Kohler REOD 10, 15, 20, REOZD 10, 15, 20 Industrial Generator Sets Operation Manual
REOD 10, REOD 15, REOD 20, REOZD 10, REOZD 15, REOZD 20 are Kohler industrial generator sets equipped with the ADC 2100 Advanced Digital Control. These generators offer reliable power for a variety of applications.
Advertisement
Advertisement
Operation
Industrial Generator Sets
Models:
10/15/20REOD/REOZD
Controller:
ADC 2100 Advanced Digital Control
TP-6392 8/05
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
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 ADC 2100
Engine Identification
Record the product identification information from the engine nameplate.
Manufacturer
Model Designation
Serial Number
Yanmar
2 TP-6392 8/05
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Safety Precautions and Instructions
Introduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
11
11
11
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Section 1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2
Alternator Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3
Advanced Digital Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2
Exercising the Generator Set
2.3
Generator Set Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1
ADC 2100 Controls and Indicators
2.3.2
Local Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3
Remote/Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5
Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . .
2.3.6
Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.7
Controller Software Version Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1
Line Circuit Breaker
2.4.2
Fuses
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
16
16
16
17
17
17
19
19
19
19
19
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2
Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3
Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1
Oil Specifications
3.4.2
Oil Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.3
Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.4
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.1
Checking the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.2
Draining the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.3
Filling the Cooling System
3.8.4
Flushing and Cleaning
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.5
Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9
Belt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
31
32
32
32
33
27
27
27
28
29
30
30
21
21
22
24
25
25
25
26
TP-6392 8/05 Table of Contents 3
Table of Contents, continued
3.11 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.1
Lubricating System
3.11.2
Cooling System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.4
Exterior
3.11.5
Battery
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
34
34
34
34
34
Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2
Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5 Reconnection/Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
Four-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1
100--120-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2
100--120/200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3
200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2
Twelve-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3
ADC 2100 Adjustment after Reconnection
5.3.1
Configuration Mode Time Out
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2
Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.3
Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
35
39
39
39
39
40
41
42
42
42
43
Section 6 Wiring Diagrams
Appendix A Abbreviations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
53
Appendix B Operating Hour Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
4 Table of Contents TP-6392 8/05
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment, including generator sets and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.
Read and follow all safety precautions and instructions.
SAVE
THESE INSTRUCTIONS.
This manual has several types of safety precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.
WARNING
Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.
CAUTION
Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.
The decals are shown throughout this publication to improve operator recognition.
Replace missing or damaged decals.
Accidental Starting
WARNING
Battery
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing.
Battery acid may cause blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.
Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.
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.
TP-6392 8/05 5
Battery acid cleanup. Battery acid can cause severe injury or death.
Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.
Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.
Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.
Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits.
Explosion can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Disconnect the battery before generator set installation or maintenance.
Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the fuel system. A flash fire can cause severe injury or death.
Do not smoke or permit flames or sparks near the fuel injection system, 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 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 air cleaner on a turbocharged engine.
A sudden engine backfire or turbocharger compressor failure can cause severe injury or death.
Do not operate the generator set with the air cleaner removed.
Burns from hot turbocharger components may occur.
Foreign objects sucked into the turbocharger can cause mechanical damage and the potential for high velocity projectiles.
Combustible materials. A fire can cause severe injury or death.
Generator set engine fuels and fuel vapors are flammable and explosive.
Handle these materials carefully to minimize the risk of fire or explosion.
Equip the compartment or nearby area with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as recommended by the local fire code or an authorized agency.
Train all personnel on fire extinguisher operation and fire prevention procedures.
Using engine starting fluid.
A sudden backfire can cause severe injury or death. Do not use starting fluid or similar agents to start an engine equipped with air preheating (glow plugs/starter element).
The starter element may cause an explosion in the inlet manifold.
Engine Fluids and
Chemical Products
WARNING
Handling caustic engine fluids and chemical products.
Can cause severe chemical burns, nausea, fainting, or death.
Most chemicals such as used engine oil, antifreeze/coolant, rustproofing agent, inhibiting oil, degreasing agent, spray paint, and adhesives are hazardous to health. Read and follow the user information found on the packaging. Avoid inhalation and skin contact. Use only in well-ventilated areas and use a protective mask when spraying. Store engine fluids and chemical products in a locked cabinet. Contact your local recycling center for disposal information and locations.
6 TP-6392 8/05
WARNING
Exhaust System
WARNING
Flammable engine solvents and cleaners.
Can cause severe injury or death.
Do not smoke or permit flames or sparks near flammable engine solvents and cleaners.
Read and follow the user information found on the packaging.
Use only in wellventilated areas. Never use gasoline or low flash-point solvents as cleaning agents.
Leaking or accumulated engine fluids. A fire can cause severe injury or death.
Clean up engine fluids including fuel, oil, grease, and coolant.
Determine the source of engine leaks and correct before starting the generator set. Keep the generator set area clean and remove combustible materials.
Used engine oil. Contact with used engine oil may cause severe skin irritation. Repeated and prolonged skin exposure may have other health risks.
Used engine oil is a suspected carcinogen. Avoid contact with skin. Thoroughly wash your hands and nails with soap and water shortly after handling used engine oil. Wash or dispose of clothing or rags containing used engine oil.
Dispose of used engine oil in a responsible manner.
Contact your local recycling center for disposal information and locations.
Fire-damaged or burned O-rings may cause the formation of hydrofluoric acid.
Contact with hydrofluoric acid may cause severe skin irritation and chemical burns.
O-rings and other fluoroelastomer seals exposed to fire or temperatures above 316
_C (600_F) (i.e., during welding) may decompose forming hydrofluoric acid. Avoid inhalation or skin contact. Do not incinerate O-rings.
Dispose of O-ring waste material in a responsible manner.
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.
Carbon monoxide symptoms.
Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases.
Carbon monoxide poisoning symptoms include but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in joints and muscles
D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.
Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.
Copper tubing exhaust systems.
Carbon monoxide can cause severe nausea, fainting, or death. Do not use copper tubing in diesel exhaust systems.
Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust leakage.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
WARNING
Avoid high pressure fluids.
Can cause severe injury or death.
Do not work on high pressure fuel or hydraulic systems without protective gloves. Avoid the hazard by relieving pressure before disconnecting fuel injection pressure lines. Search for leaks using a piece of cardboard.
Always protect hands and body from high pressure fluids. If an accident occurs, seek medical attention immediately. Any fluid injected in the skin tissues must be surgically removed within a few hours or gangrene may result.
TP-6392 8/05 7
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.
Fuel tanks. Explosive fuel vapors can cause severe injury or death.
Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks.
Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.
Hazardous Noise
CAUTION
Hazardous Voltage/
Electrical Shock
WARNING
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
Hazardous voltage.
Backfeed to the utility system can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.
CAUTION
Welding the generator set.
Can cause severe electrical equipment damage.
Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).
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.
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.
Welding on the generator set. Can cause severe electrical equipment damage.
Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module
(ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection close to the weld location.
Installing the battery charger.
Hazardous voltage can cause severe injury or death.
An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.
8 TP-6392 8/05
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).
Servicing the day tank. Hazardous voltage can cause severe injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipment manual. Disconnect the power to the day tank before servicing.
Press the day tank ECM OFF pushbutton to disconnect the power.
Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded.
Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution.
Short circuits.
Hazardous voltage/current can cause severe injury or death.
Short circuits can cause bodily injury and/or equipment damage.
Do not contact electrical connections with tools or jewelry while making adjustments or repairs.
Remove all jewelry before servicing the equipment.
Engine block heater.
Hazardous voltage can cause severe injury or death. The engine block heater can cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections.
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
WARNING
Unbalanced weight.
Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes.
Lift the generator set using lifting bars inserted through the lifting holes on the skid.
Hot Parts
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until it cools.
WARNING
Hot engine oil.
Can cause severe injury or death.
Avoid skin contact with hot oil. Do not start or operate the generator set with the engine oil filler cap removed, as hot oil can spray out. Ensure that the lubrication system is not under pressure when servicing.
Do not work on the generator set until it cools.
Checking the coolant level.
Hot coolant can cause severe injury or death.
Allow the engine to cool.
Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled.
Check the coolant level at the tank if the generator set has a coolant recovery tank.
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.
TP-6392 8/05 9
Moving Parts
WARNING
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when all guards, screens, and covers are in place.
WARNING
Tightening the hardware.
Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury.
Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.
Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.
Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.
Notice
NOTICE
This generator set has been rewired from its nameplate voltage to
NOTICE
Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate.
Order voltage reconnection decal 246242 from an authorized service distributor/dealer.
