RES generator set, and CH980 engine used on the

17/18RES generator set are 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 or EPA emission requirements. The following table provides the engine compliance period

(in hours) associated with the category descriptor, which may be found on the certification label.

EPA

CARB

Emission Compliance Period

Category C

250 hours

Category B

500 hours

Category A

1000 hours

Moderate

125 hours

Intermediate

250 hours

Extended

500 hours

Figure 1 Emission Compliance Period

Refer to the certification label for engine displacement.

The exhaust emission control system for the CH640,

CH740, and CH980 engines is EM for U.S. EPA,

California, and Europe.

The engine used in the Model 17/18RES generator set is certified for emergency standby use only.

TP-6515 1/11 Introduction 9

For professional advice on generator set 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

KohlerPower.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

3 rue de Brennus

93200 Saint Denis

France

Phone: (33) 1 49 178300

Fax: (33) 1 49 178301

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

Service Assistance

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

10 Service Assistance TP-6515 1/11

1.1 Introduction

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 PowerBoostt voltage regulation system, which provides instant response to load changes.

PowerBoostt ensures reliable motor starting and consistent voltage levels. PowerBoostt 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 Kohlerr engine. The engine operates on cleanburning 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 viceversa) while maintaining CARB emission certification.

Digital spark advance optimizes ignition timing for the selected fuel. (12 --18 kW models)

Section 1 Specifications

1.4 Advanced Digital Control

The generator set is equipped with the Kohlerr

ADC-RES Advanced Digital Control.

Controller features include the following:

Compact controller

Integrally mounted to the generator set

LED display:

Engine runtime, hours

AC voltage

Frequency (Hz)

Battery voltage

Crank cycle status

Setup information

Application software version

LED display communicates faults:

High battery voltage

High engine temperature

Low battery voltage

Low oil pressure

Overcrank safety

Overfrequency

Overspeed

Overvoltage

Underfrequency

Undervoltage

Membrane keypad for configuration and adjustment

Password-protected user access to menus

Voltage, gain, and speed adjustment

System configuration (system voltage/frequency settings and generator set model)

Remote two-wire start/stop capability

Digital isochronous governor to maintain steadystate speed at all loads

Digital voltage regulation: 1.5% RMS no-load to full-load

Automatic start for programmed cranking cycle

Master control switch mounted on the junction box:

Run/Off-Reset/Auto

Upgradeable application software

TP-6515 1/11 Section 1 Specifications 11

1.5 Service Views for Maintenance

1 2 3 4 5 6 7

17 18 19 20 21

ADV-7466-

24 14 13 12 11

1. Muffler

2. Oil check

3. Oil fill

4. Air cleaner

5. Fuses

6. RS-232 connector (for application program updates)

7. Controller user interface (see Figure 2-1)

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

9. Line circuit breaker (single-phase models)*

10. Field-connection terminal block location (single-phase models)*

11. Spark plug locations (both sides)

12. Oil drain hose

* See Figure 1-3 for additional components for 3-phase models.

[

See Figure 2-9 for 3-phase battery charger locations.

Figure 1-1 Generator Set Components, 8.5/12 kW

13. Oil drain valve

14. Oil filter

15. Exhaust

16. Equipment ground

17. Relay board location (optional)

18. Battery charger (single-phase models)[

19. DSAI lead location (12 kW models)

20. Fuel block

21. Gas regulator assembly

22. Fuel solenoid valve

23. Fuel inlet

24. Air intake

25. Engine starting battery location (battery purchased separately)

12 Section 1 Specifications TP-6515 1/11

Control detail, top view

2 3 4

5 6 7

See control detail

20 21 22

ADV-7341A-B

25 16 15 14 13

1. Muffler

2. Oil check

3. Oil fill

4. Air cleaner

5. Spark plug locations (both sides)

6. Oil filter

7. Oil cooler location

8. ADC-RES Advanced Digital Control user interface

9. Generator set master switch (RUN-OFF/RESET-AUTO)

10. Line circuit breaker (single-phase models )*

11. Fuses

12. RS-232 connector (for application program updates)

13. Engine starting battery location (battery purchased separately)

14. Oil drain hose

15. Nameplate location (on base)

16. Oil drain valve

17. Exhaust outlet

18. Relay board location (optional)

19. Carburetor heater access opening

20. LP fuel orifice location (inside hose fitting)

21. Gas regulator assembly

22. DSAI leads

23. Fuel solenoid valve

24. Fuel inlet

25. Air intake

26. Battery cables

27. Battery charger (single-phase models)[

28. Field-connection terminal block location (single-phase models)*

29. 120 VAC receptacles for battery charger and optional carburetor heater (single-phase models)

* See Figure 1-3 for additional components for 3-phase models.

[

See Figure 2-9 for 3-phase battery charger locations.

