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

Operation

Residential/Commercial Generator Sets

Models:

17RES

Controller:

Advanced Digital Control ADC-RES

TP-6515 10/07

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.

Generator Set Identification Numbers

Record the product identification numbers from the
generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.

Controller Description

Engine Identification

Record the product identification information from the
engine nameplate.

Manufacturer

Model Designation

Serial Number

Table of Contents

Product Identification Information 2............................................................

Safety Precautions and Instructions 5........................................................

Introduction 9...............................................................................

Service Assistance 10........................................................................

Section 1 Features 11........................................................................

1.1 Specifications 11.........................................................

1.2 Generator 11............................................................

1.3 Engine 11...............................................................

1.4 Advanced Digital Control 11...............................................

1.5 Generator Set Components 12.............................................

Section 2 Operation 13.......................................................................

2.1 Prestart Checklist 13.....................................................

2.2 Exercising Generator Set 13...............................................

2.3 ADC-RES Controls and Indicators 13.......................................

2.3.1 LED Display 13..................................................

2.3.2 Controller Keypad 14.............................................

2.3.3 Generator Set Master Switch 14...................................

2.4 Controller Power 15......................................................

2.4.1 Standby Mode 15................................................

2.4.2 Sleep Mode 15..................................................

2.5 Generator Set Operation 15...............................................

2.5.1 Starting Generator Set 15.........................................

2.5.2 Stopping Generator Set 15........................................

2.6 Faults 16...............................................................

2.6.1 Shutdowns 16...................................................

2.6.2 Warnings 16.....................................................

2.6.3 Resetting Controller after a Fault Shutdown 16.......................

2.7 Battery Charger 18.......................................................

2.7.1 Battery Charger Operation 18......................................

Section 3 Scheduled Maintenance 19..........................................................

3.1 Routine Maintenance 19..................................................

3.2 Service Schedule 20.....................................................

3.3 Lubrication System 21....................................................

3.3.1 Low Oil Pressure Shutdown 21....................................

3.3.2 Oil Check 21....................................................

3.3.3 Engine Oil Recommendation 21....................................

3.3.4 Oil Change Procedure 21.........................................

3.3.5 Oil Cooler 22....................................................

3.4 Spark Plugs 22..........................................................

3.5 Air Cleaner Service 23....................................................

3.6 Cooling System 23.......................................................

3.7 Exhaust System 24......................................................

3.8 Battery 24...............................................................

3.9 Battery Charger 25.......................................................

3.10 Circuit Protection 25......................................................

3.10.1 Line Circuit Breaker 25...........................................

3.10.2 Fuses 25.......................................................

TP-6515 10/07 Table of Contents

Table of Contents, continued

3.11 Storage Procedure 26....................................................

3.11.1 Lubricating System 26............................................

3.11.2 Fuel System 26..................................................

3.11.3 Cylinder Lubrication 26...........................................

3.11.4 Exterior Preparation 26...........................................

3.11.5 Battery 26.......................................................

Section 4 Troubleshooting 27.................................................................

4.1 Introduction 27..........................................................

4.2 Controller Troubleshooting 27.............................................

4.3 Generator Set Troubleshooting 28..........................................

4.4 Battery Charger Troubleshooting 29........................................

Appendix A Abbreviations 31................................................................

TP-6515 10/07Table of Contents

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.

This manual has severaltypesofsafety
precautions and instructions: Danger,
Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a
hazard that will cause severe

personal injury,death,orsubstantial
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

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set.
Accidental starting can cause
severe injury or death. Before

working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.

Battery

WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.

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

WARNING

Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.

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

Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid

can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.

Battery acid cleanup. Battery acid
can cause severe injury or death.

Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

TP-6515 10/07 5Safety Precautions and Instructions

Battery gases. Explosion can cause
severe injury or death. Battery gases

can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. 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.

Servicing the fuel system. A flash
fire can cause severe injury or death.

Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.

Combustible materials. A fire can
cause severe injury or death.

Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.

Exhaust System

WARNING

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon

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

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.

Engine Backfire/Flash
Fire

WARNING

Fire.
Can cause severe injury or death.

Do not smoke or permit flames or
sparks near fuels or the fuel system.

Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator

set with the air cleaner removed.

Generator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building. Never operate the generator
set where exhaust gas could seep
inside or be drawn into a potentially
occupied building through windows, air
intake vents, or other openings.

TP-6515 10/076 Safety Precautions and Instructions

Fuel System

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

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

Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an

explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. A successful
test depends on the ability of the
solution to bubble.

Hazardous Noise

CAUTION

Hazardous Voltage/
Moving Parts

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

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

Moving parts.

Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution

is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turnoff the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.

Welding on the generator set. Can
cause severe electrical equipment
damage. Before welding on the

generator set perform the following
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery­charging alternator connections.
(5) Attach the weld ground connection
close to the weld location.

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

Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).

Short circuits. Hazardous

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.

TP-6515 10/07 7Safety Precautions and Instructions

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).

voltage/current can cause severe
injury or death. Short circuits can

cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.

Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install

a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.

WARNING

Airborne particles.
Can cause severe injury or
blindness.

Hot Parts

WARNING

Hot engine and exhaust system.
Can cause severe injury or death.

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

Heavy Equipment

WARNING

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

Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.

Do not work on the generator set until
it cools.

Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.

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

Servicing the engine heater. Hot
parts can cause minor personal
injury or property damage. Install the

heater before connecting it to power.
Operating the heater before installation
can cause burns and component
damage. Disconnect power to the
heater and allow it to cool before
servicing the heater or nearby parts.

Notice

NOTICE

Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

TP-6515 10/078 Safety Precautions and Instructions

Introduction

This manual provides operation and maintenance
instructions for model 17RES generator sets equipped
with the Kohlerr ADC-RES Advanced Digital Control.

This generator set is approved for use in stationary
applications in locations served by a reliable utility
power source. Have the generator set installed by an
authorized distributor/dealer or service technician.
Refer to TP-6514, Installation Manual, for installation
instructions.

Information in this publication represents data available
at the time of print. The manufacturer may provide this
manual for models not listed on the front cover. Kohler
Co. reserves the right to change this publication and the
products represented without notice and without any
obligation or liability whatsoever.

Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

Emission Compliance

An engine or generator set with the following
identification label is certified to meet Small Off-Road
Engine emission standards for EPA/CARB.

This engine/generator is certified to operate using
natural gas or propane fuel.