NOTICE
Hardware damage. The engine and generator set may use both American
Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not substitute with inferior grade hardware.
Screws and nuts are available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.
NOTICE
Canadian installations only.
For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
Airborne particles.
Can cause severe injury or blindness.
Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
246242
10 TP-6392 8/05
Introduction
This manual provides operation instructions for Model
10/15/20REOD/REOZD generator sets.
Refer to the engine operation manual for generator set engine scheduled maintenance information.
Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.
The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals.
Obtain service from an authorized service distributor/dealer to keep equipment in top condition.
List of Related Literature
Figure 1 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel should install or service the generator set.
Literature Type
Installation Manual
Operation Manual (Generator)
Operation Manual (Engine)
Parts Catalog*
Service Manual (Generator)
Service Manual (Engine)
Part Number
TP-6393
TP-6392
TP-6412
TP-6395
TBD
TP-6293
* One manual combines Generator and Engine information.
Figure 1 Generator Set Literature x:in:001:005
Maintenance and Service Parts
Figure 2 identifies maintenance and service parts for your generator set.
Obtain a complete list of maintenance and service parts from your authorized generator distributor/dealer.
Part Description
Air Cleaner Element for:
10REOD/REOZD
15REOD/REOZD
Air Cleaner Element for:
20REOD/REOZD
Belt
Fuel Filter Element
Fuel/Water Separator Element
Fuse, Auxiliary Winding (F1):
20 amp for 12 lead generator sets
10 amp for 4 lead generator sets
Fuse, Relay Interface Board (F2) 10 amp
Fuse, Controller (F3) 10 amp
Oil Filter
Spray Paint (Black)
Part Number
GM42265
GM42266
GM42428
GM32359
225259
GM39266
223316
223316
223316
252834
221292
Figure 2 Maintenance and Service Parts x:in:001:004
TP-6392 8/05 Introduction 11
Service Assistance
For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.
D
Consult the Yellow Pages under the heading
Generators—Electric
D
Visit the Kohler Power Systems website at
KohlerPowerSystems.com
D
Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product
D
Call toll free in the US and Canada 1-800-544-2444
D
Outside the US and Canada, call the nearest regional office
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems
ZI Senia 122
12, rue des Hauts Flouviers
94517 Thiais Cedex
France
Phone: (33) 1 41 735500
Fax: (33) 1 41 735501
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
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
12 Introduction TP-6392 8/05
1.1 Specifications
The spec sheets for each generator set provide specific alternator and engine information. The controller spec sheet provides specifications particular to the controller.
Refer to the respective spec sheet for data not supplied in this manual.
Consult the generator set service manual, generator set installation manual, engine operation manual, and engine service manual for additional specifications.
1.2 Alternator Features
The Model REOD alternator is equipped with Kohler’s
PowerBoost t voltage regulation system which provides instant response to load changes.
PowerBoost t is a unique system that ensures reliable motor starting and consistent voltage levels.
PowerBoost t utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage.
1.3 Advanced Digital Control
The generator set is equipped with the Kohler r
Advanced Digital Control (ADC 2100).
Controller features include the following:
D
Compact controller
D
Integrally mounted to the generator set
D
LED display:
D
Runtime hours
D
Crank cycle status
D
Diagnostics
Section 1 Features
D
LED display communicates faults:
D
High battery voltage
D
High engine temperature
D
Low battery voltage
D
Low oil pressure
D
Overcrank safety
D
Overspeed
D
Overfrequency
D
Overvoltage
D
Underfrequency
D
Undervoltage
D
Membrane keypad for configuration and adjustment:
D
Password-protected user access to menus
D
System configuration
D
Voltage adjustment
D
Master control switch: Run/Off-Reset/Auto
D
Remote two-wire start/stop capability
D
Superior electronics protection from corrosion and vibration:
D
Potted electronics
D
Sealed connections
D
Digital voltage regulation:
±1.5% RMS no-load to full-load
D
Automatic start for programmed cranking cycle
TP-6392 8/05 Section 1 Features 13
Notes
14 Section 1 Features TP-6392 8/05
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 air cleaner element to prevent unfiltered air from entering the engine.
Air Inlets. Check for clean and unobstructed air inlets.
Air Shrouding.
Check for securely installed and positioned air shrouding.
Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.
Coolant Level. Check the coolant level according to the cooling system maintenance information.
Note: Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system before energizing the block heater.
Drive Belt(s). Check the belt condition and tension of the water pump and battery charging alternator belt(s).
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 for cracks and corrosion (exhaust manifold, exhaust line, exhaust clamps, and muffler).
D
Check for corroded or broken metal parts and replace them as needed.
D
Check for loose, corroded, or missing clamps and hangers.
Tighten or replace the exhaust clamps and/or hangers as needed.
D
Check that the exhaust outlet is unobstructed.
D
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.
Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply.
Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.
Operating Area.
Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.
2.2 Exercising the Generator Set
Operate the generator set without load once each week for 20 minutes. If the generator set does not have a programmed exercise mode or an automatic transfer switch (ATS) with an exercise option, exercise the unit in the presence of an operator.
The operator should perform all of the prestart checks before starting the exercise procedure.
Start the generator set according to the starting procedure in
Section 2.3.2 of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks. Check the air inlets and outlets and remove any items restricting the air flow.
TP-6392 8/05 Section 2 Operation 15
2.3 Generator Set Operation
Figure 2-1 illustrates the user interface on the Advanced
Digital Control (ADC 2100) generator set controller.
2
1
3
4 GM28707A-C
1. LED display
2. Select button
3. Up and down arrow buttons (use for setup and adjustment only)
4. Generator set master switch
Figure 2-1 ADC 2100 User Interface
2.3.1
ADC 2100 Controls and Indicators
Figure 2-2 describes the controls and indicators located on the ADC 2100.
The LED display indicates generator set status. The
LED display is activated when the generator set master switch is moved to the RUN or AUTO position and remains active until the master switch is moved to the
OFF/RESET position or power to the controller is removed.
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 system configuration is factory-set and should not require changes under normal operating conditions. Contact an authorized distributor/dealer or service technician if adjustments are required.
2.3.2
Local Operation
Local Starting
Move the generator set master switch to the RUN position 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 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.
Note: There is no engine cooldown time delay on the
ADC 2100 controller.
Control or Indicator
LED display
Item
Runtime hours
Description
Displays total generator set runtime hours while the generator set is running and when no other codes are displayed.
Crank indication Displays CC_1, CC_2, or CC_3 to indicate the first, second, or third attempt to start the engine. The last digit flashes during the crank cycle rest periods.
Fault codes
Fuel
Software version number
Flashes a 2- or 3-letter fault code to indicate various fault conditions. See Section 2.3.4.
Displays FUEL during fuel pump priming procedure. See Section 3.5.4.
See Section 2.3.7.
Keypad
Generator set master switch
Select and arrow buttons
Three-position switch
The keypad is used for controller setup and adjustment only. Have setup and adjustments performed only by an authorized distributor/dealer. The setup and adjustment functions are password-protected.
Switch functions as the generator set operation and controller reset switch.
Figure 2-2 ADC 2100 Controls and Indicators
16 Section 2 Operation TP-6392 8/05
2.3.3
Remote/Automatic Operation
A remote switch or an automatic transfer switch (ATS) can be used to start and stop the generator set.
Connect the remote start/stop switch or the ATS engine start contacts to ADC 2100 engine start leads 3 and 4.
Move the generator set master switch to the AUTO position.
Automatic Starting
With the generator set master switch in the AUTO position, close the remote start contact connected to engine start leads 3 and 4 to signal the generator set to start.
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.
Automatic Stopping
With the generator set master switch in the AUTO position, open the remote switch or contact to stop the generator set.
If the generator set was started by a start signal from a remote start/stop switch or ATS, moving the generator set master switch on the ADC 2100 to the OFF/RESET position also stops the generator set.
Note: There is no engine cooldown time delay on the
ADC 2100 controller.
2.3.4
Faults
Figure 2-3 lists fault codes displayed by the ADC 2100.
If the generator set shuts down on a fault condition, it 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 high and low battery voltage warning conditions.
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.
TP-6392 8/05 Section 2 Operation 17
Code
AF
HE
LCL
LOC
LOP
OC
OF
OS
OU
UF
UU
Fault
Auxiliary fault input shutdown
Description
Input from a customer-supplied contact that closes on a fault condition. The generator set shuts down 2 seconds after the fault is detected and will not start when the fault is active (input is grounded).
Check
Check the condition and operation of customer-supplied equipment connected to the auxiliary fault input P21-6 on the customer interface connector.