Figure 1-2 Generator Set Components, 17/18 kW

TP-6515 1/11 Section 1 Specifications 13

GM66010

1. Emergency stop switch

2. Field-connection terminal block and circuit breakers

3. Cable inlet area

Figure 1-3 Additional Components, TRES (3-phase)

Models

14 Section 1 Specifications TP-6515 1/11

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 condition and check for tight exhaust system connections.

Inspect the exhaust system components for cracks, leaks, and corrosion.

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

Check that the exhaust outlet is unobstructed.

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.

2.2 Exercising Generator Set

Operate the generator set without load once each week for 20 minutes. If the generator set is not connected to 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.

TP-6515 1/11

Section 2 Operation

2.3 ADC-RES Controls and

Indicators

Figure 2-1 illustrates the ADC-RES user interface and other items on the generator set junction box.

Figure 2-2 describes the ADC-RES controls and indicators.

1. LED display

2. Up and down arrow buttons

3. Generator set master switch

4. Line circuit breaker (single-phase models)

5. Fuses

6. RS-232 connector (for application program upgrade)

7. Select button (use for setup and adjustment only)

Figure 2-1 ADC-RES Controls

2.3.1 LED Display

The LED display is activated by a start or RUN command as follows:

Move the master switch to RUN.

With the master switch in AUTO, send a remote start command (close the remote start contact across leads 3 and 4).

The LED display indicates generator set status as shown in Figure 2-2. When the generator set is running, engine runtime hours are shown unless the arrow buttons are used to step through the other displays as described in Section 2.3.2.

When the master switch is in AUTO, the display may turn off 48 hours after generator set shutdown. See

Section 2.4, Controller Power.

Section 2 Operation 15

Control or Indicator Item

LED display Runtime hours

Description

Displays total generator set runtime hours while the generator set is running and when no other codes are displayed.

Metering display

Displays AC voltage (output), frequency, and battery voltage. Press the up or down arrow when runtime hours are displayed to step through these displays.

Keypad

Generator set master switch

Crank indication Displays CC_1, CC_2, or CC_3 to indicate the first, second, or third attempt to start the engine. The last digit flashes during the crank cycle rest periods.

Software version number

Fault codes

The software version number (v#.##) is displayed when entering configuration mode. See the installation manual.

Flashes a 2- or 3-letter fault code to indicate various fault conditions. See

Section 2.6.

Select and arrow buttons

Three-position switch

Use the arrow buttons to step through the data displays. See Figure 2-3.

The keypad is also used for controller setup and adjustment. The setup and adjustment functions are password-protected. Have setup and adjustments performed only by an authorized distributor/dealer.

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

Figure 2-2 ADC-RES Controls and Indicators

2.3.2 Controller Keypad

The three buttons on the controller keypad are Select,

Up, and Down. See Figure 2-1.

When the generator set is running, the up and down arrow buttons can be used to step through system data displays as shown in Figure 2-3. After 10 seconds, the display returns to engine runtime hours.

The buttons on the controller keypad are also used 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.

2.3.3 Generator Set Master Switch

The generator set master switch is located on the junction box below the ADC-RES user interface. The master switch positions are RUN, OFF/RESET, and

AUTO. See Section 2.5 for operation instructions.

Engine Runtime

XXX.X hours

Output Voltage

VAC

Output Frequency

Battery Voltage

VDC

Generator set master switch in AUTO

Step through using up or down arrow buttons

After 10 seconds, display returns to runtime hours

Figure 2-3 Data Displays tp6515

16 Section 2 Operation TP-6515 1/11

2.4 Controller Power

The ADC-RES is powered by the generator set engine starting battery.

Note: The generator sets are equipped with factoryinstalled battery chargers to prevent battery discharge.

The battery charger must be connected to utility power.

2.4.1 Standby Mode

When the generator set master switch is in the AUTO position and the engine is not running, the controller is in standby mode. Engine runtime hours are shown on the display. A remote start signal (contact closure) will start and run the generator set.

The controller can be set to go into sleep mode if there is no start signal for 48 hours.

2.4.2 Sleep Mode

Controllers with application code version 1.13 or higher are shipped with the sleep mode disabled and J1939 communication enabled. The controller will remain in standby mode whenever the master switch is in AUTO and the engine is not running.

Communication parameter Cn can be changed to disable communication and enable the sleep mode if remote communication is not required. See Installation

Manual TP-6514 for instructions to change parameter

Cn.

Sleep Mode.

If the controller communication is disabled and the generator set master switch is in the

AUTO position, the controller powers down automatically after 48 hours of inactivity. The controller display is dark and battery draw is minimized. A remote start signal from a transfer switch or a remote start/stop switch connected to controller leads 3 and 4 reactivates the controller. Moving the generator set master switch to the RUN position also activates the controller.

2.5 Generator Set Operation

2.5.1 Starting Generator Set

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. Close a contact across engine start leads 3 and 4 to signal the controller to start the generator set.

Crank Cycle

The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and

15 seconds off). See Figure 2-2 for display information during the crank cycle. If the generator set does not start in three attempts, the system shuts down on an overcrank fault. See Section 2.6.

