Kohler 12RES, 8.5RES Operation And Installation Instructions Manual
Kohler 8.5RES is a residential/commercial generator set that can provide backup power to your home or business in the event of a power outage. It features an advanced digital controller that provides precise control and monitoring of the generator set, and comes equipped with a battery charger to keep the battery charged and ready to use. The generator set is easy to operate and maintain, and is backed by a comprehensive warranty.
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Operation and
Installation
Residential/Commercial Generator Sets
Models:
8.5RES
12RES
Controller:
Advanced Digital Control
KOHLERo
POWERSYSTEMS
m
POWERSYSJEMS
NATIONALLY REGISTERED
TP-6195 1/04
California Proposition 65
& WARNING
Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.
Record field-installed kit numbers after installing the kits.
Generator Set Identification Numbers
Record the product identification numbers from the generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Controller
Identification
Record the controller description from the generator set operation manual, spec sheet, or sales invoice.
Controller Description
Engine
Identification
Record the product identification information from the engine nameplate.
Manufacturer
Model Designation
Serial Number
Table of Contents
Product Identification Information
............................................
Safety Precautions and Instructions
........................................................
Introduction
...............................................................................
Service Assistance
........................................................................
Section I Specifications and Features
......................................................
1.1
Specifications .........................................................
1.2
Generator ............................................................
1.3
Engine ...............................................................
1.4
Advanced Digital Control ...............................................
1.5
Service Views ........................................................
Section 2 Operation
.......................................................................
2.1
Prestart Checklist .....................................................
2.2
Exercising the Generator Set ...........................................
2.3
Generator Set Operation ...............................................
2.3.1
Controls and Indicators ........................................
2.3.2
Starting the Generator Set ......................................
2.3.3
2.3.4
Stopping the Generator Set .....................................
Fault Shutdowns ..............................................
2.3.5
2.3.6
Resetting the Controller after a Fault Shutdown ....................
Continuous Power Mode .......................................
2.4
Circuit Protection ......................................................
2.4.1
Line Circuit Breaker ...........................................
2.4.2
Fuses .......................................................
2.5
Battery Charger .......................................................
2.5.1
Battery Charger Operation ......................................
Section 3 Scheduled Maintenance
..........................................................
3.1
Routine Maintenance
..................................................
3.2
Service Schedule .....................................................
3.3
Lubrication System ....................................................
3.3.1
Low Oil Pressure Shutdown ....................................
3.3.2
Oil Check ....................................................
3.3.3
3.3.4
Engine Oil Recommendation ....................................
Oil Change Procedure .........................................
3.4
Spark Plugs ..........................................................
3.5
Air Cleaner Element and Precleaner .....................................
3.5.1
Precleaner Service ............................................
3.5.2
Paper Element Service .........................................
3.6
Cooling System .......................................................
3.7
Exhaust System ......................................................
3.8
Battery ...............................................................
3.8.1
Cleaning the Battery ...........................................
3.8.2
3.8.3
Checking Battery Electrolyte Level ...............................
Checking Electrolyte Specific Gravity ............................
3.9
Battery Charger .......................................................
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 .......................................................
Inside front cover
ti t
I
14
14
15
15
16
17
17
18
17
17
17
17
11
11
11
11
11
12
12
12
12
13
9
9
9
3
3
4
4
4
5
7
7
6
6
7
3
3
7
8
1
1
2
1
1
1
TP-6195 1/04 Table of Contents
Table of Contents, continued
Section 4 Troubleshooting
.................................................................
4.1
Introduction ..........................................................
4.2
Generator Set Troubleshooting ..........................................
4.3
Fault Codes ..........................................................
4.4
Controller Troubleshooting .............................................
4.5
Battery Charger Troubleshooting ........................................
Section 5 Wiring Diagrams
................................................................
5.1
Specification Numbers .................................................
5.2
Controller Wiring Diagram Reference ....................................
Section 6 Installation ......................................................................
6.1
General ..............................................................
6.2
Weight ...............................................................
6.3
Generator Set Inspection ...............................................
6.4
Mounting .............................................................
6.5
Exhaust Requirements .................................................
6.6
Air Requirements .....................................................
6.7
Power Supply .........................................................
6.8
Fuel System ..........................................................
6.8.1
Fuel Supply ..................................................
6.8.2
6.8.3
Fuel Pipe Size ................................................
Fuel Conversion ..............................................
6.9
Electrical Connections .................................................
6.9.1
AC Load Lead Connections .....................................
6.9.2
6.9.3
6.9.4
6.9.5
Remote Start Connection
Continuous
(optional)
Power Mode Jumper
..............................
................................
Battery .......................................................
Battery Charger ...............................................
6.10
Accessories ..........................................................
6.10.1
Common Fault and Run Relay Board ............................
6.10.2
Carburetor Heater .............................................
6.11
Controller Configuration ................................................
6.11.1
System Configuration ..........................................
6.11.2
Advanced Configuration Mode ..................................
6.12
Prestart Installation Check ..............................................
6.13
Warranty Registration ..................................................
Appendix A Abbreviations ..................................................................
37
37
37
37
37
25
25
25
25
25
25
27
27
32
32
33
34
35
35
36
27
27
28
28
31
31
21
21
21
A-1
19
19
19
20
20
20
Table of Contents
TP-6195
1/04
Safety Precautions and Instructions
IMPORTANT
SAFETY
INSTRUCTIONS.
Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained.
To prevent accidents be aware of potential dangers and act safely.
Read and follow all safety
precautions and instructions.
SAVE
THESE INSTRUCTIONS.
This manual has severaltypes 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.
damaged decals.
Replace missing
or
Accidental Starting
_1_ 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 asfollows:
(1) Movethe
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
_1_ WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
_1_ 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.
TP-6195 1/04 Safety Precautions and Instructions I
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging.
Do not dispose of a battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your
body
before touching
batteries by first touching a grounded
metal surface awayfrom 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
Disconnect equipment the battery damage.
before generator maintenance.
set installation
or
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
_1_ 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
operation
procedures.
on
fire and fire extinguisher prevention
Exhaust
A
System
WARNING
Carbon monoxide.
Can cause severe fainting, or death.
nausea,
The exhaust system must be leakproof and routinely inspected.
Generator set operation.
Carbon monoxide can cause severe nausea, fainting, or death.
Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time.
Avoid breathing exhaust fumes when working
on or near the generator set.
Never
operate the generator set inside a building.
Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death.
Carbon monoxide is a poisonous gas present in exhaust gases.
Carbon monoxide poisoning symptoms include but are not limited to the following:
• 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.
II Safety Precautions and Instructions
TP-6195
1/04
Fuel System
_1_ WARNING
Hazardous Noise
_1_ CAUTION
_1_ WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
The fuel system.
Explosive fuel vapors can cause severe injury or death.
Vaporized fuels are highly explosive.
Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children.
Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.
Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors.
Keep the fuel lines and connections tight and in good condition.
Do not replace flexible fuel lines with rigid lines.
Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Gas fuel
leaks.
Explosive fuel vapors can cause severe injury or death.
Fuel leakage can cause an explosion.
Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to
6-8 ounces per square inch
(10-14 inches water column).
Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation.
Asuccessful test depends on the ability of the solution to bubble.
Hazardous noise.
Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Engine noise.
Hazardous noise can
cause hearing loss.
Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Electrical Shock
A
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
_1_ WARNING
Hazardous voltage Moving
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Hazardous voltage.
Backfeed to the utility system can cause property damage, severe injury, or death.
if the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.
_1_ CAUTION
Welding the generator set.
Can
cause severe electrical
equipment
damage.
Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause severe injury or death.
Electrocution is
possible whenever
electricity
is
present.
Open
the
main
circuit
breakers of all power sources before
servicing the equipment. Configurethe installation
to electrically ground the
generator
set, transfer switch, and related
equipment
and
electrical
circuitsto comply with applicable codes and
standards.
Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
TP-6195 1/04 Safety Precautions and Instructions Ill
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.
instilling
Hazardous severe the battery voltage can injury or death.
charger.
cause
An ungrounded
battery charger
may
cause electrical shock.
Connect the battery charger enclosure to the ground
of a permanent wiring system.
As an
alternative,
install an
equipment
grounding conductor with circuit conductors
and
connect
it
to the
equipment grounding terminal or the
lead on the battery charger. Install the battery charger as prescribed in the
equipment manual.
Install the battery
charger in compliance with local codes
and ordinances.
Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
Have a qualified electrician install the battery(ies).
Short circuits.
Hazardous voltige/current can cause severe injury or death.
Short circuits can
cause bodily injury and/or equipment
damage.
Do not contact electrical
connections with tools or jewelry while making adjustments
or
repairs.
Remove all jewelry before servicing the equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can cause severe injury or death,
install
a transfer switch in standby power installations to prevent the connection of standby and other sources of power.
Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.
Heavy Equipment
_1_ WARNING
Unbalanced weight.
Improper lifting
injury damage.
or death can cause severe and
Do not use lifting eyes.
Liftthe generator set using lifting bars inserted through the lifting holes on the skid.
Hot Parts
_1_ WARNING
equipment
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the generator.
Hot parts can cause severe injury or death.
Avoid touching the generator set field
or exciter armature.
When shorted,the generator set field and exciter armature become hot enough to cause severe burns.
Servicing the exhaust system.
Hot parts can cause severe injury or death.
Do not touch hot engine parts.
The engine and exhaust system components become extremely hot during operation.
Servicing the engine heater.
Hot parts can cause minor personal injury or property damage.
Install the
heater before connecting it to power.
Operating the heater before installation
can cause burns
and
component damage.
Disconnect
power to the heater
and allow it to cool before
servicing the heater or nearby parts.
Moving Parts
_1_ WARNING
Hazardous voltage
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Moving
_1_ WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when all guards, screens, and covers are in place.
_1_ WARNING
Airborne particles.
Can cause severe injury or blindness.
Wear protective goggles and clothing when using power tools, hand tools,
or compressed air.
Tightening the hardware.
Flying projectiles can cause severe injury or death.
Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal
injury.
Retorque
all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotorthrubolt when making adjustments or servicing the generator
set. Rotate the crankshaft manually in a clockwise direction only. Turning the
crankshaft
bolt
or rotor thrubolt
counterclockwise
hardware.
can
loosen
the
IV Safety Precautions and Instructions
TP-6195
1/04
Servicing the generator
set when it is operating.
Exposed moving parts can cause severe injury or death.