The 17RES generator set engine is certified to meet
emission regulations for U.S. EPA phase 2 small
off-road engines and CA 2006 and later LSI engines
(large spark-ignited engines at or below 1 liter).

The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Obtain service from an authorized service distributor/
dealer to keep equipment in top condition.

Nameplate

The following illustration shows a typical generator set
nameplate. Copy the model, serial, and specification
numbers from the nameplate into the spaces provided in
the product information section on the inside front cover
of this manual. See Section 1.5, Service Views, for the
nameplate location.

Figure 1 Engine Identification Label

The Emission Compliance Period referred to on the
Engine Identification label indicates the number of
operating hours for which the engine has been shown to
meet EPA emission requirements. The engine
compliance period (in hours), associated with the
Category A descriptor found on the certification label, is
1000 hours.

Refer to the certification label for engine displacement.

The exhaust emission control system for the CH980
engine is EM.

TP-6515 10/07 9Introduction

Service Assistance

For professional advice on generator set 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

KohlerPower.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: [phone]
Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

(86) 10 6518 7951
(86) 10 6518 7952

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6515 10/0710 Service Assistance

Section 1 Features

1.1 Specifications

The generator set specification sheets provide specific
generator and engine information. Refer to the spec
sheet for data not supplied in this manual. Consult the
generator set service manual, engine operation manual,
and engine service manual for additional specifications.
Obtain copies of the latest spec sheets, manuals,
diagrams, and drawings from your local distributor/
dealer.

1.2 Generator

The generator uses Kohler’s unique PowerBoostt
voltage regulation system, which provides instant
response to load changes.

PowerBoostt ensures reliable motor starting and
consistent voltage levels. PowerBoostt utilizes a
voltage excitation system that employs a winding
independent of the main output windings to provide
excitation voltage.

1.3 Engine

The generator set has a four-cycle, twin cylinder, air­cooled Kohlerr engine. The engine operates on clean­burning natural gas or propane (LP) vapor. Engine
features include:

D Efficient overhead valve design and full pressure

lubrication for maximum power, torque, and reliability
under all operating conditions.

D Dependable, maintenance-free electronic ignition.

D Precision-formulated cast iron construction of parts

subjected to the most wear and tear.

D Field-convertible multi-fuel systems that allow fuel

changeover from natural gas to LP vapor (and
vice-versa) while maintaining CARB emission
certification.

D Digital spark advance optimizes ignition timing for the

selected fuel.

1.4 Advanced Digital Control

The generator set is equipped with the Kohlerr
ADC-RES Advanced Digital Control. Controller
features include the following:

D Compact controller

D Integrally mounted to the generator set

D LED display:

D Engine runtime, hours
D AC voltage
D Frequency (Hz)
D Engine temperature
D Battery voltage
D Crank cycle status
D Setup information
D Application software version

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 Overfrequency
D Overspeed
D Overvoltage
D Underfrequency
D Undervoltage

D Membrane keypad for configuration and adjustment

D Password-protected user access to menus
D Voltage, gain, and speed adjustment
D System configuration (system voltage, phase, and

frequency settings, battery voltage, and generator
set model)

D Remote two-wire start/stop capability

D Digital isochronous governor to maintain

steady-state speed at all loads

D Digital voltage regulation: ±1.5% RMS no-load to

full-load

D Automatic start for programmed cranking cycle

D Master control switch mounted on the junction box:

Run/Off-Reset/Auto

D Upgradeable application software

TP-6515 10/07 11Section 1 Features

1.5 Generator Set Components

17

Control detail, top view

12

11

8

9

10

See control

12 5421

3

6

18

19

20

22

detail

7

23

30

29

24

28

27

25

25

25

1. Muffler

2. Oil check

3. Oil fill

4. Air cleaner

5. Spark plug locations (both sides)

6. Oil filter

7. Oil cooler location

8. ADC-RES Advanced Digital Control user interface

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

10. Line circuit breaker

11. Fuses

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

13. Engine starting battery location (battery purchased
separately)

14. Oil drain hose

15. Nameplate location (on base)

16. Oil drain valve

16

Figure 1-1 Generator Set Components

13

1415

17. Exhaust outlet

18. Relay board location (optional)

19. Carburetor heater access opening

20. LP fuel orifice location (inside hose fitting)

21. Gas regulator assembly

22. DSAI leads

23. Fuel solenoid valve

24. Fuel inlet

25. Air intake

26. Battery cables

27. Battery charger

28. Field-connection terminal block location (optional)

29. 120 VAC receptacles for battery charger and optional
carburetor heater (provided with optional terminal block)

30. Field connections inside junction box if optional terminal block
is not used

26

ADV-7341A-B

TP-6515 10/0712 Section 1 Features

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering the
engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

the battery manufacturer’s instructions regarding
battery care and maintenance.

Exhaust System. Check for exhaust leaks and
blockages. Check the muffler condition and check for
tight exhaust system connections.

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

D Check for corroded or broken metal parts and replace

them as needed.

2.3 ADC-RES Controls and
Indicators

Figure 2-1 illustrates the ADC-RES user interface and
other items on the generator set junction box.
Figure 2-3 describes the ADC-RES controls and
indicators.

2

1

6

6

3

4

D Check that the exhaust outlet is unobstructed.

Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.

Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.

2.2 Exercising Generator Set

Operate the generator set without load once each week
for 20 minutes. If the generator set is not connected to
an automatic transfer switch (ATS) with an exercise
option, exercise the unit in the presence of an operator.

The operator should perform all of the prestart checks
before starting the exercise procedure. Start the
generator set according to the starting procedure in the
controller section of this manual. While the generator
set is operating, listen for a smooth-running engine and
visually inspect the generator set for fluid or exhaust
leaks. Check the air inlets and outlets and remove any
items restricting the air flow.

5

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

2. LED display

3. Up and down arrow buttons

4. Generator set master switch

5. Line circuit breaker

6. Fuses

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

xxx

Figure 2-1 ADC-RES Controls

2.3.1 LED Display

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

D Move the master switch to RUN.

D With the master switch in AUTO, send a remote start

command (close the remote start contact across
leads 3 and 4).

The LED display indicates generator set status as
shown in Figure 2-3. When the generator set is running,
engine runtime hours are shown unless the arrow

TP-6515 10/07 13Section 2 Operation

buttons are used to step through the other displays as
described in Section 2.3.2.

When the master switch is in AUTO, the display turns off
48 hours after generator set shutdown. See
Section 2.4.