2.5.2 Stopping Generator Set

Local Stopping

1. Run the generator set with 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, open the contact across engine start leads 3 and 4 to signal the generator set to stop.

An automatic transfer switch (ATS) connected to controller leads 3 and 4 operates as follows:

1. The ATS 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-RES controller.

3. The ATS opens the connection between controller leads 3 and 4. The generator set shuts down. The controller enters standby mode and displays engine runtime hours.

TP-6515 1/11 Section 2 Operation 17

Emergency Stopping (TRES Models Only)

Push the red emergency stop switch for immediate generator set shutdown in the case of an emergency.

See Figure 2-4 for the emergency stop switch location.

The emergency stop switch shuts down the generator set immediately. The controller display shows AF

(auxiliary fault) when the emergency stop button is activated.

Use the generator set master switch for normal shutdowns.

2.5.3 Resetting Emergency Stop Switch

(TRES Models only)

Use the following procedure to reset the generator set after shutdown by the emergency stop switch. See

Section 2.6.3 to reset the generator set after a fault shutdown.

1. Place the generator set master switch in the

OFF/RESET position.

2. Investigate and correct the cause of the emergency stop.

3. Rotate the emergency stop switch knob clockwise and release it. Check that the knob returns to the deactivated (out) position.

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

Verify that the controller display no longer shows a fault code. The generator set engine will not start until the reset procedure is complete.

GM66010

1. Emergency stop switch

Figure 2-4 Emergency Stop Switch, TRES Models

18 Section 2 Operation TP-6515 1/11

2.6 Faults

2.6.1 Shutdowns

Under the fault shutdown conditions listed in Figure 2-5, the generator set shuts down automatically and the controller displays a fault code. The generator set cannot be restarted until the fault condition is corrected and the controller is reset. See Section 2.6.3 to reset the controller after a fault shutdown.

The shutdown switches on the generator set will automatically reset when the problem is corrected. For example, the high engine temperature switch resets automatically when the generator set cools. However, the fault does not clear until the controller is reset.

2.6.2 Warnings

The controller displays a fault code but the generator set does not shut down on a high battery voltage warning or a low battery voltage warning. The controller resets automatically after a battery voltage fault condition is corrected.

2.6.3 Resetting Controller after a Fault

Shutdown

Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault code displayed on the ADC-RES and refer to

Figure 2-5 to identify and correct the fault condition before proceeding.

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 manual before proceeding.

3. Identify and correct the cause of the fault shutdown. See the safety precautions at the beginning of this manual 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.

TP-6515 1/11 Section 2 Operation 19

Code Fault

Auxiliary fault input shutdown

High engine temperature shutdown

LOP Low oil

OF pressure shutdown

Overcrank shutdown

Locked rotor

Overfrequency shutdown

Description

Indicates a shutdown initiated by pushing the emergency stop switch. (TRES models only)

Not used on RES models.

Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than

5 seconds. This function becomes active after the engine reaches the crank disconnect speed.

Shutdown occurs if a low oil pressure condition exists for more than 5 seconds. This function 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.

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 on OC if no engine rotation is sensed during cranking. Shuts down 3 seconds after the fault is detected.

Shutdown occurs when the governed frequency exceeds

110% of the system’s frequency setpoint for more than 5 seconds. This function becomes active 10 seconds after engine start (10 second inhibit).

Shutdown occurs if the engine speed exceeds 110% of the normal running speed for more than 0.3 seconds.

Check

Check the position of the emergency stop button. (TRES models only)

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.

Check the fuel supply, spark plug, and battery.

Check for loose connections.

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

Overspeed shutdown

Overvoltage shutdown

UF Underfrequency shutdown

Undervoltage shutdown

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

Shutdown occurs if the governed frequency falls below

54 Hz for more than 5 seconds.

Shutdown also occurs if the governed frequency falls below

56.5 Hz for more than 60 seconds.

This function becomes active 10 seconds after engine start.

(10 second inhibit).

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

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.

Reduce the load and restart the generator set.

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

Check the battery rating and condition.

Check the battery charger operation.

HB High battery voltage warning

LB Low battery voltage warning

Fault code is displayed if the engine starting battery voltage rises above 16 VDC for more than 30 seconds when the engine is running. Not operative during the engine crank cycle, this fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to an acceptable level.

Fault code is displayed if the engine starting battery voltage falls below 11 VDC for more than 30 seconds when the engine is not running. Not operative during the engine crank cycle, this fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to an acceptable level.

Figure 2-5 ADC-RES Fault Codes

Check the battery rating and condition.

Check the battery charger operation.

Charge or replace the battery.

20 Section 2 Operation TP-6515 1/11

2.7 Battery Charger

2.7.1 RES Battery Charger

RES model generator sets are equipped with a 6-amp float/equalize battery charger to maintain the engine starting battery. The charger’s power cord must be connected to a 120 VAC power source. Figure 2-6 illustrates the battery charger.

