Kohler 8.5RES, 12RES User Manual

Download

Operation

Residential/Commercial Generator Sets

Models:

8.5RES 12RES

Controller:

Advanced Digital Control (ADC 2100)

TP-6331 5/04

California Proposition 65

WARNING

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

Product Identification Information

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

Generator Set Identification Numbers

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

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Controller Identification

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

Controller Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

Table of Contents

Product Identification Information Inside front cover............................................

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

Introduction i...............................................................................

Service Assistance ii........................................................................

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

1.1 Specifications 1.........................................................

1.2 Generator 1............................................................

1.3 Engine 1...............................................................

1.4 Advanced Digital Control 1...............................................

1.5 Generator Set Components 2.............................................

Section 2 Operation 3.......................................................................

2.1 Prestart Checklist 3.....................................................

2.2 Exercising Generator Set 3...............................................

2.3 Generator Set Operation 3...............................................

2.3.1 Controls and Indicators 4........................................

2.3.2 Starting Generator Set 4.........................................

2.3.3 Stopping Generator Set 4........................................

2.4 Fault Shutdowns 5......................................................

2.4.1 Resetting Controller after a Fault Shutdown 6.......................

2.5 Continuous Power Mode 6...............................................

2.6 Battery Charger 7.......................................................

2.6.1 Battery Charger Operation 7......................................

Section 3 Scheduled Maintenance 9..........................................................

3.1 Routine Maintenance 9..................................................

3.2 Service Schedule 10.....................................................

3.3 Lubrication System 11....................................................

3.3.1 Low Oil Pressure Shutdown 11....................................

3.3.2 Oil Check 11....................................................

3.3.3 Engine Oil Recommendation 11....................................

3.3.4 Oil Change Procedure 11.........................................

3.4 Spark Plugs 12..........................................................

3.5 Air Cleaner Element and Precleaner 12.....................................

3.5.1 Precleaner Service 12............................................

3.5.2 Paper Element Service 13.........................................

3.6 Cooling System 14.......................................................

3.7 Exhaust System 14......................................................

3.8 Battery 14...............................................................

3.9 Battery Charger 15.......................................................

3.10 Circuit Protection 16......................................................

3.10.1 Line Circuit Breaker 16...........................................

3.10.2 Fuses 16.......................................................

3.11 Storage Procedure 16....................................................

3.11.1 Lubricating System 16............................................

3.11.2 Fuel System 16..................................................

3.11.3 Cylinder Lubrication 17...........................................

3.11.4 Exterior Preparation 17...........................................

3.11.5 Battery 17.......................................................

TP-6331 5/04 Table of Contents

Table of Contents, continued

Section 4 Troubleshooting 19.................................................................

4.1 Introduction 19..........................................................

4.2 Generator Set Troubleshooting 19..........................................

4.3 Fault Codes 20..........................................................

4.4 Troubleshooting 20.......................................................

4.5 Battery Charger Troubleshooting 20........................................

Appendix A Abbreviations A-1..................................................................

TP-6331 5/04Table 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-6331 5/04 ISafety 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.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

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

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

set with the air cleaner removed.

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

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

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

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

Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

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

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

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

monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

TPTPS-6331 5/04II Safety Precautions and Instructions

Fuel System

Hazardous Noise

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly

explosive. Use extreme care when handling and storing fuels. Store fuels inawell-ventilatedareaawayfrom 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. Donot operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

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

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

CAUTION

Hazardous noise. Can cause hearing loss.

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

Engine noise. Hazardous noise can cause hearing loss. Generator sets

not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Electrical Shock

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

WARNING

Hazardous voltage. Can cause severe injury or death.

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

Moving rotor.

Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death.

If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

CAUTION

Welding the generator set. Can cause severe electrical equipment damage.

Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM).

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

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

TP-6331 5/04 IIISafety Precautions and Instructions

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

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

Installing the battery charger. Hazardous voltage can cause severe injury or death. An

ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.