2.3.3 Generator Set Master Switch

The generator set master switch is located on the
junction box below the ADC-RES user interface. The
master switch positions are RUN, OFF/RESET, and
AUTO. See Section 2.5 for operation instructions.

2.3.2 Controller Keypad

The three buttons on the controller keypad are Select,
Up, and Down.

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

The buttons on the controller keypad are also used for
system configuration and adjustment. The system
configuration is factory-set and should not require
changes under normal operating conditions. Contact an
authorized distributor/dealer or service technician if
adjustments are required.

Control or Indicator Item Description

LED display

Keypad Select and arrow

Generator set master
switch

Runtime hours Displays total generator set runtime hours while the generator set is running and when no

Metering display Displays AC voltage (output), frequency, and battery voltage. Press the up or down arrow

Crank indication Displays CC_1, CC_2, or CC_3 to indicate the first, second, or third attempt to start the

Software version
number

Fault codes Flashes a 2- or 3-letter fault code to indicate various fault conditions. See Section 2.6.

buttons

Three-position
switch

other codes are displayed.

when runtime hours are displayed to step through these displays.

engine. The last digit flashes during the crank cycle rest periods.

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

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

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

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

Engine Runtime

XXX.X hours

Output Voltage

VAC

Output Frequency

Hz

Battery Voltage

VDC

tp6515

1. Generator set master switch in AUTO

2. Step through using up or down arrow buttons

3. After 10 seconds, display returns to runtime hours

Figure 2-2 Data Displays

Figure 2-3 ADC-RES Controls and Indicators

TP-6515 10/0714 Section 2 Operation

2.4 Controller Power

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

Note: The generator sets are equipped with factory-

installed battery chargers to prevent battery
discharge. The battery charger must be
connected to 120 VAC.

2.4.1 Standby Mode

When the generator set master switch is in the AUTO
position, the controller is in standby mode. Engine
runtime hours are shown on the display. A remote start
signal (contact closure) will start and run the generator
set.

If there is no start signal for 48 hours, the controller goes
into sleep mode.

Crank Cycle

The controller attempts to start the generator set three
times (three crank cycles, 15 seconds crank and
15 seconds off). See Figure 2-3 for display information
during the crank cycle. If the generator set does not start
in three attempts, the system shuts down on an
overcrank fault. See Section 2.6.

2.5.2 Stopping Generator Set

Local Stopping

1. Run the generator set with no load for at least
2 minutes to ensure adequate engine cooldown.

2. Move the generator set master switch to the
OFF/RESET position. The engine stops.

Automatic Stopping

2.4.2 Sleep Mode

When the generator set master switch is in the AUTO
position, the controller powers down automatically if
there is no start signal for 48 hours after shutdown. The
controller display is dark and battery draw is minimized.
A remote start signal (from a transfer switch or a remote
start/stop switch connected to controller leads 3 and 4)
reactivates the controller. Moving the generator set
master switch to the RUN position also activates the
controller.

2.5 Generator Set Operation

2.5.1 Starting Generator Set

Local Starting

Move the generator set master switch to the RUN
position to immediately start the generator set.

Auto (Automatic) Starting

With the generator set master switch in the AUTO
position, open the contact across engine start leads 3
and 4 to signal the generator set to stop.

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

1. The ATS disconnects the load from the generator
set.

2. If the ATS is equipped with an engine cooldown
time delay, the generator set continues to run for a
preset engine cooldown time.

Note: There is no engine cooldown time delay on

the ADC-RES controller.

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

Move the generator set master switch to the AUTO
position to allow startup by an automatic transfer switch
(ATS) or remote start/stop switch, if equipped. Close a
contact across engine start leads 3 and 4 to signal the
controller to start the generator set.

TP-6515 10/07 15Section 2 Operation

2.6 Faults

Use the following procedure to reset the generator set
controller after a fault shutdown.

2.6.1 Shutdowns

Under the fault shutdown conditions listed in Figure 2-4,
the generator set shuts down automatically and the
controller displays a fault code. The generator set
cannot be restarted until the fault condition is corrected
and the controller is reset. See Section 2.6.3 to reset the
controller after a fault shutdown.

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

2.6.2 Warnings

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

2.6.3 Resetting Controller after a Fault
Shutdown

Always identify and correct the cause of a fault
shutdown before resetting the controller. Check the
fault code displayed on the ADC-RES and refer to
Figure 2-4 to identify and correct the fault condition
before proceeding.

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

2. Disconnect the generator set from the load using
the line circuit breaker or ATS. See the safety
precautions at the beginning of this manual before
proceeding.

3. Identify and correct the cause of the fault
shutdown. See the safety precautions at the
beginning of this manual before proceeding. Refer
to Section 4, Troubleshooting.

4. Start the generator set by moving the generator set
master switch to RUN. Test operate the generator
set to verify that the cause of the shutdown has
been corrected.

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

6. Reconnect the generator set to the load using the
line circuit breaker or ATS.

7. Move the generator set master switch to the AUTO
position for startup by remote transfer switch or
remote start/stop switch.

Note: The controller’s LED display remains off

until an engine start command is received.

TP-6515 10/0716 Section 2 Operation

Code Fault Description Check

Checkforlooseconnection

s

AF Auxiliary fault

input shutdown

HE High engine

temperature
shutdown

LOP Low oil pressure

shutdown

Overcrank

OC

shutdown

Locked rotor The generator set also shuts down on OC if no engine rotation is

OF Overfrequency

shutdown

OS Overspeed

shutdown

OU Overvoltage

shutdown

UF Underfrequency

shutdown

UU Undervoltage

shutdown

HB High battery

voltage warning

LB Low battery

voltage warning

Not used. —

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.

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.

sensed during cranking. Shuts down 3 seconds after the fault is
detected.

Shutdown occurs when the governed frequency exceeds 110% of
the system’s frequency setpoint for more than 5 seconds. This
protective becomes active 10 seconds after engine start
(10 second inhibit).

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

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

Shutdown occurs if the governed frequency falls below 54 Hz for
more than 5 seconds.

Shutdown also occurs if the governed frequency falls below

56.5 Hz for more than 60 seconds.

This 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.

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

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

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

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

Check for blocked air inlets and exhaust
outlets.

Check for leaks in the lubrication system.

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

Check the fuel supply, spark plug, and
battery.

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

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

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

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

Reduce the load and restart the generator
set.

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

Reduce the load and restart the generator
set.