The battery charger uses an AGS 10 inline fuse. The fuse is located in the battery lead. See Figure 2-6.

Battery Charger Operation

Figure 2-7 illustrates the three-stage charging method.

Red and green LEDs indicate charger operation. The chart in Figure 2-8 describes the LED indicator operation during each stage of the charging process.

See Section 4.4 for battery charger troubleshooting information, if necessary.

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

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.

DATE:

Allowable Battery Types: Lead Acid a

2608KH nd Gel Cell

53AB

1. LED indicators

2. AC power cord

3. Fuse

4. Battery leads, 12 VDC

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

Figure 2-7 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 4.4 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 4.4 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 4.4 in this manual.

Figure 2-8 Battery Charger LED Indicator Functions

TP-6515 1/11 Section 2 Operation 21

2.7.2 TRES Battery Charger

Three-phase model TRES generator sets are equipped with a 2.5-amp battery charger to maintain the engine starting battery. Utility power must be supplied to the generator set for the battery charger.

The battery charger is located in or near the controller junction box. See Figure 2-9 for the battery charger location.

A green LED on the side of the battery charger indicates battery charger operation. See Figure 2-10.

Two internal fuses protect the battery charger. See

Section 4.4 for battery charger troubleshooting information, if necessary.

1. Carburetor heater power connection

2. LED

3. Cover (open for fuse access)

Figure 2-10 Battery Charger for 3-Phase Models pdf

12 kW

17/18 kW

1. Battery charger

Figure 2-9 Battery Charger Location, TRES

(3-phase) Models

ADV-7713

22 Section 2 Operation TP-6515 1/11

Section 3 Scheduled Maintenance

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

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

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

Disabling the generator set. Accidental starting can

cause severe injury or death. 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.

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.

Hazardous voltage.

Moving parts.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

Servicing the generator set when it is operating. Exposed

moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

3.1 Scheduled Maintenance

Refer to the following service schedules and the runtime hours displayed on the ADC-RES display to schedule routine maintenance. Intervals are shown in hours of operation and/or time intervals (i.e. weekly, monthly, quarterly, etc.) 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-6515 1/11 Section 3 Scheduled Maintenance 23

3.1.1 Service Schedule, 8.5/12 kW Models

See

Section

Procedure

Visually

Inspect Check Change Clean Test

System Component or Procedure

Fuel

Flexible lines and connections

Main tank supply level

Fuel piping

Lubrication

Oil level

3.2

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 (Meggerr, 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

3.5

3.6

3.7

3.4

3.3

* *Not necessary for maintenance-free batteries.

[

Service more frequently under extremely dusty/dirty conditions.

Meggerr is a registered trademark of Biddle Instruments.

X X X

X Action

D Authorized distributor/dealer only

R Replace as necessary

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

Monthly

Yearly

Monthly

Quarterly

Six Months

3 Years or 500 hours

Weekly

Yearly or 100 hours

Yearly or 300 hours

500 hours

Quarterly

Weekly

Yearly

3 Years

Weekly

Quarterly

24 Section 3 Scheduled Maintenance TP-6515 1/11

3.1.2 Service Schedule, 17/18 kW Models

See

Section

Procedure

Visually

Inspect Check Change Clean

Test

System Component or Procedure

Fuel

Flexible lines and connections

Main tank supply level

Fuel piping

Lubrication

Oil level

3.2

Change oil

Replace filter

Crankcase breather hose

Oil cooler

Cooling

Air ducts, louvers

Exhaust System

Leakage

Insulation, fire hazards

Obstructions or combustible materials near exhaust outlet

DC Electrical System

Battery charger operation, charge rate

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

3.5

3.6

3.7

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 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 (Meggerr, with

SCR assembly or rectifier and load leads disconnected)

General Condition of Equipment

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

3.4

3.3

Interior of sound enclosure

* Not necessary for maintenance-free batteries.

[

Service more frequently under extremely dusty/dirty conditions.

Meggerr is a registered trademark of Biddle Instruments.

150

300

X X

X = Action

D Authorized distributor/dealer only

R Replace as necessary

Frequency

Quarterly

Weekly

Yearly

8 hours or before each use

Yearly or 150 hours

Yearly or 500 hours

Yearly or 100 hours

Yearly

Weekly

Yearly

Weekly

Monthly

Yearly

Monthly

Quarterly

Six Months

3 Years or 500 hours

Weekly

Yearly or hours shown

500 hours

Quarterly

Weekly

Yearly

3 Years

Weekly

Quarterly

TP-6515 1/11 Section 3 Scheduled Maintenance 25

3.2 Lubrication System

See the service schedules in Section 3.1 for oil change and oil filter replacement intervals. See the service views in Section 1.5 for the oil drain, oil check, oil fill, and oil filter locations.

3.2.1 Low Oil Pressure Shutdown

The low oil pressure (LOP) shutdown feature protects the engine against internal damage if the oil pressure drops below a minimum pressure because of oil pump failure or other malfunction.