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

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

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

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

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

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

Heavy Equipment

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

Do not work on the generator set until it cools.

Servicing the generator. Hot parts can cause severe injury or death.

Avoid touching the generator set field or exciter armature. When shorted, the generator set field and exciter armature become hot enough to cause severe burns.

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

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

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

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

Moving Parts

WARNING

Hazardous voltage. Can cause severe injury or death.

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

WARNING

Rotating parts. Can cause severe injury or death.

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

WARNING

Airborne particles. Can cause severe injury or blindness.

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

Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause

the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

Moving rotor.

TPTPS-6331 5/04IV Safety Precautions and Instructions

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

246242

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

NOTICE

Electrostatic discharge damage.

Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short,to ground.

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are

available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

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

TP-6331 5/04 VSafety Precautions and Instructions

Notes

TPTPS-6331 5/04VI Safety Precautions and Instructions

Introduction

This manual provides operation and maintenance instructions for model 8.5RES and 12RES generator sets equipped with the Kohlerr Advanced Digital Control (ADC 2100).

This generator set is approved for use in stationary applications in locations served by a reliable utility power source. Have the generator set installed by an authorized distributor/dealer or service technician. Refer to TP-6328, Installation Manual, for installation instructions.

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

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

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

EPA and California Emission Certification

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

8.5RES and 12RES generator sets with multi-fuel systems are emission-certified.

tp6195

Figure 1 Emissions Label, 8.5RES Engine (CH20)

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 2 Emissions Label, 12 RES Engine (CH740)

TP-6331 5/04 iIntroduction

tp6195

of operating hours for which the engine has been shown to meet CARB emission requirements. The following table provides the engine compliance period (in hours) associated with the category descriptor found on the certification label.

Emission Compliance Period (hours)

CARB

Moderate,

125

Intermediate,

250

Extended,

500

Figure 3 Air Index Label, 8.5/12RES

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

The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number

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

Refer to the certification label for engine displacement.

The exhaust emission control system for the 8.5RES (CH20) and 12RES (CH740) is EM.

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

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 264-6422 Fax: (65) 264-6455

TP-6331 5/04ii 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 clean-burning 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.

1.4 Advanced Digital Control

The generator set is equipped with the Kohlerr 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

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 Voltage, gain, and speed adjustment

D System configuration (system voltage, phase,

and frequency settings, battery voltage, and generator set model)

D Master control switch: Run/Off-Reset/Auto

D Remote two-wire start/stop capability

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 module (DSAM) optimizes

ignition timing for the selected fuel (12RES).

D Superior electronics protection from corrosion and

vibration

D Potted electronics

D Sealed connections

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

TP-6331 5/04 1Section 1 Features

1.5 Generator Set Components

123 657 19

1. Enclosure

2. Muffler

3. Oil check

4. Oil fill

5. Air cleaner

6. Spark plug locations (both sides)

7. ADC 2100

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

9. Nameplate

10. Line circuit breaker

11. Engine starting battery location

12. Oil drain hose

1314

13. Oil drain valve

14. Oil filter

15. Alternator cooling air intake

16. Exhaust

17. DSAM leads

18. Multi-fuel block

19. Gas regulator assembly

20. Fuel solenoid valve

21. Air intake

22. Battery charger

23. Relay board

ADV-6823-A

Figure 1-1 Generator Set Components

TP-6331 5/042 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 and piping condition and check for tight exhaust system connections.

Inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for cracks, leaks, and corrosion.

D Check for corroded or broken metal parts and replace

them as needed.

2.2 Exercising Generator Set

Operate the generator set without load once each week for 20 minutes. If the generator set does not have a programmed exercise mode or an automatic transfer switch (ATS) with an exercise option, exercise the unit in the presence of an operator.

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

2.3 Generator Set Operation

Figure 2-1 illustrates the user interface on the Advanced Digital Control (ADC 2100) generator set controller.

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.