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

Check the battery rating and condition.

Check the battery charger operation.

Check the battery rating and condition.

Check the battery charger operation.

Charge or replace the battery.

.

Figure 2-4 ADC-RES Fault Codes

TP-6515 10/07 17Section 2 Operation

2.7 Battery Charger

The generator set is equipped with a 6-amp
float/equalize battery charger to maintain the engine
starting battery. The charger’s power cord must be
connected to a 120 VAC power source. Figure 2-5
illustrates the battery charger.

The battery charger uses an AGS 10 inline fuse. The
fuse is located in the battery lead. See Figure 2-5.

1

INDICATOR
Red:

VOLTS=11.8--14.0
AMPS=5.0--6.0

Red& Green:

VOLTS=14.0--14.5
AMPS=1.5--5.0

Green:

VOLTS=13.0--13.6
AMPS=0.1--1.5

CAUTION:Toreduce the riskof elect rical shock,

connectonly to properly grounded outlet.

INPUT:115 VAC50/60Hz @ 1.6A

OUTPUT:12 VDC @6 Amps

MAX.BAT.: 180Amp Hr. Max.

DATE:

AllowableBattery Types:Lead Acida nd GelCell

4

6AMP AUTOMATIC
BATTERYCHARGER

R

C USLISTED

BATTERYCHARGER

53AB

2608KH

2

3

1. LED indicators

2. AC power cord

3. Fuse

4. Battery leads, 12 VDC

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

2.7.1 Battery Charger Operation

Figure 2-6 Charging Method

Display Operating Condition

Red ON
Green OFF

Red ON
Green ON

Red OFF
Green ON

When the red LED is on, it indicates the battery is
discharged and the battery charger is recharging at
the BULK rate (stage 1). This charging rate is
6 amps. While the red LED is on, the voltage
measured (with the battery charger on) will be

11.8--14 volts.

If the red LED stays on for more than 24 hours,
refer to Section 4.4 in this manual.

When both the green and the red LEDs are on, the
battery charger is charging at an ABSORPTION
rate of between 1.5 and 5 amps (stage 2). This
mode of charging gradually tops off your battery,
and reduces harmful sulfating. While both LEDs
are on, the voltage measured (with the battery
charger on) should be approximately

14.0--14.5 VDC.

If both LEDs stay on longer than 24 hours, refer to
Section 4.4 in this manual.

When the green LED is on, the battery charger is
charging at a FLOAT or MAINTENANCE rate of
less than 1.5 amps (stage 3). Your battery is now
90% charged and ready for use. This float
charging current will gradually decrease to as low
as 0.1 amps as the battery reaches 100% charge.
It will now be kept at full charge without
overcharging.

If the green LED stays on when your battery is
known to be low, refer to Section 4.4 in this manual.

Figure 2-6 illustrates the three-stage charging method.
Red and green LEDs indicate charger operation. The
chart in Figure 2-7 describes the LED indicator
operation during each stage of the charging process.

Figure 2-7 Battery Charger LED Indicator Functions

TP-6515 10/0718 Section 2 Operation

Section 3 Scheduled Maintenance

WARNING

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the

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

WARNING

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

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.

Moving parts.

3.1 Routine Maintenance

Refer to the following service schedule and the runtime
hours displayed on the ADC-RES display to schedule
routine maintenance. Intervals are shown in hours of
operation and/or time intervals (i.e. weekly, monthly,
quarterly, etc.) Have an authorized distributor/ dealer
service the generator set at the designated intervals in
the service schedule for the life of the generator set.
Service units subject to extreme weather, long operating
hours, or dusty or dirty conditions more frequently.

Hot engine and exhaust system.
Can cause severe injury or death.

Do not work on the generator set until
it cools.

Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The

engine and exhaust system components become extremely
hot during operation.

Contact an authorized distributor/dealer for parts.

TP-6515 10/07 19Section 3 Scheduled Maintenance

3.2 Service Schedule

Procedure

See

System Component or Procedure

Section

Fuel

Flexible lines and connections Q R

Main tank supply level W

Fuel piping Y

Lubrication

Oil level 3.3.2 8orE

Change oil 3.3.4 Yor150

Replace filter 3.3.4 Yor150

Crankcase breather hose Yor500

Oil cooler 3.3.5 Y Yor100

Cooling

Air ducts, louvers Y Y

Exhaust System

Leakage W W

Insulation, fire hazards Y

Obstructions or combustible materials near exhaust outlet W

DC Electrical System

Battery charger operation, charge rate M

Remove corrosion, clean and dry battery and rack Y Y

Clean and tighten battery terminals and inspect boots Y Y

Battery electrolyte level and specific gravity * Y

3.3

3.6

3.7

3.8

AC Electrical System

Tighten control and power wiring connections Y

Remote control system, if equipped M

Visible wear or damage Q

Wire abrasions where subject to motion 6 months 6 months

Wire-cable insulation condition 3Y or 500

Engine and Mounting

Visible wear or damage W

Air cleaner service [

Spark plugs 3.4 150 300

Replace stepper motor coupling and bushing S/M 500 (D)

3.5 150 300

Generator

Visible wear or damage 2.1 Q

Exercise generator set 2.2 W

Brushes and collector ring S/M Y(D) Y(D)

Measure and record resistance readings of windings with
insulation tester (Meggerr, with SCR assembly or rectifier and
load leads disconnected)

S/M 3Y (D)

General Condition of Equipment

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

Interior of sound enclosure Q Q

* Not necessary for maintenance-free batteries.
[ Service more frequently under extremely dusty/dirty conditions.
Meggerr is a registered trademark of Biddle Instruments.

EEachuse
W Weekly
M Monthly
Q Quarterly
Y Yearly

Visually

Inspect

W W W

Check Change Clean Test

Number = hours of operation
D Authorized distributor/dealer only
R Replace as necessary
S/M Service Manual

TP-6515 10/0720 Section 3 Scheduled Maintenance

3.3 Lubrication System

See Section 3.2, Service Schedule, for oil change and
oil filter replacement intervals. See Section 1.5, Service
Views, for the oil drain, oil check, oil fill, and oil filter
locations.

3.3.1 Low Oil Pressure Shutdown

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

Note: The LOP shutdown feature does not protect

against damage caused by operating when the
oil level is low; it is not a low oil level shutdown.
Check the oil level regularly, and add oil as
needed.

3.3.2 Oil Check

The generator set is shipped with oil. Before operating
the generator set, check the engine oil in the crankcase.
See Figure 3-1 for the dipstick location.