High engine temperature shutdown
Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds. This protective becomes active after the engine reaches the crank disconnect speed.
Low coolant level Not used.
Loss of coolant Not used.
Low oil pressure shutdown
Overcrank shutdown
Overfrequency shutdown
Check for blocked air inlets and exhaust outlets.
—
—
Shutdown occurs if a low oil pressure condition exists for more than 5 seconds. This protective becomes active 30 seconds after the engine has reached crank disconnect speed
(30 second inhibit).
Note: The low oil pressure shutdown does not protect against low oil level. Check the oil level at the engine.
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 for leaks in the lubrication system.
Check the oil level and add oil if the level is low.
The generator set also shuts down if no engine rotation is sensed during cranking. Shuts down 1 second after the fault is detected.
Shutdown occurs when the governed frequency exceeds 110% of the system’s frequency setpoint for more than 5 seconds.
This protective becomes active 10 seconds after engine start
(10 second inhibit).
Check the fuel supply, spark plug, and battery.
Check for loose connections.
Contact an authorized distributor/dealer for service if problem continues.
Contact an authorized distributor/dealer for service if problem continues.
Overspeed shutdown
Overvoltage shutdown
Underfrequency shutdown
Undervoltage shutdown
Shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than 0.3 seconds.
Shutdown occurs if the voltage exceeds 120% of the system nominal voltage for more than 2 seconds.
Contact an authorized distributor/dealer for service if problem continues.
Contact an authorized distributor/dealer for service if problem continues.
Shutdown occurs when the governed frequency falls blow 90% of the nominal system frequency for more than 5 seconds.
This protective becomes active 10 seconds after engine start.
(10 second inhibit).
Shutdown occurs if the voltage falls below 80% of the nominal system voltage for more than 10 seconds.
Reduce the load and restart the generator set.
Contact an authorized distributor/dealer for service if problem continues.
Reduce the load and restart the generator set.
Contact an authorized distributor/dealer for service if problem continues.
HB
LB
High battery voltage warning
Low battery voltage warning
Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running. This fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.
Fault code is displayed if the engine starting battery voltage falls below 8 VDC for a 12 VDC system or below 16 VDC for a
24 VDC system for more than 10 seconds when the engine is not running. This fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a voltage within the limits for more than 10 seconds.
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.
Figure 2-3 ADC 2100 Fault Codes
18 Section 2 Operation TP-6392 8/05
2.3.6
Power Down
The controller is powered by the generator set engine starting battery.
If the ADC 2100 is not configured for the optional
Remote Digital Gauge (communication setting Cn00), the controller powers down after 48 hours of no activity when the master switch is in the AUTO position. (See the Installation Manual for more information about ADC
2100 controller settings.) A start signal from a remote start/stop switch or a transfer switch connected to engine start leads 3 and 4 energizes the controller and initiates the crank cycle.
Moving the generator set master switch to the RUN position also turns the controller back on.
If the ADC 2100 is configured for the optional Remote
Digital Gauge (communications setting Cn01), the controller remains active at all times when the generator set master switch is in the AUTO position.
Note: The ADC 2100 consumes 250 mA when the master switch is in the AUTO position with the
Remote Digital Gauge connected. Exercise the generator set weekly and consider using a battery charger to maintain the battery.
2.3.7
Controller Software Version
Number
The application software for controller operation is factory-loaded onto the Advanced Digital Control. At times, it may be necessary to check the software version number for troubleshooting purposes. Use the following procedure.
Displaying the Software Version Number
1. Press and hold the Select button
2100.
on the ADC
2. Move the generator set master switch to the Run postion. The generator set will not start.
3. After approximately five seconds, the software version number is shown on the ADC 2100 display.
For example, 01.18 will be displayed for software version 1.18.
4. Move the generator set master switch to the
OFF/RESET position and release the Select button.
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 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 3-1. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position.
2.4.2
Fuses
The junction box contains three inline fuses. 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.
Obtain service from an authorized distributor/dealer.
Controller Fuse. A replaceable 10-amp fuse protects the controller circuitry. If the controller display is dark, check the battery and battery connections and then check the controller fuse. Replace the fuse if it is blown.
Relay Fuse. A replaceable 10-amp fuse protects the engine relays. If the generator set does not crank, check the battery and battery connections and then check the relay fuse. Replace the fuse if it is blown.
Auxiliary Winding Fuse. A replaceable 10-amp fuse for 4 lead generator sets (20-amp fuse for 12 lead generator sets) protects the alternator.
TP-6392 8/05 Section 2 Operation 19
Notes
20 Section 2 Operation TP-6392 8/05
Section 3 Scheduled Maintenance
3.1 General Maintenance
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
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.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when all guards, screens, and covers 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.
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.
See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized distributor/dealer perform generator set service.
Engine Service. Perform generator set engine service at the intervals specified by the engine operation manual.
Generator Set Exercise. Operate the generator set without load once each week for 20 minutes. If the transfer switch does not have an exercise option, exercise the unit in the presence of an operator.
Generator Set Service. Perform generator set service at the intervals specified by the generator set operation manual.
If the generator set operates under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator. With the generator set running, direct the stream of air in through the cooling slots at the alternator end.
Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the runtime hours shown on the ADC 2100 to determine when to schedule routine maintenance. Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions.
Service Log. Use the Operating Hour Service Log located in the back of this manual to document performed services.
Service Schedule. Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set.
For example, an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months, 300 hours or 9 months, and so on.
TP-6392 8/05 Section 3 Scheduled Maintenance 21
3.2 Service Schedule
System—Component
FUEL
Day tank level
Flexible lines and connections
Main tank supply level
Fuel/water separator
Filter(s)
Drain tank and replace fuel
Fuel piping
Tank vents and return lines for obstructions
Fuel injection system
LUBRICATION
Oil level
Crankcase breather
[
Change oil
Replace filter(s)*
COOLING
Block heater operation
Coolant level
Flexible hoses and connectors
Water pump(s)
Fan and alternator belts
Air ducts, louvers *
Louver motors and controls
Radiator exterior *
EXHAUST SYSTEM
Drain condensate trap
Leakage
Insulation, fire hazards
Flexible connector(s)
Excessive back pressure
Hangers and supports
DC ELECTRICAL SYSTEM
Battery charger operation, charge rate
Recharge after engine start
Battery electrolyte level
Battery specific gravity, charge state
Remove corrosion, clean and dry battery and rack
Clean and tighten battery terminals
Tighten DC electrical connections
* Service more frequently if operated in dusty areas.
[ Consult your local distributor/dealer for service.
w Do not break manufacturer’s seals or internally inspect these devices.
Check
W
W
W
M (drain)
W
1500
M
M
M
M
Y
Y
W
W
W
W
W
W
Q
W
Q
Q
Y
Y
Change
R
Procedure
Q
50 or M then 250
R
Clean
S
S
Q
S
D: Daily, before operation
Y: Yearly
2Y: Every 2 years or 2000 hours
R: Replace as necessary
Number: Hours of operation
S
Y
Y
Y
Test
Y
Y
Y
M
W: Weekly
M: Monthly
Q: Quarterly
S: Six months
Section
3.5
3.5
Eng. S/M
3.4
Eng. S/M
3.4
3.4
3.8
3.9
3.8
I/M
3.7
3.7
3.7
I/M
3.7
Battery instructions
’
22 Section 3 Scheduled Maintenance TP-6392 8/05
System—Component
AC ELECTRICAL SYSTEM
General Inspection
Circuit breakers, fuses w
Wire abrasions where subject to motion
Tighten control and power wiring connections
Wire-cable insulation breakdown
ENGINE AND MOUNTING
General inspection (check for leaks)
Air cleaner service *
Valve clearance
Bolt torque
REMOTE CONTROL SYSTEM, ETC.
Compartment condition *
Remote control
GENERATOR
General inspection
Rotor and stator
[
Bearing condition
[
Exciter
[
Measure and record resistance readings of windings with insulation tester (Megger, with SCR assembly or rectifier disconnected)
[
Blow dust out of generator*
GENERAL CONDITION OF EQUIPMENT
Any condition of vibration, leakage, unusual noise, temperature, or deterioration
Run generator set (exercise)
Ensure that system is set for automatic operation
Interior of equipment room or outdoor weather housing *
* Service more frequently if operated in dusty areas.
[ Consult your local distributor/dealer for service.
w Do not break manufacturer’s seals or internally inspect these devices.