Keep hands, feet, hair, clothing, and test leads away from the belts and
pulleys
when the generator set is running. Replace guards, screens, and covers before operating the generator set.
Notice
NOTICE
This generator set has been rewired from its nameplate voltage to
I I
246242
NOTICE
Voltage reconnection.
Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate.
Order voltage reconnection decal 246242 from an authorized service distributor/dealer.
NOTICE
Hardware damage.
The engine and
generator set may use both American
Standard and metric hardware.
Use the correct size tools to prevent
rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not substitute hardware.
with
Screws
inferior and grade nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of markings, and metric hardware uses a numeric system.
Check the markings on the bolt heads and nuts for identification.
NOTICE
Canadian installations only.
For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
NOTICE
Electrostatic
Electrostatic
discharge
discharge
damage.
(ESD)
damages
electronic
circuit boards.
Prevent
electrostatic
discharge damage by wearing an approved
grounding
wrist strap when handling
electronic circuit boards or integrated
circuits. An approved
grounding wrist
strap provides a high resistance (about
1 megohm),
net a direct short,
to
ground.
TP-6195 1/04 Safety Precautions and Instructions V
Notes
Vl Safety Precautions and Instructions TP-6195 1/04
Introduction
This manual provides operation and installation instructions for model 8.5RES and 12RES generator sets equipped with the Kohler _ Advanced Digital
Control (ADC 2100).
Information in this publication represents data available at the time of print. The manufacturer may provide this manual for models not listed on the front cover.
Kohler
Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the beginning of this manual.
Keep this manual with the equipment for future reference.
The generator set is approved for use in stationary applications in locations served by a reliable utility power source.
The equipment service requirements are very important to safe and efficient operation.
Inspect the parts often and perform required service at the prescribed intervals.
Obtain service from an authorized service distributor/ dealer to keep equipment in top condition.
Nameplate
The following illustration shows a typical generator set nameplate.
Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual. See Section 1.5, Service Views, for the nameplate location.
KOHLER,o
KOHLER CO. KOHLER Wl. USA
SERIAL: MODEL:
RPEC:
SERVICE DUTY:
HZ: RPM:
I ...........
I
GEN, MODEL:
INSULATION:NEMA CLASS
BAI"r, V
KWVARIES WITH BTU CON]ENT OF FUEL
EPA and California Emission
Certification
An engine or generator set with the following
identification labels is certified to meet Small Off-Road
Engine emission standards for EPA!CARB.
All model
8.5RES
and 12RES generator sets with multhfuel systems are emission-certified.
IMPORTANT ENGINE
INFORMATION
THIS ENGINE
MEETS
U,S. EPA PH1 AND
CALIFORNIA 2006 EMISSION
REGS
FOR
Si SMALL OFF-ROAD
ENGINES
FAMILY
OISPL {CC)
MODEL NO.
SPEC,
NO,
SERIAL NO,
KHXS*7252NA
EMISSION
COMPUANCE
EPA:
PERIOD:
CARB: EXTENDED
THIS ENGINE
IS CERTIFIED
TO OPERATE
ON: LPG / NATURAL
GAS
REFER
TO OWNER'S
MANUAL FOR SAFETY,
MAINTENANCE
SPECS AND ADJUSTMENTS,
FOR SALES AND SERVICE tN US/CANADA,
CALL:
1-800-544-2444
KotllerEng_nes.com
KOH_ERCO KOHLER,WISCONSIN USA tp6195
Figure 1 Emissions Label, 8.5RES
Engine (CH20)
IMPORTANT ENGINE
INFORMATION
THIS ENGINE
MEETS
U,S. EPA PH1 AND
CALIFORNIA 2006 EMISSION
REGS
FOR
Si SMALL OFF-ROAD
ENGINES
FAMILY
OISPL {CC)
MODEL NO.
SPEC,
NO,
SERIAL NO,
KHXS*7252NA
725
EMISSION
COMPUANCE PERIOD:
EPA:
CARB: EXTENDED
THIS ENGINE
IS CERTIFIED
TO OPERATE
ON: LPG / NATURAL
GAS
REFER
TO OWNER'S
MANUAL FOR SAFETY,
MAINTENANCE
SPECS AND ADJUSTMENTS,
FOR SALES AND SERVICE tN US/CANADA,
CALL:
1-800-544-2444
KotllerEng_nes.com
KOH_ERCO KOHLER,WISCONSIN USA tp6195
Figure 2
Emissions Label, 12 RES Engine (CH740)
TP-6195 1/04 Introduction i
f
_T
O
CLE_,N
2 4
5
8
L_AST
10
GLE_I
NOTE:
THE LOWER TH_ Afl_ tNI_EX, THE LE,9._POtLU_ON
TH_$ ENGINE I_ O_RT]F_ED TO _E EMI,%_ION CX_MpL_ANT
FOR TH£ FOLLOWING USE: r3 MOD_ATE
CHECK OWNE_
1_11kC'_ERMaDIATE
MANU_
FOR FURTHER
D_W'A_LS
_
THIS LAI_EL TO BE R_MOV_O
By THE ULIff_ATE
pURCHASER
EXUDED
CAUTION_EL
BE,_OR E _TAWCING ENGINE, tp6185
Figure 3
Air Index Label, 8.5/12RES
This engine/generator is certified to operate using natural gas or propane fuel.
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB emission requirements.
The following table provides the engine compliance period (in hours) associated with the category descriptor found on the certification label.
CARB
Emission Compliance Period (hours)
Moderate,
125 intermediate,
250
Extended,
500
I
I
Refer to the certification label for engine displacement.
The exhaust emission control system for the 8.5RES
(CH20) and 12RES (CH740) is EM.
Service Assistance
For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.
• Consult the Yellow Pages under the heading
Generators--Electric
• Visit the Kohler Power Systems website at
KohlerPowerSystems.com
•
Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents included with the product
• Call toll free in the US and Canada 1-800-544-2444
• Outside the US and Canada, call the nearest regional office
Headquarters
Europe, Middle East, Africa
(EMEA)
Kohler Power Systems
ZI Senia 122
12, rue des Hauts FIouviers
94517 Thiais Cedex
France
Phone: (33) 1 41 735500
Fax: (33) 1 41 735501
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131 ii Service Assistance TP-6195 1/04
Section 1 Specifications and Features
1.1
Specifications
The generator set specification sheets provide specific generator and engine information.
Refer to the spec sheet for data not supplied in this manual.
Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications.
Obtain copies of the latest spec sheets, manuals, diagrams, and distributor/dealer.
drawings from your local
1.2
Generator
The generator uses Kohler's unique PowerBoosV" voltage regulation system, which provides instant response to load changes.
PowerBoost
TM ensures reliable motor starting and consistent voltage levels.
PowerBoosV" utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage.
1.3
Engine
The generator set has a four-cycle, twin cylinder, aircooled Kohler _ engine.
The engine operates on clean-burning natural gas or propane (LP) vapor.
Engine features include:
•
Efficient overhead valve design and full pressure lubrication for maximum power, torque, and reliability under all operating conditions.
• Dependable, maintenance-free electronic ignition.
• Precision-formulated cast iron construction of parts subjected to the most wear and tear.
• Field-convertible multi-fuel systems that allow fuel changeover from natural gas to LP vapor (and vice-versa) while maintaining CARB emission certification.
• Digital spark-advance module (DSAM) optimizes ignition timing for the selected fuel (12RES).
1.4
Advanced Digital Control
The generator set
is equipped
with the Kohler ®
Advanced Digital Control (ADC 2100).
Controller features include the following:
• Compact controller
• Integrally mounted to the generator set
• LED display:
• Runtime hours
• Crank cycle status
• Diagnostics
• LED display communicates faults:
• Auxiliary fault
• High battery voltage
• High engine temperature
• Low battery voltage
• Low oil pressure
• Overcrank safety
• Overspeed
• Overfrequency
• Overvoltage
• Underfrequency
• Undervoltage
• Membrane keypad for configuration and adjustment
• Password-protected user access to menus
• Voltage, gain, and speed adjustment
• System configuration (system voltage, phase, and frequency settings, battery voltage, and generator set model)
• Master control switch: Run/Off-Reset/Auto
Remote two-wire start!stop capability
Superior electronics protection from corrosion and vibration
• Potted electronics
• Sealed connections
Digital isochronous governor steady-state speed at all loads to maintain
Digital voltage regulation: -+1.5% RMS no-load to full-load
• Automatic start for programmed cranking cycle
TP-6195 1/04 Section 1 Specifications and Features 1
1.5
Service Views
2 3 4 5 6 7 18 19 20
22
15
/
14 13
1. Enclosure
2. Muffler
3. Oil check
4. 0il fill
5. Air cleaner
6. Spark plug locations (both sides)
7. Controller
8. Generator set master switch (RUN\OFF/RESET_AUTO)
9. Nameplate
10. Line circuit breaker
11. Engine starting battery location
12. Oil drain hose
12 11
13. Oil drain valve
14. Oil filter
15. Alternator cooling air intake
16. Exhaust
17. Spark arrestor
18. DSAM leads
19. Multi-fuel block
20. Gas regulator assembly
21. Fuel solenoid valve
22. Air intake
23. Battery charger
24. Relay board
Figure 1-1 Generator Set Service View
22
AD_6_3_
2 Section 1 Specifications and Features TP-6195 1/04
Section 2 Operation
2.1
Prestart Checklist
To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule.
In addition, some checks require verification after the unit starts.
Air Cleaner.
Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.
Air Inlets.
Check for clean and unobstructed air inlets.
Battery.
Check for tight battery connections.
Consult the battery manufacturer's instructions regarding battery care and maintenance.
Exhaust
System.
Check for exhaust leaks and blockages.
Check the muffler and piping condition and check for tight exhaust system connections.
Inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, muffler, and outlet pipe) for cracks, leaks, and corrosion.
•
Check for corroded or broken metal parts and replace them as needed.
• Check for loose, corroded, or missing clamps and hangers.
Tighten or replace the exhaust clamps and/or hangers as needed.
• Check that the exhaust outlet is unobstructed.
• Visually inspect for exhaust leaks (blowby). Check for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.
Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.
Operating
Area.
Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.
x:op:001:002
2.2
Exercising the Generator Set
Operate the generator set under load once each week for one hour.
If the generator
set does not have a programmed exercise mode or an automatic transfer switch (ATS) with an exercise option, exercise the unit in the presence of an operator.
During the exercise period apply a minimum of 35% load based on the nameplate standby rating.
The operator should perform all of the prestart checks before starting the exercise procedure.