Maintain the oil level at or near, not over, the full mark on
the dipstick. Add 5W-30 synthetic oil when the oil level is
low. See Section 3.3.3, Engine Oil Recommendation.

Check the oil level before each use. For extended
operation, check the oil level every 8 hours. Do not
check the oil level when the generator set is running.
Shut down the generator set and wait several minutes
before checking the oil.

and thickens less than other oils and leaves the engine
intake valves and pistons cleaner.

3.3.4 Oil Change Procedure

Note: Dispose of all waste materials (engine oil, fuel,

filter, etc.) in an environmentally safe manner.

Drain the oil while it is still warm.

1. Drain the oil.

a. Place the generator set master switch in the

OFF position.

b. Disconnect the power to the battery charger.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

d. Remove the housing side panel.

e. Clean the area around the dipstick and oil fill

cap.

f. Remove the oil drain hose from its retaining

clip. Remove the cap from the oil drain hose
and lower the hose into an oil collection
container.

g. Open the oil drain valve on the engine.

h. Remove the dipstick and oil fill cap. Allow time

for the engine oil to drain completely.

i. Close the oil drain valve. Replace the cap on

the oil drain hose. Replace the oil drain hose in
its retaining clip.

j. Replace the dipstick.

2. Replace the oil filter.

a. Clean the area around the oil filter. Remove the

oil filter by rotating it counterclockwise with an
oil filter wrench.

b. Clean the gasket sealing surface of the oil filter

adapter.

c. Apply a light coat of clean oil to the rubber seal

of the new oil filter.

6515

Figure 3-1 Oil Check

d. Install the new oil filter following the instructions

provided with the filter.

3.3.3 Engine Oil Recommendation

Use 5W-30 API (American Petroleum Institute) Service
Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes

TP-6515 10/07 21Section 3 Scheduled Maintenance

3. Fill with oil.

a. Fill the engine to the F mark on the dipstick.

The engine oil capacity is approximately 2.8 L
(3.0 qt.). See Section 3.3.3, Engine Oil
Recommendation, for oil selection.

b. Reinstall the dipstick and the oil fill cap.

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

3.4 Spark Plugs

Reset the spark plug gap or replace the plugs with new
plugs as necessary.

c. Check that the generator set master switch is in

the OFF position.

d. Reconnect the generator set engine starting

battery, negative (--) lead last.

e. Reconnect the power to the battery charger.

f. Start and run the generator set for a minute to

allow the oil pressure to reach operating range.

g. Stop the generator set, wait 1 minute, and then

recheck the oil level. Add oil to bring the level
up to the F mark on the dipstick.

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

3.3.5 Oil Cooler

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

1. Clean the area around the base of the spark plug to
keep dirt and debris out of the engine.

2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is
questionable.

3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.76 mm (0.030 in.) by
carefully bending the ground electrode. See
Figure 3-3 and Figure 3-4.

4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 24.4--29.8 Nm
(18--22 ft. lb.)

1--514

Figure 3-3 Checking the Spark Plug Gap

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

1. Oil cooler

1

62 590 01

Figure 3-2 Oil Cooler Location

1--511

Figure 3-4 Adjusting the Spark Plug Gap

TP-6515 10/0722 Section 3 Scheduled Maintenance

3.5 Air Cleaner Service

The engine is equipped with a replaceable, high density
paper air cleaner element. See Figure 3-5.

1

Kohler element. Handle new elements carefully;
do not use if the sealing surfaces are bent or
damaged.

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

2

3

4

tp6515

1. Knobs (qty.2)

2. Cover

3. Paper element

4. Air filter latch

Figure 3-5 Air Cleaner Components

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

Note: Operating the engine with loose or damaged air

cleaner components could allow unfiltered air
into the engine causing premature wear and
failure.

Note: If any loose dirt or debris fell on the air cleaner

base when the element was removed, carefully
remove it and wipe the base clean. Be careful that
none of it drops into the intake throat.

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

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

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

3.6 Cooling System

The engine fan draws cooling air through the openings
in the sides and end near the battery. The alternator fan
draws cooling air through openings on the side walls of
the enclosure. The cooling air mixes with the engine
exhaust and is discharged at the exhaust outlet. See
Figure 3-6. To prevent generator set damage caused by
overheating, keep the housing cooling inlets and outlets
clean and unobstructed at all times.

Note: Do not block the generator set cooling air inlets or

mount other equipment above them.
Overheating and severe generator damage may
occur.

Paper Element Service

Replace the paper element at the intervals indicated in
the service schedule. See Section 3.2 for the service
schedule. See Figure 3-5 for the air cleaner
components.

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

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

3. Do not wash the paper element or use pressurized
air, as this will damage the element. Replace a
dirty, bent, or damaged element with a genuine

TP-6515 10/07 23Section 3 Scheduled Maintenance

1

2

1. Exhaust outlet

2. Alternator air intake (both sides)

3. Engine air intake

Figure 3-6 Cooling Air Intake and Exhaust

3

3

tp6195

3.7 Exhaust System

Remove all combustible materials from the exhaust
location. Combustible materials include building
materials as well as natural surroundings. Keep dry field
grass, foliage, and combustible landscaping material a
minimum of 1.5 m (5 ft.) from the exhaust outlet.

Periodically inspect the exhaust system components for
cracks, leaks, and corrosion.

D Check for corroded or broken metal parts and replace

them as needed.

D Check that the exhaust outlet is clear.

3.8 Battery

WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.

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

Battery electrolyte is a diluted sulfuric acid. Battery acid
can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety
goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If
battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of
clean water. Seek immediate medical aid in the case of eye
contact. Never add acid to a battery after placing the battery in
service, as this may result in hazardous spattering of battery
acid.

Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke

or permit flames or sparks to occur near a battery at any time,
particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or

equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the
battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
starter solenoid. Do not test the battery condition by shorting
the terminals together.

Refer to this section for general battery information and
maintenance. Also consult the battery manufacturer’s
instructions for battery maintenance.

All generator set models use a negative ground with a
12-volt engine electrical system. Consult the generator
set nameplate for the engine electrical system voltage.
Consult the generator spec sheet for battery capacity
recommendations for replacement purposes. Wiring
diagrams provide battery connection information. See
Figure 3-7 for typical battery connections.

1

2

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.