Note: The LOP shutdown feature does not protect against damage caused by operating when the oil level is low; it is not a low oil level shutdown.

Check the oil level regularly, and add oil as needed.

3.2.2 Oil Check

The generator set is shipped with oil. Before operating the generator set, check the engine oil in the crankcase.

See Figure 3-1.

Maintain the oil level at or near, not over, the full mark on the dipstick. Add 5W-30 synthetic oil when the oil level is low.

Check the oil level before each use. For extended operation, check the oil level every 8 hours. 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.

Figure 3-1 Oil Check (17/18 kW shown)

6515

3.2.3 Engine Oil Recommendation

Use 5W-30 API (American Petroleum Institute) Service

Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner.

3.2.4 Oil Change Procedure

Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner.

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. Clean the area around the dipstick and oil fill cap.

f. 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.

g. Open the oil drain valve on the engine.

h. Remove the dipstick and oil fill cap. Allow time for the engine oil to drain completely.

i. Close the oil drain valve. Replace the cap on the oil drain hose. Replace the oil drain hose in its retaining clip.

j. Replace the dipstick.

2. Replace the oil filter. a. Clean the area around the oil filter. Remove the oil filter by rotating it counterclockwise with an oil filter wrench.

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.

26 Section 3 Scheduled Maintenance TP-6515 1/11

3. Fill with oil. a. Fill the engine to the F mark on the dipstick.

The engine oil capacity is shown in Figure 3-2.

See Section 3.2.3, Engine

Recommendation, for oil selection.

Oil

Generator Set

8.5/12RES

17/18RES

Oil Capacity, L (qt.)

1.9 (2.0)

2.8 (3.0)

Figure 3-2 Engine Oil Capacity 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 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.

3.2.5 Oil Cooler, 17/18 kW

Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris.

See Figure 3-3 for the oil cooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud.

Clean the outside of the oil cooler fins with a brush or with compressed air.

1. Oil cooler

Figure 3-3 Oil Cooler Location

62 590 01

TP-6515 1/11 Section 3 Scheduled Maintenance 27

3.3 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. See Figure 3-4 for the recommended spark plug gap.

Adjust the gap by carefully bending the ground electrode. See Figure 3-5 and

Figure 3-6.

4. Reinstall the spark plug into the cylinder head.

Torque the spark plug to 24.4--29.8 Nm

(18--22 ft. lb.)

Generator Set

8.5 kW

12/17/18RES

Figure 3-4 Spark Plug Gap

Spark Plug Gap

0.51 mm (0.020 in.)

0.76 mm (0.030 in.)

3.4 Air Cleaner Service

3.4.1 Air Cleaner, 8.5/12RES

The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See

Figure 3-7.

Figure 3-5 Checking the Spark Plug Gap

Figure 3-6 Adjusting the Spark Plug Gap

28 Section 3 Scheduled Maintenance

1--514

1--511

586536

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 3-7 Air Cleaner Components

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.

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.

TP-6515 1/11

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 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.

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.

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

3.4.2 Air Cleaner, 17/18RES

The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 3-8.

4 tp6515

1. Knobs (qty.2)

2. Cover

3. Paper element

4. Air filter latch

Figure 3-8 Air Cleaner Components

Check the air cleaner daily or before starting the engine.

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

Note: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure.

TP-6515 1/11 Section 3 Scheduled Maintenance 29

Paper Element Service

Replace the paper element at the intervals indicated in the service schedule. See Section 3.1.2 for the service schedule.

See Figure 3-8 for the air cleaner components.

1. Loosen the two cover retaining knobs and remove the cover.

2. Rotate the air filter latch counterclockwise to unlock, then remove the paper element.

3. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.

4. When servicing the air cleaner, check the air cleaner base and latch. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components.

Note: If any loose dirt or debris fell on the air cleaner base when the element was removed, carefully remove it and wipe the base clean. Be careful that none of it drops into the intake throat.

5. Reinstall the paper element onto the air cleaner base. Make sure the element is flat and properly seated. Rotate the latch clockwise, over the molded lip on the element.

6. Install the air cleaner cover and secure with the two retaining knobs.

7. When element replacement is necessary, order genuine Kohler parts.

3.5 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 3-9. 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 3-9 Cooling Air Intake and Exhaust

3 tp6195

3.6 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 for cracks, leaks, and corrosion.

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

Check that the exhaust outlet is clear.

30 Section 3 Scheduled Maintenance TP-6515 1/11

3.7 Battery

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acid

can cause severe injury or death. Battery acid can cause blindness and burn skin. 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.

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 a

12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage.

Consult the generator spec sheet for battery capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information. See

Figure 3-10 for typical battery connections.

EZ-273000-J

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

Figure 3-10 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery

Connection

Clean the battery and cables and tighten battery terminals using the service schedule recommendations. 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.