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

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

x:op:001:002

1. LED display

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

3. Up and down arrow buttons (use for setup and adjustment only)

4. Generator set master switch

GM28707A-C

Figure 2-1 ADC 2100 User Interface

TP-6331 5/04 3Section 2 Operation

2.3.1 Controls and Indicators

Auto (Automatic) Starting

Figure 2-2 describes the controls and indicators located on the ADC 2100. The LED display indicates generator set status as shown in Figure 2-2.

With the factory-installed continuous power mode jumper in place, the LED display is activated when the generator set master switch is moved to the RUN or AUTO position and remains active until the master switch is moved to the OFF/RESET position or power to the controller is removed. If the continuous power mode jumper has been disconnected, the LED display is activated by a start or RUN command and turns off 48 hours after generator set shutdown. See Section

2.5.

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

2.3.2 Starting Generator Set

The following procedures describe the actions required to start the generator set.

The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and 15 seconds off). If the generator set does not start in three attempts, the system shuts down on an overcrank fault.

Local Starting

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

Move the generator set master switch to the AUTO position to allow startup by an automatic transfer switch (ATS) or remote start/stop switch, if equipped.

2.3.3 Stopping Generator Set

The following procedures describe the actions required to stop the generator set.

Local Stopping

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

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

Automatic Stopping

With the generator set master switch in the AUTO position and an (ATS) or other automatic device connected to controller leads 3 and 4:

1. The ATS or other device disconnects the load from the generator set.

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

Note: There is no engine cooldown time delay on

the ADC controller.

3. The ATS or other device opens the connection between controller leads 3 and 4. The generator set shuts down.

Control or Indicator Item 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

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

Fault codes Flashes a 2- or 3-letter fault code to indicate various fault conditions. See Section 2.4.

Software version number

buttons

Three-position switch

other codes are displayed.

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

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

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

TP-6331 5/044 Section 2 Operation

2.4 Fault Shutdowns

The shutdown switches on the generator set automatically reset when the problem is corrected. The

The generator set shuts down automatically under the fault conditions listed in Figure 2-3 and the controller displays a fault code. The generator set cannot be

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

restarted until the fault condition is corrected and the controller is reset. See Section 2.4.1 to reset the controller after a fault shutdown. The controller resets automatically after a battery voltage fault condition is

The controller displays a fault code but the generator set does not shut down under the conditions shown in Figure 2-4.

corrected.

Code Fault Description Check

AF Auxiliary fault

input shutdown

HE High engine

temperature shutdown

LCL Low coolant level Not used on air-cooled models. —

LOC Loss of coolant Not used on air-cooled models. —

LOP Low oil pressure

shutdown

OC Overcrank

shutdown

OF Overfrequency

shutdown

OS Overspeed

shutdown

OU Overvoltage

shutdown

UF Underfrequency

shutdown

UU Undervoltage

shutdown

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.

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).

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

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

Shutdown occurs when the governed frequency falls blow 90% of the nominal system frequency for more than 5 seconds. This protective becomes active 10 seconds after engine start. (10 second inhibit).

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

Check for blocked air inlets and exhaust outlets.

Check for leaks in the lubrication system.

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

Check the fuel supply, spark plug, and battery.

Check for loose connections.

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

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.

Figure 2-3 ADC 2100 Fault Shutdown Codes

TP-6331 5/04 5Section 2 Operation

Code Fault Description Check

HB High battery

voltage warning

LB Low battery

voltage warning

Fault code is displayed if the engine starting battery voltage rises above 16 VDC for 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 2-4 ADC 2100 Fault Warning Codes

2.4.1 Resetting Controller after a Fault Shutdown

Always identify and correct the cause of a fault shutdown before resetting the controller. Use the following procedure to reset the generator set controller after a fault shutdown.

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

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

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

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

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

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

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

Note: The controller’s LED display remains off

until an engine start command is received.

Opening and closing a remote start/stop contact also resets the controller.

2.5 Continuous Power Mode

The ADC 2100 is powered by the generator set engine starting battery. A jumper on the back of the controller maintains power to the controller at all times. Controllers are shipped with the jumper connected.