EZ-273000-J

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

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

Figure 3-7 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery Connection

TP-6515 10/0724 Section 3 Scheduled Maintenance

Clean the battery and cables and tighten battery
terminals using the service schedule recommendations.
To prevent corrosion, maintain tight, dry electrical
connections at the battery terminals. To remove
corrosion from battery terminals, disconnect the cables
from the battery and scrub the terminals with a wire
brush. Clean the battery and cables with a solution of
baking soda and water. After cleaning, flush the battery
and cables with clean water and wipe them with a dry,
lint-free cloth.

After reconnecting the battery cables, coat the battery
terminals with petroleum jelly, silicone grease, or other
nonconductive grease.

3.9 Battery Charger

3.10 Circuit Protection

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

3.10.1 Line Circuit Breaker

A line circuit breaker interrupts the generator output in
the event of a fault in the wiring between the generator
and the load. The line circuit breaker location is shown
in Figure 1-1. The circuit breaker rating is shown in
Figure 3-9. If the circuit breaker trips, reduce the load
and switch the breaker back to the ON position. With the
breaker in the OFF position the generator set runs but
the generator output is disconnected from the load.

The generator set is equipped with a 6-amp
float/equalize battery charger to maintain the engine
starting battery. Figure 3-8 illustrates the battery
charger.

The charger’s DC leads are factory-wired. Periodically
tighten all connections.

1

2

INDICATOR
Red:

VOLTS=11.8--14.0
AMPS=5.0--6.0

Red& Green:

VOLTS=14.0--14.5
AMPS=1.5--5.0

Green:

VOLTS=13.0--13.6
AMPS=0.1--1.5

CAUTION:Toreduce the riskof elect rical shock,

connectonly to properly gr ounded outlet.

INPUT:115 VAC50/60Hz @ 1.6A

OUTPUT:12 VDC @6 Amps

MAX.BAT.: 180Amp Hr. Max.

DATE:

AllowableBattery Types:Lead Acida ndGel Cell

6AMP AUTOMATIC
BATTERYCHARGER

R

C USLISTED

BATTERYCHARGER

53AB

2608KH

5

4

2

3

Model Circuit Breaker Rating, Amp

17RES 70

Figure 3-9 Line Circuit Breaker Rating

3.10.2 Fuses

Three panel-mounted fuses protect the alternator and
electrical controls. See Section 1.5 for fuse locations.
Another 10-amp fuse protects the battery charger. See
Figure 3-8 for the battery charger fuse location.

See Figure 3-10 for fuse part numbers. Always identify
and correct the cause of a blown fuse before restarting
the generator set. Refer to Section 4, Troubleshooting,
for conditions that may indicate a blown fuse. Replace
blown fuses with identical replacement parts.

Fuse Rating, Amp Label Part Number

Auxiliary winding 20 F1 292937

Relay interface board 10 F2 223316

Controller 10 F3 223316

Battery charger 10 — AGS 10

1. LED indicators

2. Mounting flanges

4. Fuse

5. Battery leads, 12 VDC

3. AC power cord

Figure 3-8 6-Amp Float/Equalize Battery Charger

TP-6515 10/07 25Section 3 Scheduled Maintenance

Figure 3-10 Fuses

3.11 Storage Procedure

3.11.3 Cylinder Lubrication

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

Note: Run the generator set monthly whenever

possible.

3.11.1 Lubricating System

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

2. Stop the generator set.

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

4. Refill the engine crankcase with oil. See Section

3.3.3 for oil recommendations.

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

6. Stop the generator set.

3.11.2 Fuel System

1. Start the generator set.

1. Remove the spark plugs.

2. Pour one tablespoon of engine oil into each spark
plug hole. Install the spark plugs and ground the
spark plug leads. Do not connect the leads to the

plugs.

3. Toggle the generator set master switch to crank the
engine two or three revolutions to lubricate the
cylinders.

3.11.4 Exterior Preparation

1. Clean the exterior surface of the generator set.

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

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

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

3.11.5 Battery

Perform battery storage last.

1. Place the generator set master switch in the OFF/
RESET position.

2. With the generator set running, shut off the gas
supply.

3. Run the generator set until the engine stops.

4. Place the generator set master switch in the OFF/
RESET position.

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

3. Clean the battery.

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

5. Connect the battery to a float/equalize battery
charger, or charge the battery monthly using a
trickle charger. Follow the battery charger
manufacturer’s recommendations.

TP-6515 10/0726 Section 3 Scheduled Maintenance

Section 4 Troubleshooting

4.1 Introduction

Use the following charts to diagnose and correct
common problems. First check for simple causes such

4.2 Controller Troubleshooting

Figure 4-1 contains troubleshooting, diagnostic, and

repair information for the ADC-RES controller.
as a dead engine starting battery, loose connections, or
an open circuit breaker. The charts include a list of
common problems, possible causes of the problem, and
recommended corrective actions.

If the procedures in this manual do not explain how to
correct the problem, contact an authorized distributor/
dealer. Maintain a record of repairs and adjustments
performed on the equipment. Use the record to help
describe the problem and repairs or adjustments made
to the equipment.

Problem Possible Cause Corrective Action

Controller LED
displayisoff

No power to the controller:

The generator set has not run for 48 hours or
longer and the controller has powered down.

Controller fuse (F3) is blown. Replace the fuse. If the fuse blows again, contact the

Low or no battery voltage. Check connections.

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.

Controller display will automatically activate when a remote start
command is received or the generator set master switch is
moved to the RUN position. See Section 2.4.

distributor/dealer.

Check generator set battery and battery charger. See
Figure 4-2.

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

Controller display will activate when a remote start command is
received or the generator set master switch is moved to the
RUN position. Use the remote switch to start generator set and
activate the controller display, if desired. See Section 2.3.1.

Figure 4-1 ADC-RES Troubleshooting Chart

TP-6515 10/07 27Section 4 Troubleshooting

4.3 Generator Set Troubleshooting

g

a

t

erratically

.

p

p

If a fault code is displayed, identify and correct the cause

of the fault condition. Then reset the controller. See
Figure 4-2 contains generator set troubleshooting,

Section 2.6.3.
diagnostic, and repair information. Check for loose
connections before replacing parts.

Fault Codes

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

Problem Possible Cause Corrective Action

The generator set
does not crank.

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

No AC output.

Low output or
excessive drop in
voltage.

Generator set stops
suddenly.

es

Fault shutdown Check for a fault code on the controller display. See

Battery weak or dead Check power to the battery charger.