Check
W
M
Q
Y
3Y or 500
W
S
3 Y or 500
3 Y or 500
W
W
Y
Y
Y
2 Y or 300
W
R
S
R
Procedure
Change Clean
M
W
Y
X
2 Y or 300
W
W
W
D: Daily, before operation
Y: Yearly
2Y: Every 2 years or 2000 hours
R: Replace as necessary
Number: Hours of operation
W
Test
M
3Y or 500
3 Y or 500
M
Y
W
W: Weekly
M: Monthly
Q: Quarterly
S: Six months
Section
3.6
Eng. S/M
Eng. S/M
S/M
S/M
S/M
S/M
3.1
2.2, 2.3
2.3
TP-6392 8/05 Section 3 Scheduled Maintenance 23
3.3 Service Views
4 5 6 7 8 9
Service-Side View
10 11 12 13 14 15
16
17
3
2
18
1
19
20
27 26 25 24
28
23
Engine-End View
(With Radiator Removed)
29
22
30
21
1. Fuses (F1, F2, and F3)
2. Advanced Digital Control (ADC 2100)
3. Alternator cooling air inlet
4. Run-Off/Reset-Auto switch
5. Runtime hour display
6. Air intake silencer/cleaner
7. Fuel inlet connection
8. Fuel/water separator
9. Lifting eye
10. Fuel return connection
11. Fuel filter
12. Oil fill (engine top)
13. Mechanical governor
14. Coolant overflow tube
15. Pressure cap (at radiator)
Figure 3-1 Service Views
24 Section 3 Scheduled Maintenance
16. Oil fill (front gear cover)
17. Radiator
18. V-belt
19. Oil check/dipstick
20. Coolant overflow bottle
21. Lube oil filter
22. Oil drain
23. Fuel feed pump
24. Nameplate
25. Circuit breaker location
26. Remote customer interface connector
27. Load lead connection
28. Water inlet connection
29. Water outlet connection
30. Exhaust outlet
ADV7031-A
TP-6392 8/05
3.4 Lubrication System
See Figure 3-1 for the oil drain, oil check, oil fill, and oil filter locations.
WARNING
SAE
Service
Grade
10W
20W
10W30
15W40
#20
#30
Handling caustic engine fluids and chemical products.
Can cause severe chemical burns, nausea, fainting, or death.
Most chemicals such as used engine oil, antifreeze/coolant, rustproofing agent, inhibiting oil, degreasing agent, spray paint, and adhesives are hazardous to health. Read and follow the user information found on the packaging. Avoid inhalation and skin contact. Use only in well-ventilated areas and use a protective mask when spraying. Store engine fluids and chemical products in a locked cabinet. Contact your local recycling center for disposal information and locations.
Used engine oil. Contact with used engine oil may cause severe skin irritation.
Repeated and prolonged skin exposure may have other health risks. Used engine oil is a suspected carcinogen. Avoid contact with skin. Thoroughly wash your hands and nails with soap and water shortly after handling used engine oil. Wash or dispose of clothing or rags containing used engine oil. Dispose of used engine oil in a responsible manner. Contact your local recycling center for disposal information and locations.
3.4.1
Oil Specifications
Use oil that meets the American Petroleum Institute
(API) classification of CD or CF. Using an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life. Figure 3-2 shows the recommended
Society of Automotive Engineers (SAE) viscosity designation for given operating temperature ranges.
Note: Failure to observe the oil specifications may cause inadequate lubrication/oil pressure and cold-starting difficulties.
#40
°C
--30 --20 --10 0 10 20 30 40
°C
°F
0 20 40 60
Operating Temperature
80
Figure 3-2 Engine Oil Selection
100
°F
TP-5856-1
3.4.2
Oil Check
Check the oil level in the crankcase daily or before each startup to ensure that the level is in the safe range. To check the oil level, remove the dipstick and wipe the end clean, reinsert as far as possible, and remove. Maintain the oil level between the Min and Max marks on the dipstick, as shown in Figure 3-3. See Figure 3-1 for dipstick location.
Note: Do not operate the set if the oil level is below the
Min mark or above the Max mark.
1
2
1-933
1. Max level
2. Min level
Figure 3-3 Oil Level Check
TP-6392 8/05 Section 3 Scheduled Maintenance 25
3.4.3
Oil Change
See the Service Schedule in Section 3.2 for oil change and oil filter replacement intervals. Change the oil more frequently if the generator operates under dirty, dusty conditions. See Figure 3-4 for oil capacities.
Model
10REOD/REOZD
15REOD/REOZD
20REOD/REOZD
Figure 3-4 Oil Capacities
L (Qts.)
3.6
(3.8)
4.7
(5.0)
5.8
(6.1)
Oil Change Procedure
Whenever possible, 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, if equipped.
c. Disconnect the generator set engine starting battery, negative (--) lead first.
d. Place an oil collection container below the oil drain and remove the oil drain plug.
e. Allow time for the engine oil to drain completely.
f. Replace the oil drain plug.
2. Replace the oil filter.
a. Remove the oil filter by rotating it counterclockwise with an oil filter wrench.
b. Apply a light coat of clean oil to the rubber seal of the new oil filter.
c. Install the new oil filter following the instructions provided with the filter.
Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner.
3. Fill with oil. Add new oil of the weight, grade, and quantity specified in Section 3.4.
4. Check for leaks.
a. Check that the generator set master switch is in the OFF position.
b. Reconnect the generator set engine starting battery, negative (--) lead last.
c. Reconnect the power to the battery charger, if equipped.
d. Start the generator set and check for leaks around the oil filter.
e. Stop the generator set and tighten the oil filter to stop any leaks.
x:sm:001:003:
26 Section 3 Scheduled Maintenance TP-6392 8/05
3.5 Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
Fuel tanks. Explosive fuel vapors can cause severe injury or death. Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks.
Draining the fuel system.
Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.
3.5.1
Fuel Specifications
Use a clean, good quality diesel fuel oil with a cetane number of 45 or greater. Clean fuel prevents the diesel fuel injectors and pumps from clogging.
United States
Fuel Recommendations
ISO 8217 DMA, BS 2869 A1 or A2
United Kingdom BS 2869-1983, Part 2 Class A2
Germany DIN 51 601-1978
Japan JIS. No. K2204-2
Note: Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to produce flaking that quickly clogs filters or causes fuel pump or injector failure.
Note: Avoid storing fuel for more than one month. Take special precautions to keep all dirt, water, and other contaminants out of fuel to prevent the growth of microbes. Microbes form slime that clogs the fuel filter and lines.
Note: Do not run the generator set out of fuel because the fuel lines will draw in air and necessitate priming the fuel system before restarting the unit.
3.5.2
Fuel Filter
The quality and condition of the fuel largely determine the filter’s useful life. Replace the fuel filter element as listed in the service schedule. Figure 3-1 shows the typical location of a fuel filter.
Use the applicable procedure below to replace the fuel filter.
Fuel Filter Cleaning/Replacement Procedure
1. Close the fuel supply valve.
2. Loosen the fuel filter by turning it counterclockwise.
Remove the fuel filter and use rags to clean up spilled fuel oil.
Dispose of the fuel filter in an approved manner.
3. Clean the contact surface of the fuel oil filter adapter.
4. Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil. Thread the filter on the adapter until the gasket makes contact; hand-tighten the filter an additional one-half turn.
Wash hands after any contact with fuel oil.
5. Open the fuel supply valve.
6. Prime the fuel system. See Section 3.5.4, Priming the Fuel System.
TP-6392 8/05 Section 3 Scheduled Maintenance 27
3.5.3
Fuel/Water Separator
These generator set models include a fuel/water separator. The fuel/water separator helps to remove water and sediment from the fuel system.
Fuel/Water Separator Draining Procedure
At the interval specified in the service schedule, drain the water from the fuel/water separator. Hold a suitable container beneath the fuel/water separator and push up on the drain valve. See Figure 3-5. Release the valve when fuel (free of water) flows from the fuel/water separator.
Fuel/Water Separator’s Element Replacement
Procedure
At the interval specified in the service schedule, replace the fuel/water separator element.
1. Close the fuel valve at the nearest point to the water filter inlet or at the fuel tank.
2. Remove the water drain plug (or push up the drain valve) and allow water and fuel to flow into a suitable container.
Note: Depending upon the location of the fuel valve, a considerable amount of fuel may drain out.
3. Remove the separator’s element from the mounting head by twisting in a counterclockwise direction.
4. Remove the bowl from the fuel/water separator element. Wipe the excess fuel from the bowl and the O-ring. Do not discard the bowl or O-ring.
5. Inspect the components for wear or damage.
Replace parts as necessary.