Start the generator set according to the starting procedure in the controller section of this manual.
While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks. Check the air inlets and outlets and remove any items restricting the air flow.
2.3
Generator Set Operation
Figure 2-1 illustrates the user interface on the Advanced
Digital Control (ADC 2100) generator set controller.
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TP-6195 1/04 Section 2 Operation 3
2.3.1
Controls and Indicators
Figure 2-2 describes the controls and indicators located on the generator set controller.
The LED display
indicates generator
set status as shown in Figure 2-2. The display is activated by a start or run command and remains active until the generator set master switch is moved to the OFF/RESET position or power to the controller
is removed.
If the factory-installed continuous power mode jumper has been disconnected, the LED display turns off 48 hours after generator set shutdown.
See Section 2.3.6.
The buttons on the controller keypad are used only for system configuration and adjustment.
The controller is factory-set and should not require configuration or adjustment under normal operating conditions.
Contact an authorized distributor/dealer or service technician if adjustments are required.
2.3.2
Starting the Generator Set
The following procedures describe the actions required to start the generator set.
The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and 15 seconds off). If the generator set does not start in three attempts, the system shuts down on an overcrank fault.
Local Starting
Move the generator set master switch to the RUN
position to immediately start the generator set.
Auto (Automatic) Starting
Move the generator set master switch to the AUTO position to allow startup by the ATS or the remote start/stop switch.
(A remote start/stop switch can be connected to controller leads 3 and 4. See the wiring diagrams in Section 5).
2.3.3
Stopping the Generator Set
The following procedures describe the actions required to stop the generator set.
Local Stopping
1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.
2. Move the generator set master switch to the
OFF/RESET position.
The engine stops.
Automatic Stopping
With the generator set master switch
in the AUTO
position and an automatic transfer switch (ATS) or other automatic device connected to controller leads 3 and 4:
1.
The ATS or other device disconnects the load from the generator set.
2.
If the ATS is equipped with an engine cooldown time delay, the generator set continues to run for a preset engine cooldown time.
Note: There is no engine cooldown time delay on
the ADC controller.
3. The ATS or other device opens the connection between controller leads 3 and 4. The generator set shuts down.
Control
or Indicator
LED display
Item
Runtime hours
Crank indication
Description
Displays total generator set runtime hours while the generator set is running.
Displays CC1, CC2, or CC3 to indicate the first, second or third attempt to start the
engine.
The last digit flashes during the crank cycle rest periods.
Flashes a 2- or 3-letter fault code to indicate various fault conditions.
See Section 2.3,4.
See TP-6196, Generator Set Service Manual.
Fault codes
Software version number
Select and arrow buttons
Keypad The keypad is used for controller setup and adjustment only. Have setup and adjustments performed only by an authorized distributor/dealer, password-protected.
The setup and adjustment functions are
Switch functions as the generator set operation and controller reset switch, Generator set master switch
Three-position switch
Figure 2-2
ADC 2100 Controls and Indicators
4 Section 2 Operation
TP-6195
1/04
2.3.4
Fault Shutdowns
The generator set shuts down automatically under the fault conditions listed in Figure 2-3 and the controller displays a fault code.
The generator set cannot be restarted until the fault condition is corrected and the controller is reset.
See Section 2.3.5 to reset the controller after a fault shutdown.
The controller resets automatically after a battery voltage fault condition is corrected.
The shutdown switches on the generator set automatically reset when the problem is corrected.
The high engine temperature switch automatically resets when the generator set cools.
However, the fault does not clear until the controller is reset.
The controller displays a fault code but the generator set does not shut down under the conditions shown in
Figure 2-4.
Code
AF
HE
LOP
Fault
Auxiliary fault
input shutdown
High engine temperature shutdown
Low oil pressure shutdown
Description
Input from a customer-supplied switch that closes when the
fault is active. The generator set shuts down and will not start when the fault is active (input is grounded),
Check
Check the cause of the auxiliary fault.
Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds, This protective becomes active after the engine reaches the crank disconnect speed,
Check for blocked air inlets and exhaust outlets,
Shutdown occurs if a low oil pressure condition exists 7 Check for leaks in the lubdcation system, seconds after the engine has reached crank disconnect speed.
Check the oil level and add oil if the level
Note: The low oil pressure shutdown does not protect against low oil level, Check the oil level at the engine, is low.
OC Overcrank shutdown
Shutdown occurs after 3 unsuccessful starting attempts.
The crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest.
Check the fuel supply, spark plug, and battery.
Check for loose connections.
The generator set also shuts down after 1 crank attempt if no Contact an authorized distributor/dealer for speed signal is sensed, Shuts down 1 second after the fault is service if problem continues.
detected.
OF
OS
OU
UF
UU
Overfrequency shutdown
Overspeed shutdown
Overvoltage shutdown
Underfrequency shutdown
Undervoltage shutdown
Shutdown occurs when the governed frequency exceeds 110% Contact an authorized distributor/dealer for of the system's frequency setpoint for more than 1 second, service if problem continues.
This protective becomes active 30 seconds after engine start.
Shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than 1 second,
Shutdown occurs if the voltage exceeds 120% of the voltage regulator setpoint for more than 1 second,
Contact an authorized distributor/dealer service if problem continues.
Contact an authodzed distributor/dealer service if problem continues.
for for
Shutdown occurs when the governed frequency falls 1 Hz Reduce the load and restart the generator below the system's frequency setpoint for more than 1 second, set,
Contact an authodzed distributor/dealer for service if problem continues.
Shutdown occurs if the voltage falls below 80% of the voltage regulator setpoint for more than 1 second.
This protective becomes active 30 seconds after engine start.
Reduce the load and restart the generator set,
Contact an authorized distributor/dealer for service if problem continues.
Figure
2-3 ADC Fault Shutdown Codes
Code
HB
Fault
High battery voltage warning
Description
Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a
24 VDC system for more than 10 seconds when the engine is not running, This fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.
LB
Low battery voltage warning
Fault code is displayed if the engine starting battery voltage falls below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 10 seconds when the engine is not running.
This fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.
Figure 2-4
ADC Fault Warning Codes
Check
Check the battery rating and condition.
Check the battery charger operation.
Check the battery rating and condition.
Check the battery charger operation.
Charge or replace the battery.
TP-6195 1/04 Section 2 Operation 5
2.3.5
Resetting the Controller after a
Fault Shutdown
Always identify and correct the cause of a fault shutdown before resetting the controller.
Use the following procedure to reset the generator set controller after a fault shutdown.
1. Move the generator set master switch to
OFF/RESET.
2. Disconnect the generator set from the load using the line circuit breaker or ATS.
See the safety precautions at the beginning of this section before proceeding.
3. Identify and correct the cause of the fault shutdown.
See the safety precautions at the beginning of this section before proceeding.
Refer to Section 4, Troubleshooting.
4. Start the generator set by moving the generator set master switch to RUN. Test operate the generator set to verify that the cause of the shutdown has been corrected.
5. Move the generator set master switch to
OFF/RESET.
6. Reconnect the generator set to the load using the line circuit breaker or ATS.
7. Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start/stop switch.
Note: The controller's
LED display remains off until an engine start command is received.
Opening and closing a remote start/stop contact also resets the controller.
2.3.6
Continuous Power Mode
The controller is powered by the generator set engine starting battery. A jumper on the back of the controller maintains power to the controller at all times.
Controllers are shipped with the jumper connected.
Note: The 8.5 and 12 RES generator sets are equipped
with factory-installed battery chargers to prevent battery discharge.
Disconnecting the jumper allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the
AUTO position.
A remote start signal (from a transfer switch or a remote start/stop switch connected to controller leads 3 and 4) or moving the generator set master switch to the RUN position turns the controller back on.
See Section 6.9.3 for instructions to disconnect the jumper.
6 Section 2 Operation
TP-6195
1/04
2.4
Circuit Protection
If the generator set circuit breaker trips or the fuses blow repeatedly, see Section 4, Troubleshooting, for possible causes.
2.4.1
Line Circuit
Breaker
A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. The line circuit breaker location is shown in Figure 1-1.
See Figure 2-5 for the circuit breaker ratings.
If the circuit breaker trips, reduce the load and switch the breaker back to the ON position.
With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load.
Model
8.5RES
12RES
Figure 2-5
Circuit Breaker
Rating, Amps
40
50
Line Circuit Breakers
2.4.2
Fuses
The engine harness contains two 1O-amp and one
20-amp inline fuses.
See Figure 2-6. Another 10-amp fuse protects the battery charger.
Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to Section 4,
Troubleshooting, for conditions that may indicate a blown fuse.
Replace blown fuses with
identical
replacement parts.
Fuse
Auxiliary Winding
Relay Interface
Board
Controller
Battery Charger
Label
F1
F2
F3
--
Part
Number
292937
223316
Location
Lead 55
Lead PF2
358337
AGS 10
Lead PF1
Battery charger DC lead. See Section 2.5.
Figure 2-6
Fuses
2.5
Battery Charger
The generator set
is
equipped with a 6-amp float/equalize battery charger to maintain the engine starting battery.
The charger's power cord must be connected to a 120 VAC power source.
Figure 2-7
illustrates the battery charger.
The battery charger uses an AGS 10 inline fuse.
The fuse is located in the battery lead. See Figure 2-7.
3
2 F 4
1. LED indicators
2, Battery leads, 12 VDC
3, Fuse
4, AC power cord
Figure 2-7
6-Amp Float!Equalize
Battery Charger
TP-6195 1/04 Section 2 Operation 7
2.5.1
Battery Charger Operation
Figure 2-8 illustrates the three-stage charging method.
Red and green LEDs indicate charger operation.
The chart in Figure2-9 describes the LED indicator operation during each stage of the charging process.
Figure 2-8
Charging Method
Display
Red ON
Green OFF
Operating
Condition
When the red LED is on, it indicates the battery is discharged and the battery charger is recharging at the
BULK rate (stage 1). This charging rate is 6 amps, While the red LED is on, the voltage measured (with the battery charger on) will be 11.8-14 volts.
If the red LED stays on for more than 24 hours, refer to Section 4,5 in this manual,
Red ON
Green ON
Red OFF
Green ON
When both the green and the red LEDs are on, the battery charger is charging at an ABSORPTION rate of between 1,5 and 5 amps (stage 2), This mode of charging gradually tops off your battery, and reduces harmful sulfating.
While both LEDs are on, the voltage measured (with the battery charger on) should be approximately 14,0-14.5
VDC.
If both LEDs stay on longer than 24 hours, refer to Section 4.5 in this manual.
When the green LED is on, the battery charger is charging at a FLOAT or MAINTENANCE rate of less than 1.5 amps (stage 3), Your battery is now 90% charged and ready for use. This float charging current will gradually decrease to as low as 0.1 amps as the battery reaches 100% charge.
It will now be kept at full charge without overcharging,
If the green LED stays on when your battery is known to be low, refer to Section 4.5 in this manual.
Figure 2-9 Battery Charger
LED Indicator Functions
8
Section 2 Operation TP-6195 1/04
Section 3 Scheduled Maintenance
_1_ WARNING
_1_ 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
setas follows: (1) Movethegeneratorsetmasterswitchtothe
OFFposition.
(2) Disconnectthepowertothebatterycharger.
(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.
_1_ WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until 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 r.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Servicing the generator set when it is operating.
Exposed moving parts can cause severe injury or death.
Keep
hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.
Replace
guards, screens, and covers before operating the generator
set.
3.1
Routine Maintenance
Refer to the service schedule following and the runtime hours displayed on the ADC 2100 display to schedule routine maintenance.
Have an authorized distributor/ dealer perform all generator set service.
Perform maintenance on each item in the service schedule atthe designated
interval for the life of the generator
set.
Service units subject to extreme weather, long operating hours, or dusty or dirty conditions more frequently.
3.2
Service Schedule
Perform the tasks listed in the following service schedule at the designated intervals for the life of the generator set.
For example, an item serviced every
100 hours of operation or 3 months must also be serviced after 200 hours or 6 months, 300 hours or
9 months and so on.
Rough operation, lack of power, and excessive oil use indicate serious generator set problems.
Have an authorized distributor/ dealer perform all generator set service.
TP-6195 1/04 Section 3 Scheduled Maintenance 9
Procedure
System Component
Fuel or Procedure
Flexible lines and connections
Main tank supply level
Fuel piping
Lubrication
Oil level
See
Section
Visually
Inspect
3.3
Crankcase breather*
Change oil
Replace filter*
Cooling
Air ducts, louvers
Exhaust Line
Leakage
Insulation, fire hazards
Hangers and supports
DO Electrical
System
Battery charger operation, charge rate (if equipped)
Remove corrosion, clean and dry battery and rack
Clean and tighten battery terminals
Battery electrolyte level and specific gravity-;
AC Electrical
System
Visible wear or damage
Wire abrasions where subject to motion
Tighten control and power wiring connections
Wire-cable insulation breakdown
*
Engine and Mounting
Visible wear or damage
Air cleaner service
Spark plugs
Replace stepper motor coupling and bushing *
Compartment condition
Remote Control System
Remote control
Run generator set
Generator
Visible wear or damage
Exercise generator set
Rotor and stator *
Measure and record resistance readings of windings with insulation tester (Megger, with
SCR assembly or rectifier disconnected)
General Condition of Equipment
Evidence of vibration, leakage,
excessive
noise, temperature, or deterioration
Interior of sound enclosure
• Contact your local distributor/dealer for parts or service,
Not necessary for maintenance-free batteries,
Figure 3-1 Service Schedule
3.6
3.7
3.8
3.5
3.4
2.1
2.2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Check Change
Clean Test
X
X
X
X X
X
X Action
R Replace as necessary
R
X
X
X
R
X
X
X
X
X
X
X
X
X
X
X
X
Frequency
Quarterly
Weekly
Yearly
8 hours or before use
Yearly or 500 hours
Yearly or 100 hours
Yearly or 200 hours
Yearly
Weekly
Yearly
Yearly
Monthly
Yearly
Yearly
Yearly
Quarterly
Six Months
Yearly
3 Years or 500 hours
Weekly
Yearly or 100 hours
Yearly or 300 hours
500 hours
Weekly
Monthly
Weekly
Quarterly
Weekly
Yearly
3 Years
Weekly
Quarterly
10 Section 3 Scheduled Maintenance TP-6195 1/04
3.3
Lubrication System
See Section 3.2, Service Schedule, for oil change and oil filter replacement intervals. See Section 1.5, Service
Views, for the oil drain, oil check, oil fill, and oil filter locations.
For extended operation, check the oil level every 8 hours. Maintain the oil level at or near, not over, the full mark on the dipstick.
3.3.1
Low Oil Pressure Shutdown
The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below 24.1 kPa +-13.8 kPa (3.5 psi -+1.5 psi) because of oil pump failure or other malfunction.
The shutdown feature does not protect against damage caused by operating with the oil level below the safe range; it is not a low oil level shutdown.
Check the oil level regularly, and add oil as needed.
3.3.2
Oil Check
The generator set is shipped with oil. Before operating a new generator set, check the engine oil
in the
crankcase.
See 1.5, Service Views.
Verify that the oil level is at the F mark on the dipstick.
Add oil that has a viscosity appropriate for the climate. See Section 3.3.3,
Engine Oil Recommendation.
Do not check the oil level when the generator set is running.
Shut down the generator set and wait several minutes before checking the oil level.
3.3.3
Engine Oil Recommendation
Use API (American Petroleum Institute) Service Class
SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner.
Select the viscosity based on the air temperature at the time of operation.
See Figure 3-2.
°F -20
°C -30 -20
0
-10
20 32 40
0
60
10 20
80
30
100
40
Temperature Range Expected Before Next Oil Change
Figure 3-2
Engine Oil Selection
TP-6195 1/04
3.3.4
Oil Change
Procedure
Drain the oil while it is still warm.
1. Drain the oil. a.
Place the generator set master switch in the
OFF position.
b. Disconnect the power to the battery charger.
c. Disconnect the generator set engine starting battery, negative (-) lead first.
d.
Remove the housing side panel.
e.
Remove the oil drain hose from its retaining clip.
Remove the cap from the oil drain hose and lower the hose into an oil collection container.
f. Open the oil drain valve on the engine.
g.
Allow time for the engine oil to drain completely.
h. Close the oil drain valve.
k Replace the cap on the oil drain hose. Replace the oil drain hose in its retaining clip.
2. Replace the oil filter.
a.
Remove the oil filter by rotating it counterclockwise with an oil filter wrench.
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 filterfollowing the instructions provided with the filter.
Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner.
3. Fill with oil. a.
Remove the oil fillcap and fillthe engine to the F mark on the dipstick. The engine oil capacity is
1.9 L (2.0 qt.).
See Section 3.3.3, Engine Oil
Recommendation, for oil selection.
b. Reinstall the dipstick and the oil fill cap.
c. Check that the generator set master switch is in the OFF position.
Section 3 Scheduled Maintenance 11
d.
Reconnect the generator set engine starting battery, negative (-) lead last.
e.
Reconnect the power to the battery charger.
f.
Start and run the generator set for a minute to allow the oil pressure to reach the operating range.
g.
Stop the generator set, wait I minute, and then recheck the oil level. Add oil to bring the level up to the F mark on the dipstick.
4. Check for leaks. a.
Check for oil leaks.
b.
Fix leaks and recheck the oil level.
c. Reinstall the housing side panel.
3.4
Spark Plugs
Reset the spark plug gap or replace the plugs with new plugs as necessary.
1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.
2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is questionable.
3. Check the spark plug gap using a wire feeler gauge.
Adjust the gap to 0.76 mm (0.030 in.) by carefully bending the ground
Figure 3-3 and Figure 3-4.
electrode.
See
Figure 3-3
Checking the Spark Plug Gap
3.5
Air Cleaner
Element and
Precleaner
The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner.
See
Figure 3-5.
Check for a buildup of dirt and debris around the air cleaner system.
Keep this area clean.
Note: Operating the engine with loose or damaged air
cleaner components could allow unfiltered air into the engine causing premature wear and failure.
3.5.1
Precleaner Service
Use the following procedure to wash and reoil the precleaner as indicated in the service schedule.
Wash and reoil the precleaner more often under extremely dusty or dirty conditions.
1. Place the generator set master switch in the
OFF/RESET position.
2. Disconnect the power to the battery charger.
3. Disconnect the battery, negative (-) lead first.
4. Loosen the cover retaining knob and remove the cover.
Remove the precleaner from the paper element.
Wash the precleaner in warm water with detergent.
Rinse the precleaner thoroughly until all traces of detergent are eliminated.
Squeeze out excess water (de not wring). Allow the precleaner to air dry.
5. Saturate the precleaner with new engine oil.
Squeeze out all of the excess oil.
6. Reinstall the precleaner over the paper element.
7. Reinstall the air cleaner cover.
Secure the cover with the cover retaining knob.
8. Reconnect the power to the battery charger.
9. Reconnect the generator set engine starting battery, negative (-) lead last.
3.5.2
Paper Element Service
Use the following procedure to replace the paper element at the intervals specified in the service schedule.
Replace the paper element more often under extremely dusty or dirty conditions.
Figure 3-4
Adjusting the Spark Plug Gap
1-514
1-511
12 Section 3 Scheduled Maintenance
TP-6195
1/04
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.
3.6
Cooling
System
The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure.
The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet.
See
Figure 3-6. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times.
Note: Do not blockthe generator set cooling air inlets or
mount other equipment above them.
Overheating and severe generator damage may
OCCUr.
3
5
6
7
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 3-5
Air Cleaner Components
1
\
\
_@_ POWER_TE/&_ [_
586536
\
2
1, Exhaust outlet
2, Alternator air intake (both sides)
3, Engine air intake
Figure 3-6
Cooling Air Intake and Exhaust
\
3 tp6195
TP-6195 1/04 Section 3 Scheduled Maintenance 13
3.7
Exhaust System
Remove all combustible materials from the exhaust location.
Combustible materials include building materials as well as natural surroundings.
Keep dry field grass, foliage, and combustible landscaping material a minimum of 0.3 m (1 ft.) from the exhaust outlet.
Periodically inspect the exhaust system components
(exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for cracks, leaks, and corrosion.
• Check for corroded or broken metal parts and replace them as needed.
• Check for loose, corroded, or missing clamps and hangers.
Tighten or replace clamps and/or hangers as needed.
• Check for and remove loose insulation in the exhaust duct.
• Check that the exhaust outlet is clear.
3.8
Battery
_1_ 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 (f lb.) of bicarbonate of soda (baking
soda) to a container with 4 L (f 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.
14 Section 3 Scheduled Maintenance
TP-6195
1/04
Refer to this section for general battery information and maintenance.
All generator set models use a negative ground with a12-volt engine electrical system.
Consult the generator set nameplate for the engine electrical system voltage.
Consult the generator spec sheet for battery capacity recommendations for replacement purposes.
Wiring diagrams provide battery connection information.
connections.
See Figure3-7 for typical battery
Check the electrolyte level and specific gravity of batteries with filler caps. Maintenance-free batteries do not require electrolyte level checking or specific gravity testing.
Clean the battery and cables and tighten battery terminals using the service schedule recommendations.
Clean the battery by wiping it with a damp cloth. Clean both battery terminals with baking soda.
Keep the electrical connections dry and tight.
jl 2 from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water.
Do not allow the cleaning solution to enter the battery's cells. 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.
3.8.2
Checking
Battery Electrolyte
Level
Check the battery electrolyte level before each startup.
Remove the filler caps and verify that the electrolyte level reaches the bottoms of the filler holes; see
Figure 3-8.
Refill as necessary with distilled water or clean tap water.
Do not add electrolyte.
Install and tighten filler caps.
After adding water to the battery in freezing temperatures, run the generator set
20-30 minutes to mix the added water and the battery electrolyte.
Mixing the water and the electrolyte prevents the added water from freezing and damaging the battery.
EZ-273000-J
1. To positive (+) terminal on starter solenoid.
2. To ground (-) terminal on or near starter motor.
Figure 3-7 12-Volt Engine Electrical System Single
Starter Motor, Typical Battery Connection
3.8.1
Cleaning
the Battery
To prevent dirt and grime buildup, occasionally wipe the battery with a damp cloth.
To prevent corrosion, maintain tight, dry electrical connections at the battery terminals.
To remove corrosion from battery terminals, disconnect the cables
©
1
1. Filler caps
2. Electrolyte level
Figure 3-8
Checking Electrolyte Level
2
5810321
TP-6195 1/04 Section 3 Scheduled Maintenance 15
3.8.3
Checking Electrolyte Specific
Gravity
Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell.
Use the hydrometer's test instructions, if available, or Figure 3-9 for bead-type testers.
Number of
Beads Floating
5
4
3
1, 2
0
Battery
Condition
Overcharged
Full Charge
Adequate Charge
Low Charge
Battery Dead
Figure 3-9
Electrolyte Testing Chart
Temperature affects specific gravity; correct the indicated hydrometer readings for temperature.
If the hydrometer does net have a correction table, use
Figure3-10.
A fully charged battery should have a specific gravity of 1.260 with the electrolyte at 26.7°C
(80°F).
Charge the battery if the specific gravity from cell to cell varies by more than 0.01. Charge the battery if the specific gravity is less than 1.215 with the electrolyte at 26.7°C (80°F).
°C
71.1
°F
160
65.6
150
60.0
140
54.4
130
48.9
120
43.3
110
37.8
100
32.2
90
26.7
80
21.1
70
15.6
60
10 50
4,4
40
- 1.1
30
- 6.7
20
- 122 10
022
024
026
028
012
014
016
018
020
0
002
004
-. 006
008
010
+ 022
+ 020
+ 018
+ 016
+ 014
+ 012
+ 010
+ 008
+ 006
+ 004
+ 002
Correction
+ 032
+ 030
+ 028
Example 1:
+ 026
+ 024
Temperature below 26,7°C (80°F)
Hydrometer
Electrolyte
-6,7°C
Subtract .024 Specific Gravity
Corrected Specific Gravity is 1,226
Example
Temperature
(20°F)
Hydrometer
Electrolyte
37.8°C
2:
Temperature
Reading 1.250
above 26.7°C
Reading 1,235
Temperature
(100°F)
Add ,008 Specific Gravity
Corrected
1,243
Specific Gravity is
(80°F)
The temperature correction amounts to about .004 (4 points) of specific gravity for each 5,5°C (10°F) change in electrolyte temperature,
5810322
Figure
3-10 Specific Gravity Temperature Correction
16 Section 3 Scheduled Maintenance TP-6195 1/04
3.9
Battery Charger
The generator set is equipped with a 6-amp float/equalize battery charger to maintain the engine starting battery.
The charger's DC leads are factory-wired.
charger.
Figure3-11 illustrates the battery
1
2
3_ zJ
5
1. LED indicators
2. Mounting flanges
3. Battery leads, 12 VDC
4. Fuse
5, AC powerco_
Figure 3-11 6-Amp Float/Equalize
Battery Charger
Periodically tighten all connections.
No other maintenance on the battery charger is required.
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 the engine crankcase with oil. See Section
3.3.3 for oil recommendations.
5. Run the generator set for a few minutes to distribute the clean oil.
6. Stop the generator set.
3.10.2
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.
TP-6195 1/04 Section 3 Scheduled Maintenance 17
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.
Refer to Section 3.8.1 for the cleaning procedure.
4. Place the battery in a warm, dry location.
5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger.
Follow the battery charger manufacturer's recommendations.
18 Section 3 Scheduled Maintenance TP-6195 1/04
Section 4 Troubleshooting
4.1
Introduction
Use the following charts to diagnose and correct common problems.
First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker.
The charts include a list of common problems, possible causes of the problem, and recommended corrective actions.
dealer.
Maintain a record of repairs and adjustments performed on the equipment.
Use the record to help describe the problem and repairs or adjustments made to the equipment.
4.2
Generator Set Troubleshooting
If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/
Figure4-1 contains generator set troubleshooting, diagnostic, and repair information.
Check for loose connections before replacing parts.
Problem
The generator set does not crank.
Possible Cause
Battery weak or dead
Battery charger fuse blown
Battery connections
Controller reversed fuse (F3) blown or poor
Relay interface board fuse (F2) blown
The generator set cranks but does not start, starts hard, lacks power, or operates erratically.
Generator set master switch in the OFF position
Air cleaner clogged
Battery weak or dead
No AC output.
Battery connection
poor
Spark plug wire connection loose
Low oil pressure shutdown
Fuel pressure insufficient
Engine malfunction
AC circuit breaker in the OFF position
AC circuit breaker tripping because of overload
AC circuit breaker tripping because of short circuit
Generator set overloaded
Low output or excessive drop in voltage.
Generator set stops suddenly.
Low oil pressure shutdown
Out of fuel
Overcrank shutdown
Corrective Action
Check power to the battery charger.
Recharge or replace the battery.
Replace the fuse, Contact an authorized distributor/dealer
for service if fuse blows repeatedly,
Check the connections,
Replace the fuse, Contact an authorized distributor/dealer
for service if fuse blows repeatedly,
Replace the fuse, Contact an authorized distributor/dealer
for service if fuse blows repeatedly,
Move the master switch to the RUN position,
Clean and/or replace the air cleaner.
Check power to the battery charger.
Recharge or replace the battery.
Clean and tighten the battery connections,
Check the spark plug wires,
Check the oil level,
Check the fuel supply and valves,
Contact the distributor/dealer.
Place the circuit breaker in the ON position.
Reduce the load on the generator set.
Contact an authorized distributor/dealer for service,
Reduce the load,
Controller
Overspeed fuse (F3) blown shutdown
Check the oil level,
Check fuel supply.
Reset the controller.
If the overcrank contact the distributor/dealer,
Replace the fuse, distributor/dealer.
fault occurs again,
If the fuse blows again, contact the
Reset the controller.
If the overspeed contact the distributor/dealer, fault occurs again,
Move the switch to the correct position (RUN or AUTO).
Generator set master switch in the OFF/RESET
)oaltion
Remote stop command received from a remote switch
or ATS
Engine malfunction
Auxiliary winding fuse (F1) blown
Check the remote switch position,
Contact the distributor/dealer.
Replace the fuse, Contact an authorized distdbutor/dealer for service if fuse blows repeatedly,
Figure 4-1
General Troubleshooting Chart
TP-6195 1/04 Section 4 Troubleshooting 19
4.3
Fault Codes
The Advanced Digital Control displays fault codes to aid in troubleshooting.
Fault codes, descriptions, and recommended actions are listed in Figure 2-3.
Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown.
See
Section 2.3.5.
4.5
Battery Charger
Troubleshooting
Use the battery charger's LED indicators and the table in
Figure 4-3 to troubleshoot battery charger operation problems.
4.4
Controller Troubleshooting
Figure 4-2 contains troubleshooting, diagnostic, and repair information for the Advanced Digital Control.
Problem
Controller LED display is off
Possible Cause
No power to the controller:
Continuous power mode jumper is disconnected and the generator set has not run for 48 hours or longer.
Controller fuse (F3) is blown.
Low or no battery voltage.
Generator set master switch is in the OFF/RESET
)osition.
Generator set master switch in AUTO but no start command has been received since last controller reset,
Corrective Action
Controller display will automatically activate when a remote start command is received or the generator set master switch is moved to the RUN position.
Connect the jumper to maintain continuous power to the controller, if desired.
See Sections 2.3.6 and 6.9.3.
Replace the fuse.
If the fuse blows again, contact the distributor/dealer.
Check connections.
Check generator set battery and battery charger.
See
Figure 4-1.
Move generator set master switch to the AUTO or RUN position,
No action required (see Section 2.3.1).
Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position, Use the remote switch to start generator set and activate the controller display, if desired.
Figure
4-2
Controller Troubleshooting
Chart
Problem
Red LED stays
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
_,olution
One or more defective or damaged cells.
Load test the battery and replace, if necessary
Battery charger has reduced its output voltage below Remove the source of the overload or short.
Disconnect the the normal level due to a DC overload or a DC short, battery charger's black (NEGATIVE) ring terminal from the battery.
Reapply AC power and the green LED only should now light.
Onboard DC systems are drawing more current than the battery charger can replace.
Onboard DC systems are drawing between 1.5 and
5 amps.
Turn off all DC equipment while charging.
Turn off all DC equipment while charging.
One or more defective or damaged cells.
Extremely low AC voltage at the battery charger.
Open DC output fuse.
Load test the battery and replace, if necessary
Apply a higher AC voltage source or reduce the length of the extension cord.
Replace AGS-10 fuse.
Faulty or contaminated terminal connections.
One or more defective or damaged cells.
No AC power available at the battery charger.
Clean and tighten or repair all terminal connections.
Load test the battery and replace, if necessary.
Connect AC power or reset the AC breaker on the main panel.
Component failure.
Figure 4-3
Battery Charger Troubleshooting
Replace battery charger.