3.8 Battery Charger

The generator set is equipped with a battery charger to maintain the engine starting battery. The charger’s DC leads are factory-wired. Periodically check and tighten all connections.

See Section 2.7, Battery Charger.

TP-6515 1/11 Section 3 Scheduled Maintenance 31

3.9 Circuit Protection

If the generator set circuit breaker trips or the fuses blow repeatedly, see Section 4, Troubleshooting, for possible causes.

3.9.1 Line Circuit Breaker

A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. The line circuit breaker location is shown in Figure 1-2. The circuit breaker rating is shown in

Figure 3-11. 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

12TRES

17/18RES

18TRES

Circuit Breaker Rating, Amp

Figure 3-11 Line Circuit Breaker Rating

3.9.2 Fuses

Three panel-mounted fuses protect the alternator and electrical controls. See Section 1.5 for fuse locations.

Another 10-amp fuse protects the battery charger.

See Figure 3-12 for fuse part numbers. 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

(RES)

Figure 3-12 Fuses

Rating, Amp Label Part Number

20 F1 292937

10 F2 223316

—

223316

32 Section 3 Scheduled Maintenance TP-6515 1/11

3.10 Storage Procedure

Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer’s recommendations for storage, if available.

Note: Run the generator set monthly whenever possible.

3.10.1 Lubricating System

1. Operate the generator set until it reaches operating temperature, or about 15 minutes.

2. Stop the generator set.

3. While the engine is still warm, drain the engine lubrication oil from the engine crankcase.

4. Refill engine crankcase with oil. See Section 3.2.3

for oil recommendations.

5. Run the generator set for a few minutes to distribute the clean oil.

6. Stop the generator set.

3.10.2 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.

3.10.3 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.

3.10.4 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.

3.10.5 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.

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-6515 1/11 Section 3 Scheduled Maintenance 33

Notes

34 Section 3 Scheduled Maintenance TP-6515 1/11

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.

Problem

Controller LED display is off

Possible Cause

No power to the controller:

Controller fuse (F3) is blown.

Low or no battery voltage.

Generator set master switch is in the

OFF/RESET position.

The controller is in sleep mode. See Section

2.4.2.

4.2 Controller Troubleshooting

Figure 4-1 contains troubleshooting, diagnostic, and repair information for the ADC-RES controller.

4.3 Generator Set Troubleshooting

Figure 4-2 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts.

Fault Codes

The Advanced Digital Control displays fault codes to aid in troubleshooting. Fault codes, descriptions, and recommended actions are listed in Section 2.6.

If a fault code is displayed, identify and correct the cause of the fault condition. Then reset the controller. See

Section 2.6.3.

Corrective Action

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

Check connections.

Check the engine starting battery and battery charger.

See Figure 4-3.

Move generator set master switch to the AUTO or RUN position. In AUTO, the display will not turn on until the first start command is received.

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. See Section 2.4.

Controllers with application code version 1.13 or higher can be configured to enable or disable the sleep mode.

See the generator set Installation Manual for instructions.

Figure 4-1 ADC-RES Troubleshooting Chart

TP-6515 1/11 Section 4 Troubleshooting 35

Problem

The generator set does not crank.

The generator set cranks but does not start, starts hard, lacks power, or operates erratically.

No AC output.

Possible Cause

Fault shutdown

Battery weak or dead

Battery charger fuse blown

Battery connections reversed or poor

Fuse F2 blown

Corrective Action

Check for a fault code on the controller display. See

Section 2.6.

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.

Fuse F3 blown Replace the fuse. Contact an authorized distributor/ dealer for service if fuse blows repeatedly.

Generator set master switch in the OFF position Move the master switch to AUTO for remote start or to RUN for local start.

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

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 an authorized distributor/dealer.

Place the circuit breaker in the ON position.

AC circuit breaker tripping because of overload Reduce the load on the generator set.

AC circuit breaker tripping because of short circuit

Contact an authorized distributor/dealer for service.

Auxiliary winding fuse (F1) blown

Generator set overloaded

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 stops suddenly.

Low oil pressure shutdown

Out of fuel

Overcrank shutdown

Controller fuse (F3) blown

Overspeed shutdown

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 oil level. Check for signs of oil leaks.

Check fuel supply.

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

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

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

Move the switch to the correct position (RUN or

AUTO).

Check the remote switch position.

Contact an authorized distributor/dealer.

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

Figure 4-2 General Troubleshooting Chart

36 Section 4 Troubleshooting TP-6515 1/11

4.4 Battery Charger

Troubleshooting

Use the battery charger’s LED indicators and the table in Figure 4-3 or Figure 4-4 to troubleshoot battery charger operation problems.

Problem

Red LED stays on for more than

24 hours

Red and green

LEDs stay on for more than 24 hours

Green LED stays on when the battery is known to be low

Neither of the LEDs turn on when the

AC power is applied

Cause

One or more inoperative 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.

Turn off all DC equipment while charging.

One or more inoperative or damaged cells.

Extremely low AC voltage 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.

Open DC output fuse.

Replace AGS-10 fuse.

Faulty or contaminated terminal connections. Clean and tighten or repair all terminal connections.

One or more inoperative or damaged cells.

Load test the battery and replace, if necessary.

No AC power available at the battery charger. Connect AC power or reset the AC breaker on the main panel.

Component failure.

Replace battery charger.

Figure 4-3 6-Amp Battery Charger Troubleshooting (for single-phase models)

Problem

Green LED is off and there is no output voltage.

Abnormal low voltage, charger is operating.

The battery is discharged, but the charger has power and is operating.

Cause

No power to the battery charger.

The battery completely discharged and the charger is operating at the current limit.

Blown fuse.

Solution

Check the power supply to the charger.

Check the upstream circuit breakers and fuses.

Check fuse FS (1A-T) inside the battery charger.

Disconnect the battery and verify that the charger output is 13.2 VDC.

Reconnect the charger and allow time for the battery to recharge. The battery voltage should rise gradually.

Test the battery.

Check the 5-amp fuse F2 (5A-T) inside the battery charger and replace if necessary.

Check inline fuse F4 and replace if necessary.

Figure 4-4 2.5-Amp Battery Charger Troubleshooting (for three-phase models)

TP-6515 1/11 Section 4 Troubleshooting 37

Notes

38 Section 4 Troubleshooting TP-6515 1/11

Appendix A Abbreviations

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

A, amp

ABDC

A/D

ADC adj.

ADV

AHWT

AISI

ALOP alt.

ANSI aluminum

American National Standards

Institute (formerly American

Standards Association, ASA)

APDC anticipatory only

Air Pollution Control District

API American Petroleum Institute approx.

approximate, approximately

APU

AQMD

AS ampere after bottom dead center alternating current analog to digital advanced digital control; analog to digital converter adjust, adjustment advertising dimensional drawing amp-hour anticipatory high water temperature

American Iron and Steel

Institute anticipatory low oil pressure alternator

ASE

ASME assy.

ASTM

ATDC

ATS auto.

aux.

avg.

AVR

AWG

AWM bat.

BBDC

Auxiliary Power Unit

Air Quality Management District as required, as requested as supplied, as stated, as suggested

American Society of Engineers

American Society of

Mechanical Engineers assembly

American Society for Testing

Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator

American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator BCA

BCI

BDC

BHP blk.

Battery Council International before dead center brake horsepower black (paint color), block

(engine) blk. htr.

block heater

BMEP bps br.

BTDC brake mean effective pressure bits per second brass before top dead center

Btu British thermal unit

Btu/min.

British thermal units per minute

C cal.

CAN

CARB

CAT5

CC cc

CCA ccw.

CEC cert.

cfh

Celsius, centigrade calorie controller area network

California Air Resources Board

Category 5 (network cable) circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise

Canadian Electrical Code certificate, certification, certified cubic feet per hour cfm

CID

CL cm

CMOS com coml

Coml/Rec Commercial/Recreational conn.

cont.

CPVC crit.

CSA

Cu cUL

CUL cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) communications (port) commercial connection continued chlorinated polyvinyl chloride critical

Canadian Standards

Association current transformer copper

Canadian Underwriter’s

Laboratories

Canadian Underwriter’s

Laboratories cubic inch clockwise city water-cooled cylinder cu. in.

cw.

CWC cyl.

D/A

DAC dB dB(A)

DCR deg.,  dept.

dia.

DI/EO

DIN

DIP

DPDT

DPST

DVR digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet

Deutsches Institut fur Normung e. V. (also Deutsche Industrie

Normenausschuss) dual inline package double-pole, double-throw double-pole, single-throw disconnect switch digital voltage regulator

PROM, EEPROM memory

E, emer.

emergency (power source)

ECM electrically-erasable programmable read-only

EDI

EFR e.g.

EGSA electronic control module, engine control module electronic data interchange emergency frequency relay

EIA

EI/EO

EMI emiss.

eng.

EPA

EPS

ESD est.

E-Stop etc.

for example (exempli gratia) electronic governor

Electrical Generating Systems

Association

Electronic Industries

Association end inlet/end outlet electromagnetic interference emission engine

Environmental Protection

Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge estimated emergency stop et cetera (and so forth) exh.

ext.

FHM fl. oz.

flex.

freq.

FS ft.

ft. lb.

ft./min.

ftp g ga.

gal.

gen.

genset

GFI exhaust external

Fahrenheit, female flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute file transfer protocol gram gauge (meters, wire size) gallon generator generator set ground fault interrupter hex

HHC

HP hr.

HS hsg.

HVAC

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 temp., high engine temp.

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

IBC

IEC

IEEE hertz (cycles per second)

International Building Code integrated circuit inside diameter, identification

International Electrotechnical

Commission

Institute of Electrical and

Electronics Engineers

IMS in.

in. H

2 improved motor starting inch in. Hg

O inches of water k

JIS kA

KBus kg in. lb.

Inc.

ind.

int.

int./ext.

internal/external

I/O

ISO inches of mercury inch pounds incorporated industrial internal input/output internet protocol

International Organization for

Standardization joule

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

10 bytes)

Kohler communication protocol kilogram

TP-6515 1/11 Appendix 39

kg/cm kgm kg/m

2 kilograms per square centimeter kilogram-meter kilograms per cubic meter kHz kJ kilohertz kilojoule km kilometer kOhm, k kilo-ohm kPa kph kV kVA kVAR kW kWh kWm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical kWth

L kilowatt-thermal liter

LAN local area network

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

lbm/ft

L wa

LWL

LWT m

LCB

LCD

LED

Lph

Lpm

LOP

LPG pound, pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level, A weighted low water level low water temperature meter, milli (1/1000) mega (10

6 when used with SI m m

/hr.

3 units), male cubic meter

3 cubic meters per hour

/min.

cubic meters per minute mA man.

max.

MB milliampere manual maximum megabyte (2

20 bytes)

MCCB

MCM molded-case circuit breaker one thousand circular mils meggar megohmmeter

MHz mi.

mil min.

misc.

MJ mJ mm megahertz mile one one-thousandth of an inch minimum, minute miscellaneous megajoule millijoule millimeter mOhm, mmilliohm

MOhm, Mmegohm

MOV

MPa mpg mph

MS ms m/sec.

mtg.

MTU

MW mW metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting

Motoren-und Turbinen-Union megawatt

F milliwatt microfarad

N, norm. normal (power source)

NA not available, not applicable nat. gas natural gas

OV oz.

p., pp.

PCB pF

PF ph., 

PHC

NBS

NEC

NEMA

NFPA

National Bureau of Standards normally closed

National Electrical Code

National Electrical

Manufacturers Association

National Fire Protection

Association newton meter Nm

NO normally open no., nos. number, numbers

NPS

NPSC

NPT

NPTF

NR ns

OEM

OF opt.

OSHA psi psig pt.

PTC

PTO

PVC qt.

qty.

PHH

PHM

PLC

PMG pot ppm

PROM

National Pipe, Straight

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

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

Occupational Safety and Health

Administration overvoltage ounce page, pages personal computer printed circuit board picofarad power factor phase

Phillipsr head Crimptiter

(screw)

Phillipsr hex head (screw) pan head machine (screw) programmable logic control permanent magnet generator potentiometer, potential parts per million

RHM rly.

rms rnd.

ROM rot.

rpm

RTDs programmable read-only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart, quarts quantity replacement (emergency) power source radiator, radius random access memory relay driver output reference rad.

RAM

RDO ref.

rem.

remote

Res/Coml Residential/Commercial

RFI

RH radio frequency interference round head round head machine (screw) relay root mean square round read only read only memory rotate, rotating revolutions per minute right side

Resistance Temperature

Detectors

SI/EO sil.

SMTP

SNMP

SPDT

SPST spec specs sq.

sq. cm sq. in.

SMS

SS std.

stl.

tach.

TCP

TDC

TDEC

TDEN

RTU

RTV

SAE scfm

SCR s, sec.

UHF

UIF

UNC

UNF univ.

URL

TDES

TDNE

TDOE

TDON temp.

term.

THD

TIF tol.

turbo.

typ.

VHF

WCR w/

WO w/o wt.

xfmr

VAC

VAR

VDC

VFD

VGA remote terminal unit room temperature vulcanization read/write

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units side in/end out silencer simple mail transfer protocol serial number simple network management protocol single-pole, double-throw single-pole, single-throw specification specification(s) square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency user interface

Underwriter’s Laboratories, Inc.

unified coarse thread (was NC) unified fine thread (was NF) universal uniform resource locator

(web address) 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 write only without weight transformer

40 Appendix TP-6515 1/11

Notes

TP-6515 1/11f

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-457-4441, Fax 920-459-1646

For the nearest sales/service outlet in the

US and Canada, phone 1-800-544-2444

KohlerPower.com

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619159

Phone (65) 6264-6422, Fax (65) 6264-6455

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Key features

Automatic start
Digital voltage regulation
Quiet operation
Easy to operate
Reliable performance
Durable construction

Frequently asked questions

Before or at each startup, the user should: Check for a clean and installed air cleaner element, Check for clean and unobstructed air inlets. Check for tight battery connections, Inspect the exhaust system components for cracks, leaks, and corrosion. Maintain the oil level at or near, not over, the full mark on the dipstick. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean.

Operate the generator set without load once each week for 20 minutes.

The generator set master switch positions are RUN, OFF/RESET, and AUTO.

Move the generator set master switch to the RUN position. If the generator set does not start in three attempts, the system shuts down on an overcrank fault.

Move the generator set master switch to the OFF/RESET position.