6. Lubricate the O-ring with clean diesel fuel and replace it in the bowl.
7. Install the bowl onto a new fuel/water separator filter element.
8. Lubricate the bowl/element assembly with clean fuel.
Install the bowl/element onto the filter mounting head.
9. Replace the water drain plug (if removed) and close the vent.
10. Remove the air bleed screw from the fuel/water separator.
11. Open the fuel supply valve.
12. After fuel fills the water separator, allow fuel to flow from the air bleed hole until all air is displaced (fuel flows free of air bubbles).
13. Replace the air bleed screw.
1
3
1. Air bleed screw
2. Drain plug
3. Drain valve
Figure 3-5 Fuel/Water Separator
2
GM32181
28 Section 3 Scheduled Maintenance TP-6392 8/05
3.5.4
Priming the Fuel System
Prime the fuel system under the following conditions:
D
Before starting the engine for the first time
D
After running out of fuel and adding fuel to the tank
D
After fuel system maintenance such as changing the fuel filter, draining the fuel/water separator, or replacing a fuel system component
Note: Do not open the air vent valve while priming the fuel system. The fuel filter has an internal air bleed port.
Do not crank the engine to prime the fuel system. Use the following procedure.
Fuel System Priming Procedure
1. Press and hold the Select button located on the ADC 2100. See Figure 3-1 and Figure 2-1.
2. Move the generator set master switch to the RUN position.
The controller displays the engine runtime.
3. Continue to hold the Select button.
After 10 seconds, the ADC 2100 will display “Fuel” and the fuel priming pump will start.
4. Continue to hold the Select button for as long as you want the fuel priming pump to function
(typically 10 seconds).
5. Release the Select button and move the Master switch to the OFF/RESET position.
6. Place the Master switch to the RUN position to start the unit.
3
1
2
1. ADC 2100 control
2. Select button
3. Generator set master switch
Figure 3-6 ADC 2100 Control
ADV7031-A
TP-6392 8/05 Section 3 Scheduled Maintenance 29
3.6 Air Cleaner
At the interval specified in the service schedule, inspect, clean, or replace the air cleaner element. Clean the element more frequently if the generator operates in dirty, dusty conditions.
Check the element for accumulated oil or dirt that could cause poor performance. Replace a damaged air cleaner element.
Follow the procedure described below. At the time of service, clean the air cleaner breather pipe and remove all dust and foreign matter from the air cleaner housing.
Air Cleaner Element Cleaning or Replacement
Procedure
1. Lift the locking lever and rotate the air cleaner cover counterclockwise to remove it. See Figure 3-7.
2. Slide the air cleaner element from the tube.
3. Tap the element lightly against a flat surface to dislodge loose surface dirt. Do not clean the element in any liquid or use compressed air as these will damage the filter element.
4. Wipe the cover and base with a clean rag to remove any dirt.
5. Ensure tight clamps at the inlet/outlet connections.
6. Slide the air cleaner element into the tube.
7. Position the cover with the dust ejector pointing down. Rotate the cover clockwise until the locking lever snaps into place.
1
2
4
1. Locking lever
2. Cover
3. Dust ejector
4. Element
Figure 3-7 Air Cleaner Components
3
GM39826
3.7 Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.
At the interval specified in the service schedule, inspect the exhaust system.
Inspection Points
Check for exhaust leaks and blockages. Check the muffler and piping condition and check for tight exhaust system connections.
Inspect the exhaust system components for cracks and corrosion (exhaust manifold, exhaust line, exhaust clamps, and muffler).
D
Check for corroded or broken metal parts and replace them as needed.
D
Check for loose, corroded, or missing clamps and hangers.
Tighten or replace the exhaust clamps and/or hangers as needed.
D
Check that the exhaust outlet is unobstructed.
D
Check the exhaust gas color. If the exhaust is blue or black, contact your local distributor/dealer.
D
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.
30 Section 3 Scheduled Maintenance TP-6392 8/05
3.8 Cooling System
WARNING
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.
Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop.
Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank.
3.8.1
Checking the Cooling System
To prevent generator shutdown or damage because of overheating, keep the cooling air inlets clean and unobstructed at all times. Inspect the radiator’s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins. Check the hoses and connections for leaks and replace any cracked, frayed, or spongy hoses.
When checking the coolant level, also check the rubber seal of the radiator’s pressure cap. Replace a cracked or deteriorated cap. See Section 3.8.5. Remove dirt and other debris from the pressure cap and filler neck.
See Figure 3-8 for the thermostat rating.
All Models
Thermostat Rating
82
_C (179_F)
Figure 3-8 Thermostat Rating
3.8.2
Draining the Cooling System
The radiator contains a coolant drain valve to drain the cooling system. When draining the coolant, remove the radiator’s pressure cap: this will allow the entire system to drain and will prevent air pockets from forming and restricting coolant passage to the block.
Note: Pay special attention to the coolant level. After the coolant drains, allow time for complete refill of the engine water jacket. Check the coolant level as described earlier.
3.8.3
Filling the Cooling System
1. Remove the radiator’s pressure cap.
2. Close the radiator’s and/or engine block’s coolant drain valve(s) and tighten the hose clamps.
Note: Do not add coolant to a hot engine.
Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until engine has cooled.
3. Fill the radiator with the recommended coolant mixture of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing. See Figure 3-9 for coolant capacities.
Note: A coolant solution of 50% ethylene glycol provides freezing protection to --37
°C (--34°F) and overheating protection to 129
°C (265°F). A coolant solution with less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine or component damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant.
Consult the engine manufacturer’s operation manual for engine coolant specifications.
4. Replace the radiator’s pressure cap.
5. Operate the engine until the thermostat opens and the radiator upper hose becomes warm.
Model
10REOD/REOZD
15REOD/REOZD
20REOD/REOZD
Engine,
L (Qts.)
1.8 (1.9)
2.0 (2.1)
2.7 (2.8)
Figure 3-9 Coolant Capacities
Engine & Unit-
Mounted Radiator,
L (Qts.)
4.1 (4.3)
9.1 (9.6)
9.3 (9.8)
TP-6392 8/05 Section 3 Scheduled Maintenance 31
6. Stop the engine and allow it to cool.
7. Remove the radiator’s pressure cap.
8. Add coolant to the radiator to just below the overflow tube on the filler neck.
9. Replace the radiator’s pressure cap.
10. Maintain the coolant level in the coolant overflow bottle between the High and Low markings.
Note: Periodically check the coolant level by removing the radiator’s pressure cap. Do not rely solely on the level in the coolant overflow bottle. Add fresh coolant until the level is just below the overflow tube opening.
3.8.4
Flushing and Cleaning
For optimum protection, drain, flush, and refill the cooling system at the interval listed in the service schedule.
Flushing and Cleaning Procedure
1. Remove the pressure cap and open the radiator’s coolant drain valve and let the system drain completely. Remove the pressure cap to simplify draining.
2. Drain, clean, and flush the coolant overflow bottle.
3. Flush the system with clean water.
4. Close the radiator’s coolant drain valve.
5. Fill the system with the recommended coolant.
6. Replace the pressure cap.
3.8.5
Pressure Cap
The cooling system utilizes a pressure cap to raise the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with a cap of the same rating. See Figure 3-10.
Pressure Cap Rating
10REOD/REOZD
15REOD/REOZD
20REOD/REOZD
97 kPa (14 psi)
83--110 kPa (12--16 psi)
Figure 3-10 Pressure Cap Rating
(for inline radiator models)
3.9 Belt Check
Check the belt tension at the intervals specified in the service schedule.
If the tension is not within specification, adjust as necessary using the following procedure.
Note: Also check the fan belt for cracks or tears and replace the belt if necessary.
Adjust the tension of the alternator/fan belt so that the belt can be depressed about 12.7 mm (0.5 in.) when applying finger pressure. Use the following procedure to adjust the belt.
1
4
2
3
1. Battery charging alternator pulley
2. Adjusting screw
3. Check the alternator belt tension here
4. Alternator pivot screw
Figure 3-11 Belt Tension
Belt Tensioning Procedure
1. Disconnect the battery, negative lead first.
2. Loosen the pivot and adjusting screws.
3. While prying the battery charging alternator outward, tighten the adjusting screw.
4. Tighten the pivot screw.
5. Recheck and adjust as necessary.
6. Reconnect the battery, negative lead last.
32 Section 3 Scheduled Maintenance TP-6392 8/05
3.10 Battery
Consult the battery manufacturer’s instructions regarding battery care and maintenance.
WARNING
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.
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 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.
TP-6392 8/05 Section 3 Scheduled Maintenance 33
3.11 Storage Procedure
Perform the following storage procedure before taking a generator set out of service for three months or longer.
Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine component storage.
x:sm:002:001
3.11.1 Lubricating System
Prepare the engine lubricating system for storage as follows:
1. Run the generator set for a minimum of 15 minutes to bring it to normal operating temperature.
2. Stop the generator set.
3. With the engine still warm, drain the oil from the crankcase.
4. Remove and replace the oil filter.
5. Refill the crankcase with oil suited to the climate.
6. Run the generator set for two minutes to distribute the clean oil.
7. Stop the generator set.
8. Check the oil level and adjust, if needed.
x:sm:002:002
3.11.2 Cooling System
Prepare the cooling system for storage as follows:
1. Check the coolant freeze protection using a coolant tester.
2. Add or replace coolant as necessary to ensure adequate freezing protection. Use the guidelines included in the engine operation manual.
3. Run the generator set for 10--15 minutes to redistribute added coolant.
x:sm:002:003
3.11.3 Fuel System
Prepare the fuel system for storage as follows:
Diesel-Fueled Engines
1. Fill the fuel tank with #2 diesel fuel.
2. Condition the fuel system with compatible additives to control microbial growth.
3. Change the fuel filter/separator and prime the fuel system.
x:sm:002:004
3.11.4 Exterior
Prepare the exterior for storage as follows:
1. Clean the exterior surface of the generator set.
2. Seal all engine openings except for the air intake with nonabsorbent adhesive tape.
3. To prevent impurities from entering the air intake and to allow moisture to escape from the engine, secure a cloth over the air intake.
4. Mask electrical connections.
5. Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion.
x:sm:002:006a
3.11.5 Battery
Perform battery storage after all other storage procedures.
1. Place the generator set master switch in the OFF position.
2. Disconnect the battery(ies), negative (--) lead first.
3. Clean the battery.
Refer to the battery manufacturer for the battery cleaning procedure.
4. Place the battery in a cool, dry location.
5. Connect the battery to a float/equalize battery charger or charge it monthly with a trickle battery charger.
Refer to the battery charger manufacturer’s recommendations.
Maintain a full charge to extend battery life.
34 Section 3 Scheduled Maintenance TP-6392 8/05
Section 4 Troubleshooting
This section contains generator set troubleshooting, diagnostic, and repair information.
Use the following charts as a quick troubleshooting reference. The table groups generator set faults and suggests likely causes and remedies. The table also refers you to more detailed information including sections of this manual, the generator set service manual (S/M), the generator set installation manual
(I/M), and the engine service manual (Engine S/M) to correct the indicated problem.
Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional problems caused by incorrect repairs, have an authorized service distributor/dealer perform service.
4.1 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.
4.2 Controller Troubleshooting
Figure 4-1 contains troubleshooting, diagnostic, and repair information for the Advanced Digital Control.
Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment.
x:gt:001:002a:
Problem
Controller LED display is off
Possible Cause
No power to the controller:
The controller automatically powers down if the generator set has not run for 48 hours or longer (if the optional Remote Digital Display is not connected).
Controller fuse (F3) is blown.
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.
Low or no battery voltage.
Generator set master switch is in the OFF/RESET position.
Generator set master switch in AUTO but no start command has been received since last controller reset.
Replace the fuse. If the fuse blows again, contact the distributor/dealer.
Check connections.
Check generator set battery.
Move generator set master switch to the AUTO or RUN position.
No action required. 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 4-1 Controller Troubleshooting Chart
TP-6392 8/05 Section 4 Troubleshooting 35
abnormalnoise
Excessiveor consumption
Highfuel pressure
Lowoil
Overheats
Lackspower suddenly
Stops outputvoltage low Noor
Startshard start doesnot
Cranksbut crank
Doesnot
36 Section 4 Troubleshooting TP-6392 8/05
start
TP-6392 8/05 low doesnot
Cranksbut crank
Doesnot
Startshard outputvoltage
Noor
Stops suddenly
Lackspower
Overheats pressure
Lowoil
Highfuel consumption
Excessiveor abnormalnoise
Section 4 Troubleshooting 37
abnormalnoise
Excessiveor consumption
Highfuel pressure
Lowoil
Overheats
Lackspower suddenly
Stops outputvoltage low Noor
Startshard start doesnot
Cranksbut crank
Doesnot
38 Section 4 Troubleshooting TP-6392 8/05
Section 5 Reconnection/Adjustments
5.1 Four-Lead Reconnection
The following information illustrates the reconnection of four-lead generator sets. In all cases, conform to the
National Electrical Code (NEC).
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.
5.1.1
100--120-Volt Configurations
If the installation requires a factory two-pole circuit breaker, do not connect the load-side terminals of the circuit breaker together; see Figure 5-1.
If the installation requires a 100--120-volt, 2-wire system, use a single-pole circuit breaker. See Figure 5-2. When connecting stator phase leads together, size the output lead (L1) to handle the amperage. Use a jumper lead on the line side of the circuit breaker to balance the load of the generator set.
5.1.2
100--120/200--240-Volt
Configurations
The 100--120/200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight
100--120 volt, 3-wire, remove the jumper lead (see
Figure 5-1 for location).
Select a two-pole circuit breaker. Application of two single-pole circuit breakers does not conform to NEC requirements for supplying a
200--240-volt load, even if the breakers are mechanically attached together. Leads L1 and L2 are for different phases; never connect them together.
L0 (Neutral)
Ground
Load
Side
Single-Pole
Circuit
Breaker
Line
Side
L0
GRD.
L1
Load
Side
Line
Side
L0 (Neutral)
Ground
L0
GRD.
L1
L2
Two-Pole
Circuit
Breaker
4 3 2 1
Stator Leads
60 Hz
L0--L1 100--120 Volt
50 Hz
100--120 Volt
Figure 5-2 100--120 Volt, 2-Wire Configuration
Jumper lead
4 3 2 1
60 Hz
L0--L1 100--120 Volt
L0--L2 100--120 Volt
50 Hz
100--120 Volt
100--120 Volt
Figure 5-1 100--120-Volt, 3-Wire Configuration
TP-6392 8/05 Section 5 Reconnection/Adjustments 39
Load
Side
Line
Side
L0 (Neutral)
Ground
L0
GRD.
L1
L2
Factory
Two-Pole
Circuit
Breaker
100--120/200--240-Volt,
3-Wire
4 3 2 1
Stator Leads
60 Hz
L0--L1 100--120 Volt
L0--L2 100--120 Volt
L1--L2 200--240 Volt
50 Hz
100--120 Volt
100--120 Volt
200--240 Volt
Figure 5-3 100--120/200--240-Volt, 3-Wire
Configuration
5.1.3
200--240-Volt Configurations
The 200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see Figure 5-1 for location). See Figure 5-4.
L0 (Neutral)
Load
Side
Ground
Line
Side
L0
GRD.
L1
Single-Pole
Circuit
Breaker
Tape to insulate from ground
4 1 3
Stator Leads
2
200--220--240 Volt
2 Wire
L0--L1
60 Hz 50 Hz
200-240 Volt 200--220--240 Volt
Figure 5-4 200--220--240-Volt, 2-Wire Configuration
40 Section 5 Reconnection/Adjustments TP-6392 8/05
5.2 Twelve-Lead Reconnection
The reconnection procedure that follows details voltage reconnections only.
If the generator set requires frequency changes, adjust the governor and voltage regulator. See the generator set service manual for information regarding frequency adjustment.
In all cases, follow National Electrical Code (NEC) guidelines.
Reconnect the stator leads of the generator set to change output phase or voltage. Refer to the following procedure and connection schematics. Follow all safety precautions at the front of this manual and in the text during reconnection procedure.
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.
Twelve-Lead Reconnection Procedure
1. Move generator set start/stop switch to the STOP position.
2. Disconnect engine starting battery, negative (--) lead first. Disconnect power to battery charger, if equipped.
3. Use Figure 5-5 to determine generator set voltage configuration. Note original voltage and reconnect as needed.
Single-Phase
Some sets not rated for single phase—see manuals
Not
Used
Generator Connections
3-Phase Delta
110/220 Volt 50 Hz
120/240 Volt 60 Hz
Remove V9 from terminal strip and tape
3-Phase WYE
110/220 Volt 50 Hz
120/240 Volt 60 Hz
3-Phase WYE
190-208 Volt 50 Hz
208-240 Volt 60 Hz
Notes:
CTs not used on all generator sets.
Current transformers dot or “HI” toward generator.
Figure 5-5 12-Lead Generator Reconnection
380-416 Volt 50 Hz
416-480 Volt 60 Hz
TP-6392 8/05
EM-250000
Section 5 Reconnection/Adjustments 41
5.3 ADC 2100 Adjustment after
Reconnection
Figure 5-6 Advanced Digital Control (ADC 2100)
The controller is factory-set for the generator set voltage and frequency and normally does not require adjustment.
If adjustment is necessary, follow the procedures in this section to set the system voltage and frequency parameter (Uu) and then adjust the output voltage.
Note: The unit configuration (UC), engine type (EC), and engine data input type (ED) are factory set and should only be changed by an authorized
Kohler dealer/distributor. Incorrect settings will make your unit non-functional.
5.3.1
Configuration Mode Time Out
The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed.
Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved.
5.3.2
Configuration Mode
Follow the instructions in Figure 5-10 to enter the configuration mode.
The settings are shown in
Figure 5-7. An X in the Display column in Figure 5-10 indicates a number from 0 to 9.
Press the Select button to step through to the Save mode as shown in Figure 5-12.
When SAVE is displayed, press the up arrow to save the new settings or the down arrow to discard the changes and exit the configuration mode without saving.
Pressing the Select button when SAVE is displayed returns to the first parameter, system voltage/frequency
(Uu).
Parameter
Unit configuration
Engine type
Battery Voltage
Communications
Setting
Uu01
Uu03
Uu04
Uu06
Uc01 *
Ec02 *
Ed01 *
Ed02
Bt12 *
Cn00 *
Cn01
* Factory settings.
Figure 5-7 Controller Parameters
Definition
Single phase, 60 Hz, 120/240 VAC
Three phase, 50 Hz, 115/230 or 200/400 VAC
Three phase, 60 Hz, 138/277 or 240/480 VAC
Single phase, 50 Hz, 115/230 VAC
Standby generator set
10/15/20REOD/REOZD
Units with standard oil pressure switch
Units with optional oil pressure sender installed (i.e. for Remote Digital Gauge)
Battery voltage 12 VDC
No CAN communications
J1939 (use for Remote Digital Gauge)
42 Section 5 Reconnection/Adjustments TP-6392 8/05
Voltage Connection
60 Hz, Single phase
50 Hz, Single phase
VAC
120/240
120/208
127/220
120/240
139/240
220/380
277/480
110/220
110/190
110/220
220/380
230/400
240/416
Voltage
Part #
333702
333700
333701
333703
333704
333705
333708
333803
333800
333802
333805
333806
333807
ADC
2100
Setting
Uu01
Uu06
Uu03
Figure 5-8 Uu Parameter Settings for Available
Voltage Connections
5.3.3
Voltage Adjustment
After setting the system voltage parameter Uu, check the output voltage and adjust, if necessary, using the following procedures.
Follow the instructions in
Figure 5-13 to adjust the voltage, gain, and volts/Hz while the engine is running. An X in the Display column in Figure 5-13 indicates a number from 0 to 9. Use the up arrow to increase a setting or the down arrow to decrease the setting.
Pressing the Select button when SAVE is displayed returns to the first parameter, voltage adjust (1P).
Note: A digital multimeter that measures voltage and frequency is required for these adjustments.
WARNING
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Short circuits.
Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.
Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.
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.
Voltage Adjustment Procedure
1. With the generator set off, connect a digital voltmeter to the output leads or an electrical outlet on the load side of the generator set. Set the meter to measure voltage.
2. Start the generator set by moving the generator set master switch to the RUN position.
3. Use the ADC controller to adjust the voltage
(parameter 1P) until the output voltage reaches the desired value. See Figure 5-9.
Measured
85--132
180--251
Approximate
Voltage Change per Step, VAC
Coarse Adjust
5
7
Fine Adjust
0.5
0.7
Figure 5-9 Voltage Adjustment
4. Adjust the voltage stability (gain, parameter 2P) to minimize light flicker.
5. Readjust the voltage, if necessary.
6. Adjust the volts/Hz (parameter 3P) until the voltage level measured by the voltmeter begins to drop.
When the volts/Hz is set correctly, the generator
(as load is applied) attempts to maintain normal output until the engine speed drops below the cut-in frequency.
7. Readjust the voltage stability (gain, parameter 2P), if necessary.
8. Readjust the voltage (parameter 1P), if necessary.
9. Stop the generator set.
TP-6392 8/05 Section 5 Reconnection/Adjustments 43
Controller Configuration Mode (Use with Figure 5-7, Controller Parameters):
Hold the Select button:
Move the generator set master switch to the RUN position. (The generator set engine will not start.)
Display:
.
0
Wait about 5 seconds until the display shows the program version number. (The number may be different than the one shown here.)
Press the down arrow key and then the up arrow key 3 times to enter the configuration mode.
(This is the controller “password.”)
1 1 8
U u 0 x
Now release the Select button.
Press: or
To set the voltage/frequency setting for 60 Hz or
50 Hz models.
or
To step to the next parameter, unit configuration
Uc.
To set the unit configuration setting, if necessary.
U u 0 x
U c 0 x
To step to the next parameter, engine type Ec.
or
To set the engine type, if necessary.
To step to the next parameter, advanced configuration mode or save mode selection.
E c 0 x
A d n c
Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs, battery voltage, and communications.
Press:
To enter advanced configuration mode.
Go to Figure 5-11.
OR: or To proceed to the save mode without entering the advanced configuration mode.
Go to Figure 5-12.
E d 0 x
S A V E
Note: Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed. “x” denotes any number from 0 to 9.
Figure 5-10 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)
44 Section 5 Reconnection/Adjustments TP-6392 8/05
Pressing the up arrow key at the Adnc display (See Figure 5-10) puts you into the Advanced Configuration Mode.
Press: or
To set the engine data input type.
To enter battery voltage selection mode.
E d 0 x or
To toggle between 12 and 24 VDC.
12-volt models
B t 1 2
To enter communications selection mode.
or
To set the communications parameter.
C n 0 x
To enter SAVE mode. Go to Figure 5-12.
S A V E
Note: Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed. “x” denotes any number from 0 to 9.
Figure 5-11 Advanced Configuration Mode (engine data input types, battery voltage, and engine communications)
There are 3 options when the display says SAVE:
Press:
To return to the first parameter, system voltage/frequency
Uu, to check or change settings before saving. See
Figure 5-10.
or
To save changes.
or
To discard changes without saving.
S A V E
U u 0
Y E S n o x
“Yes”or “no” flashes when the up or down arrow is pressed and then the controller exits the configuration mode. The display returns to the runtime hours.
x x x x
Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings when the master switch is moved to the OFF/RESET position.
* x in the runtime hours display above denotes any number from 0 to 9.
Now move the master switch to OFF/RESET.
Figure 5-12 Save Mode (after configuring generator set parameters)
TP-6392 8/05 Section 5 Reconnection/Adjustments 45
Output Voltage Adjustment Mode:
Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours.
Hold:
Wait about 5 seconds until the display changes from runtime hours to the program version number.
Display :* x x x x x.
x x
Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode. (This is the controller “password.”)
1 P x x
The controller is now in the voltage coarse adjustment mode.
Press: or
To raise or lower the voltage in large increments
(approximately 5--7 volts per step).
or or
To enter fine voltage adjustment mode.
To raise or lower the voltage in smaller increments
(approximately 0.5--0.7 volts per step).
To enter coarse voltage stability (gain) adjustment mode.
To raise or lower the voltage stability (gain) in large increments.
or
To enter fine voltage stability (gain) adjustment mode.
To raise or lower the voltage stability (gain) in smaller increments.
1 P
1 P
2 P
2 P x x x x x x x x
To enter volts/Hz adjustment mode.
To raise or lower the volts/Hz: 00=low; 09= high
3 P 0 x or
See Figure 5-12 to save.
* Shaded boxes show which character in the controller display changes for each adjustment. “x” in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.
Figure 5-13 Output Voltage Adjustments
46 Section 5 Reconnection/Adjustments
TP6196
TP-6392 8/05
Section 6 Wiring Diagrams
WARNING
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before working on the generator set.
Remove the negative (--) lead first when disconnecting the battery.
Reconnect the negative (--) lead last when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause severe injury or death.
Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
Hazardous voltage.
Moving rotor.
Can cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.