20 Section4 Troubleshooting TP-6195 1/04
Section 5 Wiring Diagrams
5.1
Specification Numbers
At the time of print, this manual applied to the model numbers and specification (spec) numbers in
Figure 5-1. On occasion the manufacturer may provide this manual with units that are not listed below, such as when similar new specs are created prior to the updated reprint or in other cases when the manual is a suitable substitute for a manual under development.
Model No.
8.5RES
12RES
Spec. No.
GM29253-GA1
GM29253-GA2
Figure
5-1
Generator Set Specification Numbers
5.2
Controller Wiring
Diagram
Reference
Figure5-2 lists the wiring diagram numbers and locations.
Wiring Diagram Description
Schematic Diagram
Sheet 1
Sheet 2
Point-to-Point Wiring Diagram
Drawing
Number
ADV-6835A
ADV-6835B
GM29358
Figure 5-2
Controller Wiring Diagrams
Page
22
23
24
TP-6195 1/04 Section 5 Wiring Diagrams 21
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P1-22
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P1-27
P1-28
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P1-30
P1-31
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P1-13
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P1-17
P1-18
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P1-2
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P1-5
P1-6
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P1-8
P1-9
P1-10
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GOVERNOR
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GOVERNOR 2A
GOVERNOR 2B
COOLANT TEMP SENSOR HiGH
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EXTERNAL CAN H
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TAGH OUT
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GROUND
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P5-1
P5-2
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P5-3
P5-4
P5-5
P5-6
P5_7
P5_8
P5_9
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J16 CONNECqqONS
P16_1
P16-2
P16-3
P16_4
P16_5
P16_6
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AUX WiNDiNG iNPUT {66)
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J15_1 AG INPUT {V7/11)
J15_2
J15-3
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P13-1 RUN RELAY GOMMON
P13-2
P13-3
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COMMON
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P13_4
P13_5
P13-6
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RUN RELAY NC
COMMON FAULT NO
P14 CONNECTIONS
P14-1
P14-2
FUELJAUX RUN RELAY GONTROL
COMMON FAULT RELAY CONTROL
P14-3
P14_4
P14_5
P14_6
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P14-8
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O(J_- [_ODE
GTS - G_]LANT T_4PlS:L_TdRIE SBNDER
EBGf_ - ENGINE BLOCK GROUND
F(_ - NI6E
F:V_ _UEL VAL'vl_
GND - _NTR_L_R B_X _qOUND
J(_ - CONNE_R'OR
LOp.
LOW OIL _RE_;URE _ITCH
Mp - _U_GNE_C PIG_tJp
OCON(#) - QUICK _DM_EGT
_R - NUG_N
CONTROLL_ RE_13RER
FOR SCtt_C
_CREW &8TN_r_ER.
SM - ETAR_i
_R - _ARTER
_s _ START_
M_TOR
RI_J_y
5OU_K_D
68P1( - SMART SPARK MODLlU_
_rAT - _rA_
_
- S_p_I MOTOR
_
AOV_
Section 6 Installation
6.1
General
Have an authorized distributor/dealer
install the
generator set outdoors according to the instructions in this section.
Do not install this generator set indoors.
The generator set installation must comply with state and local code requirements.
Use the specifications provided here only in the initial planning.
Use the generator set and transfer switch spec sheets, dimension drawings, and wiring diagrams for installation.
Contact an authorized service distributor/dealer for the most current information.
6.2
Weight
_1_ WARNING
6.4
Mounting
Install the generator set outdoors.
Maintain a minimum clearance of 0.9 m (3 ft.) from any building as shown in
Figure 6-1.
Do not install the generator set where exhaust gas could accumulate and seep inside or be drawn into a potentially occupied building.
Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials.
See Figure 6-1 for the generator set dimensions and fuel and electric
inlet
locations.
The drawing dimensions are shown in millimeters, with inches in brackets.
The generator set is shipped on a plastic mounting pad.
Prepare a flat, level mounting area covered with gravel or compacted soil. Set the plastic mounting pad directly on the gravel or compacted soil.
Do not install the mounting pad directly on the grass.
6.5
Exhaust Requirements
_1_ WARNING
Unbalanced weight.
Improper lifting
can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Liftthe generator set using lifting bars
inserted through the lifting holes on the skid.
The generator set weighs approximately 186kg
(410 lb.). Use lifting bars inserted through the holes in the skid to lift the unit.
See Figure 6-1 for lifting hole locations.
6.3
Generator Set Inspection
Complete a thorough inspection of the generator set.
Check for the following:
1. Inspect the generator set for loose or damaged parts or wires.
Repair or tighten any loose parts before installation.
2. Check the engine oil.
Fill, if necessary, with the recommended make and grade of oil.
See
Section 3.3.3 for engine oil recommendations.
Carbon monoxide.
Can cause
fainting,
or death.
severe nausea,
The exhaust system must be leakproof and routinely inspected.
Generator set operation.
Carbon monoxide can cause severe nausea, fainting, or death.
Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death ifinhaled 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 intoa potentially occupied buildingthrough
windows, air intake vents, or other openings.
The exhaust system is complete for generator sets installed outdoors.
Do not install this generator set indoors.
TP-6195 1/04 Section 6 Installation 25
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DIPSTICK
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I
Figure 6-2 gives the exhaust flow and temperature at rated load.
Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials.
Exhaust System
Exhaust flow at rated kW, m3/min. (cfm)
8,5RES
12RES
Exhaust temperature at rated kW, dry exhaust, °C (°F)
Figure
6-2
60 Hz
3.3 (115)
3,8 (135)
50 Hz
2.7 (96)
3,2 (113)
816 (1500)
Exhaust Flow and Temperature
6.6
Air Requirements
The generator set requires correct air flow for cooling and combustion.
The inlet and outlet openings in the sound enclosure provide the cooling and combustion air.
Figure 6-3 shows the locations of the cooling air intake and exhaust vents. Inspect the air inlet and outlet openings inside and outside the housing to ensure that the air flow is not blocked.
1
\
\
\
_,_ 3
\
\
2
1. Exhaust outlet
2. Alternator air intake (both sides)
3. Engine air intake
\
\\
3 tp6195
Figure 6-3
Cooling Air Intake and Exhaust
Cooling
Air
Requirements
Cooling air, m3/min. (cfm)
Total inlet air requirement, m3/min. (cfm)
Combustion air, m3/min. (cfm)
8.5RES
60 Hz 50 Hz 60 Hz
12RES
50 Hz
26,9 (950) 22.4 (790) 26,9 (950) 22.4 (790)
27,8 (980) 23,2 (820) 28.0 (990) 23,4 (825)
0,94 (33,4) 0,8 (28,0) 1,1 (39,2) 0,9 (32,6)
Figure 6-4
Cooling Air Requirements
6.7
Power Supply
Utility power must be supplied to the generator set location. Provide a 110- or 120-volt outlet connected to the utility power supply for the battery charger
(standard) and carburetor heater (optional).
Figure 6-5 lists the battery charger power requirements.
,°put
Current draw
90-135 VAC, 50/60 Hz
1_ amp at full output
Figure 6-5
Battery Charger Power Requirements
6.8
Fuel System
The generator set operates using natural gas or LP vapor fuel.
The multi-fuel system allows conversion from natural gas to LP vapor (or vice-versa) in the field while maintaining emissions-standard compliance.
A trained technician or authorized distributor/dealer can convert the fuel system.
Generator sets with multi-fuel systems are CARB- and EPA-certified for both natural gas and LP vapor fuels.
1
6.8.1
Fuel Supply
Comply with local, state, and federal codes regarding the correct storage of fuel. Because of variable climates and geographical considerations, contact an authorized service distributor/dealer for fuel system planning and
installation.
Figure6-1 shows the location of the fuel
inlet
connection.
Bring the fuel supply lines through the rear access opening.
Use flexible sections to prevent fuel line breakage caused by vibration. Remove the housing end panel and hold the fuel solenoid valve with a wrench when tightening the fuel connections.
Protect all fuel lines from machinery or equipment contact, adverse weather conditions, and environmental damage.
Verify that the output pressure from the primary gas utility (or LP tank) pressure regulator is 1.7-2.7 kPa
(7-11 in. water column) and that the utility gas meter flow rate is sufficient to supply the generator set plus all other gas-consumingappliances.
Figure 6-8showsthe flow rate required for the generator set. Figure 6-6 lists
TP-6195 1/04 Section 6 Installation 27
the recommended fuel ratings for natural gas and LP vapor fuels.
Contact the natural gas utility for flow rate information or a gas meter upgrade.
Fuel System
Fuel types
Fuel supply inlet
Fuel supply pressure,kPa (in, H20)
Nominal Fuel Rating
Natural gas
LP vapor
Figure 6-6 Fuel Supply
Natural Gas or LP Vapor
1/2 NPT
1,7-2.7 (7-11)
Btu/ft 3
1000
2500
MJ/m 3
37
93
Fuel
Consumption,
m3/hr. (cfh)
8.5RES
60 Hz
Natural Gas at % load
50 Hz
12RES
60 Hz 50 Hz
109%
75%
50%
25%
3,7 (132) 3,3 (118) 5,9 (209) 4,9 (175)
3,2 (113) 2,9 (101) 4,8 (168) 4,9 (141)
2,6 (93) 2,3 (83) 3,6(127) 3,0(106)
2,2 (77) 1,9 (69) 2,4 (85) 2,0 (71)
LP Vapor at % load
100%
75%
2,0 (72) 1,7 (61) 3,1 (108) 2,5 (89)
1,3 (45) 1,1 (38) 2,5 (87) 2,0 (72)
50%
25%
1.0 (36)
0,8 (29)
LP vapor conversion factors:
8,58 ft3= 1 lb.
36,39 ft3 = 1 gal.
0.9 (31)
0,7 (25)
1.9 (65)
1,2 (44)
1.5 (53)
1,0 (36)
Figure 6-7
Fuel Consumption
Generator Set Model
8.5RES
12RES
Gas Flow Rate
Btu/hro
132,000
202,000
MJ/hr.
139
213
Figure 6-6
Natural Gas Flow Rate
6.8.2
6.8.3
Fuel Pipe Size
Ensure that the natural gas pipe size and length meet the specifications in Figure 6-9.
Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet.
Add
2.4 m (8 ft.) to the measured length for each 90 degree elbow. Compare the pipe size and length with the chart
in Figure 6-9. If the piping is longer than the maximum
length shown for that size, replace it with the specified size before proceeding.
Contact the local LP provider for LP installation
information.