Note: The 8.5 and 12 RES generator sets are equipped

with factory-installed battery chargers to prevent battery discharge.

Disconnecting the jumper allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position. A remote start signal (from a transfer switch or a remote start/stop switch connected to controller leads 3 and 4) or moving the generator set master switch to the RUN position turns the controller back on.

Contact an authorized distributor/dealer to disconnect the jumper, if necessary.

TP-6331 5/046 Section 2 Operation

2.6 Battery Charger

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

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

INDICATOR Red:

Red& Green:

Green:

CAUTION:Toreduce the risk of electrical shock,

INPUT:115 VAC50/60Hz @ 1.6A

OUTPUT:12 VDC @6 Amps

MAX.BAT.: 180Amp Hr. Max.

DATE:

AllowableBattery Types:Lead Acida nd GelCell

VOLTS=11.8--14.0 AMPS=5.0--6.0 VOLTS=14.0--14.5 AMPS=1.5--5.0 VOLTS=13.0--13.6 AMPS=0.1--1.5

connectonly to properly grounded outlet.

6AMP AUTOMATIC BATTERYCHARGER

C USLISTED

BATTERYCHARGER

53AB

2608KH

2.6.1 Battery Charger Operation

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

1. LED indicators

2. AC power cord

3. Fuse

4. Battery leads, 12 VDC

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

Figure 2-6 Charging Method

Display Operating Condition

Red ON Green OFF

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

11.8--14 volts.

If the red LED stays on for more than 24 hours, refer to Section 4.5 in this manual.

Red ON Green ON

When both the green and the red LEDs are on, the battery charger is charging at an ABSORPTION rate of between 1.5 and 5 amps (stage 2). This mode of charging gradually tops off your battery, and reduces harmful sulfating. While both LEDs are on, the voltage measured (with the battery charger on) should be approximately 14.0 --14.5 VDC.

If both LEDs stay on longer than 24 hours, refer to Section 4.5 in this manual.

Red OFF Green ON

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

If the green LED stays on when your battery is known to be low, refer to Section 4.5 in this manual.

Figure 2-7 Battery Charger LED Indicator Functions

TP-6331 5/04 7Section 2 Operation

Notes

TP-6331 5/048 Section 2 Operation

Section 3 Scheduled Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

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

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.

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 rotor.

3.1 Routine Maintenance

Refer to the following service schedule and the runtime hours displayed on the ADC 2100 display to schedule routine maintenance. Have an authorized distributor/dealer service the generator set at the designated intervals in the service schedule for the life of the generator set. Service units subject to extreme weather, long operating hours, or dusty or dirty conditions more frequently.

Contact an authorized distributor/dealer for parts.

TP-6331 5/04 9Section 3 Scheduled Maintenance

3.2 Service Schedule

Procedure

System Component or Procedure

Section

Fuel

See

Flexible lines and connections X R Quarterly

Main tank supply level X Weekly

Fuel piping X Yearly

Lubrication

Oil level X X 8 hours or

Crankcase breather hose X Yearly or 500 hours

Change oil X Yearly or 100 hours

Replace filter X Yearly or 200 hours

Cooling

Air ducts, louvers X X Yearly

Exhaust Line

Leakage X X Weekly

Insulation, fire hazards X Yearly

Obstructions or combustible materials near exhaust outlet

DC Electrical System

Battery charger operation, charge rate (if equipped) X Monthly

Remove corrosion, clean and dry battery and rack X X Yearly

Clean and tighten battery terminals and inspect boots

Battery electrolyte level and specific gravity * X Yearly

3.3

3.6

3.7

3.8

AC Electrical System

Tighten control and power wiring connections X Yearly

Remote control system, if equipped X Monthly

Visible wear or damage X Quarterly

Wire abrasions where subject to motion X X Six Months

Wire-cable insulation condition X 3 Years or 500 hours

Engine and Mounting

Visible wear or damage X Weekly

Air cleaner and precleaner service 3.5 R Yearly or 100 hours

Spark plugs 3.4 X Yearly or 300 hours

Replace stepper motor coupling and bushing D 500 hours

Generator

Visible wear or damage 2.1 X Quarterly

Exercise generator set 2.2 X Weekly

Brushes and collector ring D D Yearly

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

General Condition of Equipment

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

Interior of sound enclosure X X Quarterly

* Not necessary for maintenance-free batteries. D Authorized distributor/dealer only

Meggerr is a registered trademark of Biddle Instruments.