Battery charger fuse blown Replace the fuse. Contact an authorized distributor/dealer

Battery connections reversed or poor Check the connections.

Fuse F2 blown Replace the fuse. Contact an authorized distributor/dealer

Fuse F3 blown Replace the fuse. Contact an authorized distributor/dealer

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

Air cleaner clogged Clean and/or replace the air cleaner.

Battery weak or dead Check power to the battery charger.

Battery connection poor Clean and tighten the battery connections.

Spark plug wire connection loose Check the spark plug wires.

Low oil pressure shutdown Check the oil level.

Fuel pressure insufficient Check the fuel supply and valves.

Engine malfunction Contact the distributor/dealer.

AC circuit breaker in the OFF position Place the circuit breaker in the ON position.

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

AC circuit breaker tripping because of short circuit Contact an authorized distributor/dealer for service.

Auxiliary winding fuse (F1) blown Replace the fuse. Contact an authorized distributor/dealer

Generator set overloaded Reduce the load.

Low oil pressure shutdown Check the oil level.

Outoffuel Check fuel supply.

Overcrank shutdown Reset the controller. If the overcrank fault occurs again,

Controller fuse (F3) blown Replace the fuse. If the fuse blows again, contact the

Overspeed shutdown Reset the controller. If the overspeed fault occurs again,

Generator set master switch in the OFF/RESET
position

Remote stop command received from a remote switch
or ATS

Engine malfunction Contact the distributor/dealer.

Auxiliary winding fuse (F1) blown Replace the fuse. Contact an authorized distributor/dealer

Section 2.6.

Recharge or replace the battery.

for service if fuse blows repeatedly.

for service if fuse blows repeatedly.

for service if fuse blows repeatedly.

RUN for local start.

Recharge or replace the battery.

for service if fuse blows repeatedly.

contact the distributor/dealer.

distributor/dealer.

contact the distributor/dealer.

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

Check the remote switch position.

for service if fuse blows repeatedly.

Figure 4-2 General Troubleshooting Chart

TP-6515 10/0728 Section 4 Troubleshooting

4.4 Battery Charger

y

y

24h

y

a

batteryisknow

n

LEDsturno

n

Troubleshooting

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

Problem Cause Solution

Red LED stays
on for more than
24 hours

Red and green
LEDs stay on for
more than

ours

Green LED stays
on when the

tteryis known

b
to be low

Neither of the
LEDs turn on
when the AC
power is applied

One or more inoperative or damaged cells. Load test the battery and replace, if necessary

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

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

Onboard DC systems are drawing between 1.5 and
5amps.

One or more inoperative or damaged cells. Load test the battery and replace, if necessary

Extremely low AC voltage at the battery charger. Apply a higher AC voltage source or reduce the length of the

Open DC output fuse. Replace AGS-10 fuse.

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

One or more inoperative or damaged cells. Load test the battery and replace, if necessary.

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

Component failure. Replace battery charger.

Remove the source of the overload or short. Disconnect the
battery charger’s black (NEGATIVE) ring terminal from the
battery. Reapply AC power and the green LED only should now
light.

Turn off all DC equipment while charging.

Turn off all DC equipment while charging.

extension cord.

Figure 4-3 Battery Charger Troubleshooting

TP-6515 10/07 29Section 4 Troubleshooting

Notes

TP-6515 10/0730 Section 4 Troubleshooting

Appendix A Abbreviations

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

A, amp ampere
ABDC after bottom dead center
AC alternating current
A/D analog to digital
ADC advanced digital control;

adj. adjust, adjustment
ADV advertising dimensional

Ah amp-hour
AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure
alt. alternator
Al aluminum
ANSI American National Standards

AO anticipatory only
APDC Air Pollution Control District
API American Petroleum Institute
approx. approximate, approximately
AQMD Air Quality Management District
AR as required, as requested
AS as supplied, as stated, as

ASE American Society of Engineers
ASME American Society of

assy. assembly
ASTM American Society for Testing

ATDC after top dead center
ATS automatic transfer switch
auto. automatic
aux. auxiliary
avg. average
AVR automatic voltage regulator
AWG American Wire Gauge
AWM appliance wiring material
bat. battery
BBDC before bottom dead center
BC battery charger, battery

BCA battery charging alternator
BCI Battery Council International
BDC before dead center
BHP brake horsepower
blk. black (paint color), block

blk. htr. block heater
BMEP brake mean effective pressure
bps bits per second
br. brass
BTDC before top dead center
Btu British thermal unit
Btu/min. British thermal units per minute
C Celsius, centigrade
cal. calorie
CAN controller area network
CARB California Air Resources Board
CB circuit breaker
cc cubic centimeter
CCA cold cranking amps
ccw. counterclockwise
CEC Canadian Electrical Code
cert. certificate, certification, certified
cfh cubic feet per hour

analog to digital converter

drawing

temperature

Institute

Institute (formerly American
Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfm cubic feet per minute
CG center of gravity
CID cubic inch displacement
CL centerline
cm centimeter
CMOS complementary metal oxide

cogen. cogeneration
com communications (port)
coml commercial
Coml/Rec Commercial/Recreational
conn. connection
cont. continued
CPVC chlorinated polyvinyl chloride
crit. critical
CRT cathode ray tube
CSA Canadian Standards

CT current transformer
Cu copper
cUL Canadian Underwriter’s

CUL Canadian Underwriter’s

cu. in. cubic inch
cw. clockwise
CWC city water-cooled
cyl. cylinder
D/A digital to analog
DAC digital to analog converter
dB decibel
dB(A) decibel (A weighted)
DC direct current
DCR direct current resistance
deg., ° degree
dept. department
DFMEA Design Failure Mode and

dia. diameter
DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung

DIP dual inline package
DPDT double-pole, double-throw
DPST double-pole, single-throw
DS disconnect switch
DVR digital voltage regulator
E, emer. emergency (power source)
ECM electronic control module,

EDI electronic data interchange
EFR emergency frequency relay
e.g. for example (exempli gratia)
EG electronic governor
EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet
EMI electromagnetic interference
emiss. emission
eng. engine
EPA Environmental Protection

EPS emergency power system
ER emergency relay
ES engineering special,

ESD electrostatic discharge

substrate (semiconductor)

Association

Laboratories

Laboratories

Effects Analysis

e. V. (also Deutsche Industrie
Normenausschuss)

engine control module

Association

Association

Agency

engineered special

est. estimated
E-Stop emergency stop
etc. et cetera (and so forth)
exh. exhaust
ext. external
F Fahrenheit, female
fglass. fiberglass
FHM flat head machine (screw)
fl. oz. fluid ounce
flex. flexible
freq. frequency
FS full scale
ft. foot, feet
ft. lb. foot pounds (torque)
ft./min. feet per minute
ftp file transfer protocol
ggram
ga. gauge (meters, wire size)
gal. gallon
gen. generator
genset generator set
GFI ground fault interrupter

GND,
gov. governor
gph gallons per hour
gpm gallons per minute
gr. grade, gross
GRD equipment ground
gr. wt. gross weight
H x W x D height by width by depth
HC hex cap
HCHT high cylinder head temperature
HD heavy duty
HET high exhaust temp., high

hex hexagon
Hg mercury (element)
HH hex head
HHC hex head cap
HP horsepower
hr. hour
HS heat shrink
hsg. housing
HVAC heating, ventilation, and air

HWT high water temperature
Hz hertz (cycles per second)
IC integrated circuit
ID inside diameter, identification
IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting
in. inch
in. H
in. Hg inches of mercury
in. lb. inch pounds
Inc. incorporated
ind. industrial
int. internal
int./ext. internal/external
I/O input/output
IP iron pipe
ISO International Organization for

J joule
JIS Japanese Industry Standard

ground

engine temp.

conditioning

Commission

Electronics Engineers

O inches of water

2

Standardization

TP-6515 10/07 Appendix 31

k kilo (1000)
K kelvin
kA kiloampere
KB kilobyte (2

10

bytes)
KBus Kohler communication protocol
kg kilogram

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter
kHz kilohertz
kJ kilojoule
km kilometer
kOhm, kΩ kilo-ohm
kPa kilopascal
kph kilometers per hour
kV kilovolt
kVA kilovolt ampere
kVAR kilovolt ampere reactive
kW kilowatt
kWh kilowatt-hour
kWm kilowatt mechanical
kWth kilowatt-thermal
L liter
LAN local area network
L x W x H length by width by height
lb. pound, pounds

3

lbm/ft

pounds mass per cubic feet
LCB line circuit breaker
LCD liquid crystal display
ld. shd. load shed
LED light emitting diode
Lph liters per hour
Lpm liters per minute
LOP low oil pressure
LP liquefied petroleum
LPG liquefied petroleum gas
LS left side
L

wa

LWL low water level

sound power level, A weighted

LWT low water temperature
m meter, milli (1/1000)
M mega (10

3

m

3

m

3

m

units), male

cubic meter

/hr. cubic meters per hour
/min. cubic meters per minute

6

when used with SI

mA milliampere
man. manual
max. maximum
MB megabyte (2

20

bytes)
MCCB molded-case circuit breaker
MCM one thousand circular mils
meggar megohmmeter
MHz megahertz
mi. mile
mil one one-thousandth of an inch
min. minimum, minute
misc. miscellaneous
MJ megajoule
mJ millijoule
mm millimeter
mOhm, mΩmilliohm
MOhm, MΩmegohm
MOV metal oxide varistor
MPa megapascal
mpg miles per gallon
mph miles per hour
MS military standard
ms millisecond
m/sec. meters per second
MTBF mean time between failure

MTBO mean time between overhauls
mtg. mounting
MTU Motoren-und Turbinen-Union
MW megawatt
mW milliwatt
μF microfarad
N, norm. normal (power source)
NA not available, not applicable
nat. gas natural gas
NBS National Bureau of Standards
NC normally closed
NEC National Electrical Code
NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association
Nm newton meter
NO normally open
no., nos. number, numbers
NPS National Pipe, Straight
NPSC National Pipe, Straight-coupling
NPT National Standard taper pipe

thread per general use
NPTF National Pipe, Taper-Fine
NR not required, normal relay
ns nanosecond
OC overcrank
OD outside diameter
OEM original equipment

manufacturer
OF overfrequency
opt. option, optional
OS oversize, overspeed
OSHA Occupational Safety and Health

Administration
OV overvoltage
oz. ounce
p., pp. page, pages
PC personal computer
PCB printed circuit board
pF picofarad
PF power factor
ph., ∅ phase
PHC Phillipsr head Crimptiter

(screw)
PHH Phillipsr hex head (screw)
PHM pan head machine (screw)
PLC programmable logic control
PMG permanent magnet generator
pot potentiometer, potential
ppm parts per million
PROM programmable read-only

memory
psi pounds per square inch
psig pounds per square inch gauge
pt. pint
PTC positive temperature coefficient
PTO power takeoff
PVC polyvinyl chloride
qt. quart, quarts
qty. quantity
R replacement (emergency)

power source
rad. radiator, radius
RAM random access memory
RDO relay driver output
ref. reference
rem. remote
Res/Coml Residential/Commercial
RFI radio frequency interference
RH round head
RHM round head machine (screw)
rly. relay

rms root mean square
rnd. round
ROM read only memory
rot. rotate, rotating
rpm revolutions per minute
RS right side
RTU remote terminal unit
RTV room temperature vulcanization
RW read/write
SAE Society of Automotive

Engineers
scfm standard cubic feet per minute
SCR silicon controlled rectifier
s, sec. second
SI Systeme international d’unites,

International System of Units
SI/EO side in/end out
sil. silencer
SN serial number
SNMP simple network management

protocol
SPDT single-pole, double-throw
SPST single-pole, single-throw
spec specification
specs specification(s)
sq. square
sq. cm square centimeter
sq. in. square inch
SS stainless steel
std. standard
stl. steel
tach. tachometer
TD time delay
TDC top dead center
TDEC time delay engine cooldown
TDEN time delay emergency to

normal
TDES time delay engine start
TDNE time delay normal to

emergency
TDOE time delay off to emergency
TDON time delay off to normal
temp. temperature
term. terminal
THD total harmonic distortion
TIF telephone influence factor
TIR total indicator reading
tol. tolerance
turbo. turbocharger
typ. typical (same in multiple

locations)
UF underfrequency
UHF ultrahigh frequency
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
US undersize, underspeed
UV ultraviolet, undervoltage
V volt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
W watt
WCR withstand and closing rating
w/ with
w/o without
wt. weight
xfmr transformer

TP-6515 10/0732 Appendix

TP-6515 10/07

E 2007 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]
For the nearest sales/service outlet in the
US and Canada, phone [phone]
KohlerPower.com

Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]