Pipe Size
3/4 in. NPT
1 in, NPT
1 1/4 in, NPT
Maximum Pipe Length m (ft.)
8.5RES
18.3
(60)
61 (209)
91,5 (300)
12RES
9,2
Figure
6-9 Maximum Natural Gas Pipe Length
(30)
30 (109)
68.6
(225)
Fuel Conversion
_1_ 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
setasfollows: (1) Movethegeneratorsetmasterswitchtothe
OFFposition.
(2) Disconnectthepowertothebatterycharger.
(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.
28 Section6 Installation
TP-6195
1/04
A
WARNING
1
\
\
2
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
The multi-fuel system allows conversion from natural gas to LP vapor (or vice-versa) in the field while maintaining emissions-standard compliance.
Atrained technician or authorized distributor/dealer can convert the fuel system.
Two fuel connections on the fuel block allow fieldconversion between natural gas and LP vapor. The fuel metering valves are factory-set and sealed to comply with applicable emission standards and to provide the best possible hot and cold starting.
Note: Do not adjust the factory-sealed
fuel-metering adjustments on the fuel block.
Changing the fuel-metering adjustments may violate federal or state laws.
Use the following procedure to convert from natural gas to LP vapor, moving the fuel connection from the natural gas to the LP port, plugging the natural gas port, and connecting the DSAM leads.
See Figure 6-10 for the fuel system component locations.
Fuel Conversion Procedure
1. Place the generator set master switch in the OFF position.
2. Disconnect the power to the battery charger.
3. Disconnect the generator set engine starting battery, negative (-) lead first.
4. Turn off the fuel supply.
5. Remove the hose clamp and fuel hose from the hose fitting in the fuel block.
See Figure 6-11.
6. Remove the hose fitting from the natural gas outlet port in the fuel block. See Figure 6-11.
1. DSAM connector location
2. Fuel block
3. Fuel inlet, 1/2 in, NPT female
GM29253
Figure 6-10 Fuel System Locations, Air Inlet Side
1
2
5
4
1. Fuel block
2. Fuel metering valves---factory-sealed,
3, Fuel inlet, 1/2 in, NPT
4, Hose fitting
5, Plug
do not adjust
Figure 6-11 Fuel Block Connections,
Natural Gas
System Shown tp6195
TP-6195 1/04 Section 6 Installation 29
7. Remove the plug from the LP port in the fuel block.
See Figure 6-11. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install the plug into the natural gas outlet port.
8. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant to the threads, and install the fitting into the LP port.
Note: Do not adjust the fuel metering valves.
9. Slide the hose onto the hose fitting and secure it with the clamp.
10. For the 12RES only: Connect the digital spark-advance module (DSAM) leads together for natural gas.
(Disconnect the leads for LP.) See
Figure 6-12.
11. Connect and turn on the new fuel supply.
12. Check that the generator set master switch is in the
OFF position.
13. Reconnect the generator set engine starting battery leads, negative (-) lead last.
14. Reconnect power to the battery charger.
15. Start the generator set by moving the generator set master switch to the RUN position.
16. Check for leaks using a gas leak detector.
17. Move the generator set master switch to the AUTO position.
To convert from LP vapor to natural gas, follow the same fuel conversion procedure, moving the hose fitting to the natural gas port and plugging the LP port.
For the
12RES model, disconnect the DSAM leads for LP vapor.
See Figure 6-12.
tp6195
1
1, DSAM leads: connect for natural gas, disconnect for LP.
Figure 6-12 Digital Spark Advance Module (DSAM)
Leads (located in generator set air intake area)
30 Section6 Installation TP-6195 1/04
6.9
Electrical Connections
6.9.1
AC Load Lead Connections
_1_ 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.
Grounding electrical equipment.
Hazardous voltage can cause severe injury or death.
Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards.
Never contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of electrocution.
Electrical
backfeed to the utility.
Hazardous backfeed
voltage can cause severe injury or death. Install a transfer
switch in standby power installations to preventthe 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.
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.
Have an authorized distributor/dealer or a licensed electrician make the following load connections.
Verify that the electrical installation complies with the National
Electrical Code (NEC) and all applicable local and state codes.
Connect the AC output leads in the controller compartment to the AC circuit breaker. Route AC leads through flexible conduit directly to the AC circuit breaker box.
See Figure 6-1 for the recommended electrical inlet location.
Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas.
See Figure 6-13 and Section 5, Wiring Diagrams, for the generator set electrical connections.
Make the following AC connections:
1. Connect the output leads going to the transfer switch (L1/L2 black leads) to the AC circuit breaker load side.
2. Connect the L0 white leads from the ATS and the main panel to the neutral terminal.
3. Connect the green lead to the equipment ground terminal (labeled GRD).
Verify that the electrical installation complies with the
National Electrical Code (NEC) and all applicable local and state codes.
1
2
2,
3
VIEW B-B
Bottom of Junction BOX
I
\
GM29253A-F
1. Line circuit breaker
2, Ground terminal (GRD)
3, Neutral terminal (L0)
Figure 6-13 Field-Installed Wiring Connections
TP-6195 1/04 Section 6 Installation 31
6.9.2
Remote Start Connection
(optional)
Connect leads 3 and 4 from the ADC 2100 controller to the automatic transfer switch's engine start terminals or to an optional remote start!stop switch.
6.9.3
Continuous Power Mode Jumper
A jumper on connector P7 on the back of the controller causes the controller to remain powered at all times.
See the wiring diagram and schematic drawing in
Section 5. Controllers are shipped from the factory with the jumper connected.
Disconnecting the jumper allows the controller to power down 48 hours after the generator set shuts down.
See Section 2.3.6.
Note: For most applications,
it is not necessary to disconnect the continuous power mode jumper.
Use the following procedure to disconnect the jumper, if desired.
Procedure to disconnect the continuous power mode jumper (optional).
1. Prevent the generator set from starting.
a.
Move the generator set master switch to the
OFF/RESET position.
b.
Disconnect power to the battery charger.
c. Disconnect the generator set engine starting battery, negative (-) lead first.
2. Remove the controller from the generator set housing.
a.
Disconnect the engine wiring harness connector P1 plug (35-pin) from the controller.
Disconnect the J15 and J16 connectors.
See
Figure 6-14.
b.
Remove the controller from the generator set housing
in order to access the back of the
controller.
3. Remove the controller's back cover to access the jumper.
a.
Note the labels on the three leads connected to the generator set master switch for reconnection later. Disconnect the leads at the pink connectors.
See Figure 6-14.
b.
Remove the cover screws and remove the controller's back cover. See Figure 6-14.
32 Section6 Installation
4.
Locate the P7 connector near the top of the controller.
See Figure 6-14.
Remove the jumper from pins 1 and 2 of the P7 connector.
If the P7 connector has three pins, connect the jumper across pins 2 and 3 for storage.
5.
Replace the controller's back cover and secure the cover screws.
6.
Reconnect the three
pink connectors
to the generator set master switch.
7.
Reconnect the J 15 and J 16 connectors.
8.
Reconnect the generator set engine starting battery, negative (-) lead last.
9.
Reconnect power to the battery charger.
10.
Place the generator set master switch in the AUTO position.
1. Engine wiring harness connector plug (P1)
2. Continuous power mode jumper location
(P7)
3, J15 connector
4, J16 connector
5, Generator set master switch connectors
Figure 6-14 Advanced Digital Control Connections
tp6195
TP-6195 1/04
6.9.4
Battery
_1_ WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles
_1_ WARNING and clothing.
Battery acid may cause blindness and burn skin.
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 (f lb.) of bicarbonate of soda (baking
soda) to a container with 4 L (f 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.
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).
electrician install the battery(ies).
Have a qualified
TP-6195 1/04 Section 6 Installation 33
Use a 12-volt battery with a minimum rating of 675 cold cranking amps at 0°E The generator set uses a negative ground with a 12-volt engine electrical system.
See Figure 6-15 for battery connections.
Make sure that the battery is correctly connected and the terminals are tight.
Note: The generator set will not start and circuit board damage may occur if the battery is connected in reverse.
Figure 6-16 shows the location of the engine starting battery.
Standard battery cables provide easy connection to the battery. Use the following procedure to install and connect the battery.
Battery Installation Procedure
1. Ensure that the starting battery is fully charged before placing the battery in service.
2. Clean the battery posts and/or adapters if necessary.
3. Install the battery post adapters, if needed.
4. Place the battery in the housing.
5. Verifythat the controller master switch is in the OFF position.
J
1 2
6. Connect the positive (+) lead to the engine starting battery.
7. Connect the negative (-) lead to the engine starting battery.
Refer to Section 3.8
for battery maintenance instructions.
6.9.5
Battery Charger
The generator set requires an external battery charger to keep the starting battery fully charged.
A 6-amp battery charger is factory-installed in the battery compartment.
factory-connected.
The battery charger's DC leads are
Plug the battery charger's power cord into a 120 VAC outlet on the load side of the system.
Refer to Section
2.5 for battery charger operation information.
1
EZ-273000-J
1. To positive (+) terminal on starter solenoid.
2. To ground (-) terminal on or near starter motor.
Figure 6-15 12-Volt Engine Electrical System Single
Starter Motor Typical Battery Connection
1. Engine starting battery location
Figure 6-16 Battery Location, Air Intake End
GM29253
34 Section6 Installation TP-6195 1/04
6.10 Accessories
Have accessories
installed
by an authorized distributor/dealer or a licensed electrician.
Follow the installation
instructions provided
with each kit.
Use separate conduit for AC and DC leads to reduce the possibility of electrical interference. Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas. Verify that the electrical installation complies with the National
Electrical Code (NEC) and all applicable local and state codes.
See Section 5, Wiring Diagrams, for more information connections.
regarding generator set electrical
6.10.1
Common Fault and Run Relay
Board
The optional relay board provides two additional relays to control customer-provided equipment:
• Common fault relay
• Auxiliary run relay
The optional relay board replaces the standard relay board. The relay board location is shown in Figure 6-17.
Connect customer equipment to the relay board harness.
Figure 6-18 lists the customer connections.
The common fault relay is energized on a fault.
The auxiliary run relay is energized when the generator set is running.
Connect to each relay's normally open or normally closed contacts depending on the application.