Visually

Inspect

XAction R Replace as necessary

Check Change Clean Test

X Weekly

X X Yearly

D 3 Years

X X X Weekly

Frequency

before use

TP-6331 5/0410 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.

10W-30

5W-20, 5W-30

For extended operation, check the oil level every 8 hours. Maintain the oil level at or near, not over, the full mark on the dipstick.

3.3.1 Low Oil Pressure Shutdown

The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below 24.1 kPa ±13.8 kPa (3.5 psi ±1.5 psi) because of oil pump failure or other malfunction. The shutdown feature does not protect against damage caused by operating with the oil level below the safe range; it is not a low oil level shutdown. Check the oil level regularly, and add oil as needed.

3.3.2 Oil Check

The generator set is shipped with oil. Before operating a new generator set, check the engine oil in the crankcase. See Section 1.5, Generator Set Components. Verify that the oil level is at the F mark on the dipstick. Add oil that has a viscosity appropriate for the climate. See Section 3.3.3, Engine Oil Recommendation.

-- 2 0

°C°F-- 3 0 Temperature Range Expected Before Next Oil Change

-- 2 0

01020

-- 1 0

32 60 80 100

02040

Figure 3-1 Engine Oil Selection

3.3.4 Oil Change Procedure

Drain the oil while it is still warm.

1. Drain the oil.

a. Place the generator set master switch in the

OFF position.

b. Disconnect the power to the battery charger.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

d. Remove the housing side panel.

e. Remove the oil drain hose from its retaining

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

Do not check the oil level when the generator set is running. Shut down the generator set and wait several minutes before checking the oil level.

3.3.3 Engine Oil Recommendation

Use API (American Petroleum Institute) Service Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner. Select the viscosity based on the air temperature at the time of operation. SeeFigure3-1.

f. Open the oil drain valve on the engine.

g. Allow time for the engine oil to drain completely.

h. Close the oil drain valve.

i. Replace the cap on the oil drain hose. Replace

the oil drain hose in its retaining clip.

2. Replace the oil filter.

a. Remove the oil filter by rotating it

counterclockwise with an oil filter wrench.

TP-6331 5/04 11Section 3 Scheduled Maintenance

b. Clean the gasket sealing surface of the oil filter

adapter.

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

of the new oil filter.

d. Install the new oil filter following the instructions

provided with the filter.

Note: Dispose of all waste materials (engine

oil, fuel, filter, etc.) in an environmentally safe manner.

3. Fill with oil.

a. Remove the oil fill cap and fill the engine to the F

mark on the dipstick. The engine oil capacity is

1.9 L (2.0 qt.). See Section 3.3.3, Engine Oil Recommendation, for oil selection.

b. Reinstall the dipstick and the oil fill cap.

carefully bending the ground electrode. See Figure 3-2 and Figure 3-3.

1--514

Figure 3-2 Checking the Spark Plug Gap

c. Check that the generator set master switch is in

the OFF position.

d. Reconnect the generator set engine starting

battery, negative (--) lead last.

e. Reconnect the power to the battery charger.

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

allow the oil pressure to reach the operating range.

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

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

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

3.4 Spark Plugs

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

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

1--511

Figure 3-3 Adjusting the Spark Plug Gap

3.5 Air Cleaner Element and Precleaner

The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See Figure 3-4.

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean.