Open the main circuit breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
TP-6392 8/05 Section 6 Wiring Diagrams 47
Figure 6-1 Wiring Diagram, GM39874-A
48 Section 6 Wiring Diagrams
GM39874-A
TP-6392 8/05
Figure 6-2 Schematic, ADV-7030, Sheet 1
TP-6392 8/05
ADV7030A-
Section 6 Wiring Diagrams 49
Figure 6-3 Schematic, ADV-7030, Sheet 2
50 Section 6 Wiring Diagrams
ADV7030B-
TP-6392 8/05
Figure 6-4 Accessory Connection, GM33846-A
TP-6392 8/05 Section 6 Wiring Diagrams 51
Notes
52 Section 6 Wiring Diagrams TP-6392 8/05
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
ATDC
ATS auto.
aux.
A/V avg.
AVR
AWG
AWM bat.
BBDC
BC
A, amp ampere
ABDC after bottom dead center
AC
A/D alternating current analog to digital
ADC adj.
ADV
AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature
AISI
ALOP alt.
Al
ANSI
American Iron and Steel
Institute anticipatory low oil pressure alternator aluminum
American National Standards
Institute
(formerly American Standards
Association, ASA)
AO
API approx.
approximate, approximately
AR as required, as requested
AS anticipatory only
American Petroleum Institute
ASE
ASME as supplied, as stated, as suggested
American Society of Engineers assy.
ASTM
American Society of
Mechanical Engineers assembly
American Society for Testing
Materials
BCA
BCI
BDC
BHP blk.
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 battery charger, battery charging battery charging alternator
Battery Council International before dead center brake horsepower black (paint color), block
(engine) blk. htr.
block heater
BMEP brake mean effective pressure bps br.
bits per second brass
BTDC before top dead center
Btu British thermal unit
Btu/min.
British thermal units per minute
C cal.
CARB
CB cc
CCA ccw.
CEC cert.
cfh
Celsius, centigrade calorie
California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise
Canadian Electrical Code certificate, certification, certified cubic feet per hour
CT
Cu cu. in.
cw.
CWC cyl.
D/A
DAC dB cfm
CG
CID
CL cm
CMOS cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogen.
com cogeneration communications (port) coml commercial
Coml/Rec Commercial/Recreational conn.
cont.
connection continued
CPVC crit.
CRT
CSA chlorinated polyvinyl chloride critical cathode ray tube
Canadian Standards
Association current transformer copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel dBA
DC
DCR deg.,
° dept.
dia.
DI/EO
DIN decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet
Deutsches Institut fur Normung e. V. (also Deutsche Industrie
Normenausschuss) dual inline package double-pole, double-throw
DIP
DPDT
DPST
DS
DVR double-pole, single-throw disconnect switch digital voltage regulator
E, emer.
emergency (power source)
EDI electronic data interchange
EFR e.g.
emergency frequency relay for example (exempli gratia)
EG
EGSA electronic governor
Electrical Generating Systems
Association
EIA
EI/EO
EMI emiss.
eng.
EPA
Electronic Industries
Association end inlet/end outlet electromagnetic interference emission engine
Environmental Protection
Agency
EPS
ER
ES emergency power system emergency relay engineering special, engineered special
ESD est.
electrostatic discharge estimated
E-Stop emergency stop etc.
et cetera (and so forth) exh.
exhaust
TP-6392 8/05 ext.
F fglass.
FHM fl. oz.
flex.
freq.
FS external
Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale ft.
ft. lb.
foot, feet foot pounds (torque) ft./min.
feet per minute g gram ga.
gal.
gen.
genset
GFI gauge (meters, wire size) gallon generator generator set ground fault interrupter hex
Hg
HH
HHC
HP hr.
HS hsg.
HVAC
GND, gov.
gph gpm ground governor gallons per hour gallons per minute gr.
GRD grade, gross equipment ground gr. wt.
gross weight
H x W x D height by width by depth
HC
HCHT
HD
HET hex cap high cylinder head temperature heavy duty high exhaust temperature, high engine temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning
HWT
Hz
IC
ID
IEC
IEEE high water temperature hertz (cycles per second) integrated circuit inside diameter, identification
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers
IMS in.
improved motor starting inch in. H
2 in. Hg
O inches of water inches of mercury in. lb.
inch pounds
Inc.
ind.
incorporated industrial int.
internal int./ext.
internal/external
I/O
IP
ISO input/output iron pipe
International Organization for
Standardization
J
JIS k
K joule
Japanese Industry Standard kilo (1000) kelvin
Appendix 53
kA
KB kg kg/cm
2 kiloampere kilobyte (2 kilogram
10 bytes) kgm kg/m
3 kHz kJ kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kilojoule km kilometer kOhm, k
Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kVA kVAR kW kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kWh kWm
L
LAN kilowatt-hour kilowatt mechanical liter local area network
L x W x H length by width by height lb.
lbm/ft
3 pound, pounds pounds mass per cubic feet
LCB
LCD line circuit breaker liquid crystal display mJ mm mOhm, m
Ω
MOhm,
M
Ω
MOV
MPa mpg mph
MS m/sec.
MTBF ld. shd.
load shed
LED light emitting diode
Lph
Lpm liters per hour liters per minute
LOP
LP
LPG
LS low oil pressure liquefied petroleum liquefied petroleum gas left side
L wa
LWL
LWT sound power level, A weighted low water level low water temperature m
M meter, milli (1/1000) mega (10
6 when used with SI m
3 m
3 units), male cubic meter
/min.
cubic meters per minute mA man.
milliampere manual max.
MB maximum megabyte (2
20 bytes) one thousand circular mils MCM
MCCB molded-case circuit breaker meggar megohmmeter
MHz mi.
mil min.
misc.
MJ megahertz mile one one-thousandth of an inch minimum, minute miscellaneous megajoule millijoule millimeter milliohm megohm metal oxide varistor megapascal miles per gallon miles per hour military standard meters per second mean time between failure
MTBO mtg.
mean time between overhauls mounting
MW megawatt mW
μF milliwatt microfarad
N, norm.
normal (power source)
NA not available, not applicable nat. gas natural gas
NBS
NC
National Bureau of Standards normally closed
NEC
NEMA
National Electrical Code
National Electrical
Manufacturers Association
NFPA
Nm
NO
National Fire Protection
Association newton meter normally open no., nos.
number, numbers
NPS National Pipe, Straight
NPSC
NPT
NPTF
NR ns
OC
OD
OEM
National Pipe, Straight-coupling
National Standard taper pipe thread per general use
National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer
OF opt.
OS
OSHA overfrequency option, optional oversize, overspeed
Occupational Safety and Health
Administration
OV oz.
p., pp.
PC
PCB pF
PF ph.,
∅
PHC
PHH
PHM
PLC
PMG pot ppm
PROM overvoltage ounce page, pages personal computer printed circuit board picofarad power factor phase
Phillips head crimptite (screw)
Phillips hex head (screw) pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable read-only memory psi pt.
PTC
PTO
PVC qt.
qty.
R pounds per square inch pint positive temperature coefficient power takeoff polyvinyl chloride quart, quarts quantity replacement (emergency) power source rad.
RAM
RDO ref.
radiator, radius random access memory relay driver output reference rem.
remote
Res/Coml Residential/Commercial
RFI
RH
RHM radio frequency interference round head round head machine (screw)
TDES
TDNE
TDOE
TDON temp.
term.
TIF
TIR tol.
turbo.
typ.
V
VAC
VAR
VDC
VFD
VGA
VHF
W
UF
UHF
UL
UNC
UNF univ.
US
UV
WCR w/ w/o wt.
xfmr rly.
rms rnd.
ROM rot.
rpm
RS
RTV
SAE scfm
SCR s, sec.
SI
SI/EO sil.
SN
SPDT
SPST spec, specs sq.
sq. cm sq. in.
SS std.
stl.
tach.
TD
TDC
TDEC
TDEN relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization
Society of Automotive
Engineers standard cubic feet per minute silicon controlled rectifier second
Systeme international d’unites,
International System of Units side in/end out silencer serial number single-pole, double-throw single-pole, single-throw specification(s) square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency
Underwriter’s Laboratories, Inc.
unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer
54 Appendix TP-6392 8/05
Appendix B Operating Hour Service Log
Use the log below to keep a cumulative record of operating hours on your generator set and the dates
Date
Run
Operating Hours
Hours
Run
Total
Hours
Service
Date required services were performed. Enter hours to the nearest quarter hour.
Service Record
Service
TP-6392 8/05 Appendix 55
Notes
56 Appendix TP-6392 8/05
Notes
TP-6392 8/05 57
Notes
58 TP-6392 8/05
TP-6392 8/05
E 2005 by Kohler Co. All rights reserved.
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Advanced Digital Control
- Industrial Generator Set
- Local and remote control
- Fault diagnosis
- Data logging
- Reliable power