1
2
\
GM30414
1. Relay board
2. Relay board harness
Figure 6-17
Common Fault and Run Relay Board
Harness
Lead
Number
88
89
90
91
92
93
Connector
Pin Number
6
2
3
4
1
5
Connection
Common fault normally open
Common fault common
Common fault normally closed
Run relay normally open
Run relay common
Run relay normally closed
I
Figure 6-18 Common Fault and Run Relay Board
Harness Connections
TP-6195 1/04 Section 6 Installation 35
6.10.2
Carburetor Heater
An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32 °F). The carburetor heater prevents condensation and carburetor icing. The heater turns on when the temperature at the thermostat falls below approximately 4°C (40 ° F) and turns off when the temperature rises above approximately 16°C
(60°F).
The heater requires a continuous source of 120 VAC power.
The heater power cord and thermostat are located in the generator set housing air intake area!battery
compartment.
See Figure 6-16.
Plug the carburetor heater into an outlet that supplies continuous
120 VAC power.
The heater thermostat is installed in the cord.
Figure 6-20 shows the location of the thermostat on the power cord.
Note: Do not place the heater thermostat
inside the generator set engine compartment.
The thermostat must be exposed to the ambient air.
The thermostat will shut off power to the heater when the ambient temperature approximately 60°F (16°C).
reaches
1. Carburetor
2. Carburetor heater (air cleaner removed to show heater) heater power cord tp6195
Figure 6-19 Carburetor Heater
1
\
\
\
\
\
\
2
\\
\
\
\
\
\
3
\
\
\
\
\
©
GM19463
1. Thermostat
2. Connector
3. Heater
Figure 6-20 Carburetor Heater with Thermostat
36 Section6 Installation TP-6195 1/04
6.11 Controller Configuration
6.11.1
System Configuration
The system configuration is factory-set and should not normally require changes in the field.
However, the controller's configuration modes allow setting of the system voltage/frequency and adjustment of the output voltage and frequency after reconnection.
Have reconnection and the related adjustments performed by an authorized distributor/dealer or service technician.
The unit configuration and engine type are factory-set for each type of generator set and engine, and should not be changed in the field.
6.11.2
Advanced Configuration Mode
The controller's advanced configuration mode allows a technician to set the data input type for different senders, change the battery voltage to 12 or 24 VDC if the battery voltage is changed in the field, and change the controller communications setting for field-installed meters.
Have these adjustments performed by an authorized distributor/dealer or service technician.
6.12 Prestart Installation Check
Review the entire installation section.
Inspect all wiring and connections to verify that the generator set is ready for operation.
Check that there are no obstructions to the air inlet and outlet.
Check all items in the Prestart
Checklist.
See Section 2.1.
6.13 Warranty Registration
Complete the startup procedure and installation checklists supplied with the startup notification form.
Return the form to the distributor/dealer or mail it directly to:
Kohler Power Systems
Generator Warranty Administrator
M.S. 072
Kohler, Wisconsin 53044
TP-6195 1/04 Section 6 Installation 37
Notes
38 Section6 Installation TP-6195 1/04
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp
ABDC
AC
A!D
ADC adj.
ADV
AHWT
AISI
ALOP alt.
AI
ANSI
AO
API ampere after bottom dead center alternating current analog to digital analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature
American iron and Steel
Institute anticipatory low oil pressure alternator aluminum
American National Standards
Institute
(formerly American Standards
Association, ASA) anticipatory only
American Petroleum Institute cfh cfm
CG
CID
CL cm
CMOS complementary metal oxide substrate (semiconductor) cogeneration cogen, corn coml communications commercial
(port)
Coml/Rec Commercial/Recreational conn.
connection cont.
continued
CPVC crit.
CRT
CSA
CT cubic feet per hour cubic feet per minute center of gravity cubic inch displacement centerline centimeter chlorinated polyvinyl chlodde critical cathode ray tube
Canadian Standards
Association current transformer approx,
AR
AS
ASE
ASME assy.
ASTM
ATDC
ATS auto, aux.
A!V
avg.
AVR
AWG
AWM bat.
BBDC
BC approximate, approximately as required, as requested as supplied, as stated, as suggested
American Society of Engineers
American Society of
Mechanical Engineers assembly
American Society for Testing
Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator
American Wire Gauge appliance wiring material battery before bottom dead center
Cu cu. in, cw.
CWC cyL
D/A
DAC dB dBA
DC
DCR deg., ° dept.
din.
DI/EO
DIN
DiP
DPDT
DPST
DS copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet
Deutsches Institut fur Normung e.V.
(also Deutsche ledustrie
Normenausschuss) dual inline package double-pale, double-throw double-pale, single-throw disconnect switch
BCA
BCI
BDC
BHP blk.
blk. htr.
BMEP bps br.
battery charger, battery charging battery charging alternator
Battery Council International before dead center brake horsepower black (paint color), block
(engine) block heater brake mean effective pressure bits per second brass
DSAM
DVR
E, emer.
EDI
EFR e.g.
EG
EGSA
EIA digital spark-advance module digital voltage regulator emergency (power source) electronic data interchange emergency frequency relay for example (exempli gratia) electronic governor
Electrical Generating Systems
Association
Electronic Industries
Association
BTDC
Btu before top dead center
British thermal unit
EI/EO end inlet/end outlet
Btu/min.
C cal.
British thermal units per minute
Celsius, centigrade calorie
EMI emiss, eng.
EPA electromagnetic interference emission
CARB
CB cc
CCA ccw.
CEC cert.
California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise
Canadian Electdcal Code certificate, certification, certified
EPS
ER
ES
ESD engine
Environmental Protection
Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge
TP-6195 1/04 freq.
FS ft.
ft. Ibs.
ft./rain, g ga.
gal.
gen.
genset
GFI est.
E-Stop etc.
exh.
ext.
F fglass,
FHM fl. oz.
flex.
estimated emergency stop et cetera (and so forth) exhaust external
Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute gram gauge (meters, wire size) gallon generator generator set ground fault interrupter
GND, O gov.
gph gpm gr.
GRD gr. wt.
ground governor gallons per hour gallons per minute grade, gross equipment ground gross weight
IMS in.
in. H20 in. Hg in. Ibs,
Inc.
ind.
int.
int./ext,
I/O
IP
H x W x D height by width by depth
HC
HCHT hex cap high cylinder head temperature
HD
HET hex
Hg
HH heavy duty high exhaust temperature, high engine temperature hexagon mercury (element) hex head
HHC
HP hr.
hex head cap horsepower hour
HS hsg.
HVAC
HWT
Hz
IC
ID
IEC
IEEE heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal/external input/output iron pipe
Appendix A-1
LOP
LP
LPG
LS
Lwa
LWL
LWT m
M m 3 m3/min, mA man.
max.
MB
MCM
ISO International for
J
JIS Japanese k
K kA
KB kg
2
Standardization joule
Industry kilo(1000) kelvin kiloampere
(2t°bytes) kilogram centimeter
MS military
MTBO mean mtg.
mounting
MW megawatt mW milliwatt uF microfarad
N,norm,normal
NA notavailable, gas
NBS National
NC normally
NEC National
NEMA National
Code
Electrical kgm kilogram-meter kg/m kilograms kHz kilohertz kJ meter km kOhm, kilojoule kilometer k_ kilo-ohm kPa kilopascal kph kilometers kV kilovolt kVA kilovolt ampere kVAR kilovolt kW kilowatt kWh kilowatt-hour kWm kilowatt
L liter
LAN local
LxWxH length
Ib.
Ibm/ft pounds
LCB linecircuit
LCD liquid display
LED shed light
Nm
NO
Pipe,
NPSC National
NPT National
NR notrequired, ns nanosecond
OC overcrank
OF opt.
Association newton normally no.,nos. number,
NPS National pergeneral
NPTF National relay
OD outside
OEM manufacturer overfrequency option, optional
Lph liters per hour OS oversize, overspeed
Lpm liters per minute OSHA Occupational Safety and Health low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level, A weighted low water leval low water temperature meter, milli (1/1000) mega (106 when used with SI units), male cubic meter cubic meters per minute milliampere manual maximum megabyte (22° bytes) one thousand circular mils
MCCB meggar
MHz mi.
rail rain.
misc.
molded-case circuit breaker megohmmeter megahertz mile one one-thousandth of an inch minimum, minute miscellaneous
MJ mJ mm megajoule millijoule millimeter mOhm, m_ milliohm
MOhm, M_
MOV megohm metal oxide varistor
MPa mpg megapascal miles per gallon mph miles per hour psi pt.
PTC
PTO
PVC qt.
qty.
R
OV oz.
p., pp.
PC
PCB pF
PF ph., _
PHC
PHH
PHM
PLC
PMG pot ppm
PROM red.
RAM
RDO ref.
overvoltage ounce page, pages personal computer printed circuit board picofared power factor phase
Phillips head edmptite (screw)
Phillips hex head (screw) pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable reed-only memory pounds per square inch pint positive temperature coefficient power takeoff palyvinyl chloride quart, quarts quantity replacement (emergency) power source radiator, radius random access memory relay driver output reference rem.
remote
Res/Coml Residential/Commercial
RFI radio frequency interference
A-2 Appendix
VAC
VAn
VDC
VFD
VGA
VHF
W
UF
UHF
UL
UNC
UNF univ.
US
UV
V
WCR w/ w/o wt.
xfmr
TDOE
TDON temp.
term.
TIF
TIn tal.
turbo, typ.
RH
RHM rly.
FinS rnd.
ROM rot.
rpm
RS
RTV
SAE scfm
SCR s, sec.
SI
SI/EO all.
SN read only memory rotate, rotating revolutions per minute right side room temperature vulcanization
Society of Automotive
Engineers standard cubic feet per minute silicon controlled rectifier second
Systeme international d'unites,
International System of Units side in/end out silencer serial number
SPDT
SPST single-pole, single-pole, spec, specs specification(s) double-throw single-throw sq.
sq. cm sq. in.
SS std.
stL square square centimeter square inch stainless standard steel steel tach.
tachometer
TD
TDC
TDEC
TDEN
TDES
TDNE round head round head machine (screw) relay root mean square round time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency
Underwriter's Laboratories, Inc.
unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervaltage volt volts alternating current valtampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer
TP-6195 1/04
TP-6195 1/04
@ 2004 by Kohler Co All rights reserved
KOHLERo
POWERSYSTEMS
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems,com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619169
Phone (66)264*6422, Fax (66)264*6465

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Key features
- Automatic starting and stopping: The generator set will automatically start when power is lost and stop when power is restored.
- Advanced digital controller: Provides precise control and monitoring of the generator set.
- Battery charger: Keeps the battery charged and ready to use.