Note: Operating the engine with loose or damaged air

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

3.5.1 Precleaner Service

Use the following procedure to wash and reoil the precleaner as indicated in the service schedule. Wash and reoil the precleaner more often under extremely dusty or dirty conditions.

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

2. Disconnect the power to the battery charger.

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

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

4. Loosen the cover retaining knob and remove the cover. Remove the precleaner from the paper element. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all

TP-6331 5/0412 Section 3 Scheduled Maintenance

traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry.

5. Saturate the precleaner with new engine oil. Squeeze out all of the excess oil.

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

6. Reinstall the precleaner over the paper element.

7. Reinstall the air cleaner cover. Secure the cover with the cover retaining knob.

8. Reconnect the power to the battery charger.

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

3.5.2 Paper Element Service

Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions.

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

2. Disconnect the power to the battery charger.

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

586536

1. Cover knob

2. Air cleaner cover

3. Element cover nut

4. Element cover

5. Foam precleaner

6. Air cleaner element

7. Air cleaner base

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

5. Remove the element cover nut, element cover, and the paper element with precleaner.

6. Remove the precleaner from the paper element.

Note: Do not wash the paper element or clean it

with pressurized air, as this will damage the element.

7. Replace the element if it is dirty, bent, or damaged.

8. Check the air cleaner base. Make sure it is secure and not bent or damaged. Also check the element cover for damage and fit. Replace all damaged air cleaner components. Remove any loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat. Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary.

9. Reinstall the paper element, precleaner, element cover, element cover nut, and the air cleaner cover. Secure the cover with the cover retaining knob.

Figure 3-4 Air Cleaner Components

10. Reconnect the power to the battery charger.

TP-6331 5/04 13Section 3 Scheduled Maintenance

3.6 Cooling System

3.8 Battery

The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet. See Figure 3-5. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times.

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

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

1. Exhaust outlet

2. Alternator air intake (both sides)

3. Engine air intake

tp6195

Figure 3-5 Cooling Air Intake and Exhaust

3.7 Exhaust System

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

Periodically inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for cracks, leaks, and corrosion.

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 clamps and/or hangers as needed.

WARNING

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

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

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

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

Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and

corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

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

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

D Check for and remove loose insulation in the exhaust

duct.

D Check that the exhaust outlet is clear.

TP-6331 5/0414 Section 3 Scheduled Maintenance

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.

3.9 Battery Charger

The generator set is equipped with a 6-amp float/equalize battery charger to maintain the engine starting battery. The charger’s DC leads are factorywired. Figure 3-7 illustrates the battery charger.

Periodically tighten all connections. No other maintenance on the battery charger is required.

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

All generator set models use a negative ground with a12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator spec sheet for battery capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information. See Figure 3-6 for typical battery connections.

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.

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 risk of elect ricalshock,

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

C USLISTED

BATTERYCHARGER

53AB

2608KH

1. LED indicators

2. Mounting flanges

3. AC power cord

4. Fuse

5. Battery leads, 12 VDC

Figure 3-7 6-Amp Float/Equalize Battery Charger

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

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

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

EZ-273000-J

Figure 3-6 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery Connection

TP-6331 5/04 15Section 3 Scheduled Maintenance

3.10 Circuit Protection

3.11 Storage Procedure

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

3.10.1 Line Circuit Breaker

A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. The line circuit breaker location is shown in Figure 1-1. See Figure 3-8 for the circuit breaker ratings. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load.

Circuit Breaker

Model

8.5RES 40

12RES 50

Rating, Amps

Figure 3-8 Line Circuit Breakers

3.10.2 Fuses

The engine harness contains two 10-amp and one 20-amp inline fuses. See Figure 3-9. Another 10-amp fuse protects the battery charger.

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

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

Note: Run the generator set monthly whenever

possible.

3.11.1 Lubricating System

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

2. Stop the generator set.

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

4. Refill the engine crankcase with oil. See Section

3.3.3 for oil recommendations.

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

6. Stop the generator set.

3.11.2 Fuel System

1. Start the generator set.

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

3. Run the generator set until the engine stops.

Part

Fuse Label

Auxiliary winding F1 292937 Lead 55

Relay interface board

Controller F3 223316 Lead PF1

Battery charger — AGS 10 Battery charger DC

Number

F2 223316 Lead PF2

Location

lead. See Section 2.6.

Figure 3-9 Fuses

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

TP-6331 5/0416 Section 3 Scheduled Maintenance

3.11.3 Cylinder Lubrication

1. Remove the spark plugs.

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

plugs.

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

3.11.4 Exterior Preparation

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

3.11.5 Battery

Perform battery storage last.

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

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

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

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. Place the battery in a warm, dry location.

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

TP-6331 5/04 17Section 3 Scheduled Maintenance

Notes

TP-6331 5/0418 Section 3 Scheduled Maintenance

Section 4 Troubleshooting

4.1 Introduction

dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help

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

describe the problem and repairs or adjustments made to the equipment.

as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of

4.2 Generator Set Troubleshooting

common problems, possible causes of the problem, and recommended corrective actions.

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

If the procedures in this manual do not explain how to

connections before replacing parts.

correct the problem, contact an authorized distributor/

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

Low output or excessive drop in voltage.

Generator set stops suddenly.

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.

Controller fuse (F3) blown Replace the fuse. Contact an authorized distributor/dealer

Relay interface board fuse (F2) blown Replace the fuse. Contact an authorized distributor/dealer

Generator set master switch in the OFF position Move the master switch to the RUN position.

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 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

Recharge or replace the battery.

for service if fuse blows repeatedly.

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 4-1 General Troubleshooting Chart

TP-6331 5/04 19Section 4 Troubleshooting

4.3 Fault Codes

24h

batteryisknow

LEDsturno

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.

4.5 Battery Charger Troubleshooting

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

Then reset the controller after a fault shutdown. See Section 2.4.1.

4.4 Troubleshooting

Figure 4-2 contains troubleshooting, diagnostic, and repair information for the Advanced Digital Control.

Problem Possible Cause Corrective Action

Controller LED display is off

No power to the controller:

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

Controller fuse (F3) is blown. 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 2.5. Connect the jumper to maintain continuous power to the controller, if desired.

distributor/dealer.

Check generator set battery and battery charger. See Figure 4-1.

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

No action required (see Section 2.3.1). Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position. Use the remote switch to start generator set and activate the controller display, if desired.

Figure 4-2 ADC 2100 Troubleshooting Chart

Problem 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 defective 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 defective 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 defective 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.

extension cord.

Figure 4-3 Battery Charger Troubleshooting

TP-6331 5/0420 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 analog to digital converter adj. adjust, adjustment ADV advertising dimensional

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 API American Petroleum Institute approx. approximate, approximately 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 A/V audiovisual 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 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

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfh cubic feet per hour 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 cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department 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 DSAM digital spark-advance module DVR digital voltage regulator E, emer. emergency (power source) 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

e. V. (also Deutsche Industrie Normenausschuss)

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. lbs. foot pounds (torque) ft./min. feet per minute 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 temperature,

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. lbs. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe

ground

high engine temperature

conditioning

Commission

Electronics Engineers

O inches of water

TP-6331 5/04 Appendix A-1

ISO International Organization for

Standardization J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square

centimeter

kilograms per cubic meter

bytes)

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 L liter LAN local area network L x W x H length by width by height lb. pound, pounds

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

sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/min. cubic meters per minute

when used with SI

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

bytes) MCM one thousand circular mils MCCB molded-case circuit breaker 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, mΩ

milliohm

MOhm, MΩ

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

MS military standard m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting 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 Phillips head crimptite (screw) PHH Phillips 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 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 RTV room temperature vulcanization 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 SPDT single--pole, double--throw SPST single--pole, single--throw spec, 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 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-6331 5/04A-2 Appendix

TP-6331 5/04

KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455

Kohler 8.5RES, 12RES User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual