Residential/Commercial Generator Sets

Residential/Commercial Generator Sets

Models:

8.5/12/17/18RES12/18TRES

Controller:Advanced Digital Control ADC-RES

TP-6515 1/11f

Operation

Engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm.

WARNINGCalifornia Proposition 65

Product Identification Information

Product identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.

Generator Set Identification NumbersRecord the product identification numbers from thegenerator set nameplate(s).

Model DesignationSpecification NumberSerial Number

Accessory Number Accessory Description

Controller Identification

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

Controller Description

Engine IdentificationRecord the product identification information from theengine nameplate.

ManufacturerModel DesignationSerial Number

Table of Contents

TP-6515 1/11 Table of Contents

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

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

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

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

Section 1 Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Generator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Engine 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Advanced Digital Control 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Service Views for Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Prestart Checklist 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Exercising Generator Set 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 ADC-RES Controls and Indicators 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 LED Display 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.2 Controller Keypad 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3.3 Generator Set Master Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Controller Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.1 Standby Mode 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.2 Sleep Mode 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Generator Set Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.1 Starting Generator Set 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.2 Stopping Generator Set 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3 Resetting Emergency Stop Switch (TRES Models only) 18. . . . . . . . . . . . .

2.6 Faults 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.1 Shutdowns 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.2 Warnings 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.3 Resetting Controller after a Fault Shutdown 19. . . . . . . . . . . . . . . . . . . . . . .

2.7 Battery Charger 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.1 RES Battery Charger 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.2 TRES Battery Charger 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Scheduled Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Scheduled Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Service Schedule, 8.5/12 kW Models 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2 Service Schedule, 17/18 kW Models 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Lubrication System 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.1 Low Oil Pressure Shutdown 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 Oil Check 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.3 Engine Oil Recommendation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.4 Oil Change Procedure 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.5 Oil Cooler, 17/18 kW 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Spark Plugs 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Air Cleaner Service 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Air Cleaner, 8.5/12RES 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.2 Air Cleaner, 17/18RES 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Cooling System 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 Exhaust System 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7 Battery 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8 Battery Charger 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-6515 1/11Table of Contents

3.9 Circuit Protection 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.1 Line Circuit Breaker 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.2 Fuses 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Storage Procedure 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.1 Lubricating System 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.2 Fuel System 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.3 Cylinder Lubrication 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.4 Exterior Preparation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.5 Battery 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Introduction 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Controller Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Generator Set Troubleshooting 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Battery Charger Troubleshooting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6515 1/11 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orconnected equipment, disable thegenerator set as follows: (1) Move thegenerator set master switch to the OFFposition. (2) Disconnect the power tothe battery charger. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent starting ofthe generator set by an automatictransfer switch, remote start/stopswitch, or engine start command fromaremote computer.

Battery

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

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

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

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery electrolyte is a dilutedsulfuric acid. Battery acid cancausesevere injury or death. Battery acidcan cause blindness and burn skin.Always wear splashproof safetygoggles, rubber gloves, and bootswhen servicing the battery. Do notopen a sealed battery or mutilate thebattery case. If battery acid splashes inthe eyes or on the skin, immediatelyflush the affected area for 15 minuteswith large quantities of clean water.Seek immediatemedical aid in the caseof eye contact. Never add acid to abattery after placing the battery inservice, as thismay result in hazardousspattering of battery acid.

Battery acid cleanup. Battery acidcan cause severe injury or death.Battery acid is electrically conductiveand corrosive. Add 500 g (1 lb.) ofbicarbonate of soda (baking soda) to acontainer with 4 L (1 gal.) of water andmix the neutralizing solution. Pour theneutralizing solution on the spilledbattery acid and continue to add theneutralizing solution to the spilledbattery acid until all evidence of achemical reaction (foaming) hasceased. Flush the resulting liquid withwater and dry the area.

TP-6515 1/116 Safety Precautions and Instructions

Battery gases. Explosion can causesevere injury or death. Battery gasescan cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of abattery in a fire. To prevent burns andsparks that could cause an explosion,avoid touching the battery terminalswith tools or other metal objects.Remove all jewelry before servicing theequipment. Discharge static electricityfrom your body before touchingbatteries by first touching a groundedmetal surface away from thebattery. Toavoid sparks, do not disturb the batterycharger connections while the batteryis charging. Always turn the batterycharger off before disconnecting thebattery connections. Ventilate thecompartments containing batteries toprevent accumulation of explosivegases.

Battery short circuits. Explosioncan cause severe injury or death.Short circuits can cause bodily injuryand/or equipment damage.Disconnect the battery beforegenerator set installation ormaintenance. Remove all jewelrybefore servicing the equipment. Usetools with insulated handles. Removethe negative (--) lead first whendisconnecting the battery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnect the negative (--) battery cableto the positive (+) connection terminalof the starter solenoid. Do not test thebattery condition by shorting theterminals together.

Engine Backfire/FlashFire

Fire.Can cause severe injury or death.

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

WARNING

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner removed.

Servicing the fuel system. A flashfire cancausesevere injuryordeath.Do not smoke or permit flames orsparks near the carburetor, fuel line,fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors.Catch fuels in an approved containerwhen removing the fuel line orcarburetor.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.

Exhaust System

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

The exhaust system must beleakproof and routinely inspected.

WARNING

Generator set operation. Carbonmonoxide can cause severe nausea,fainting, or death. Carbon monoxideis an odorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Avoidbreathing exhaust fumeswhenworkingon or near the generator set. Neveroperate the generator set inside abuilding. Never operate the generatorset where exhaust gas could seepinside or be drawn into a potentiallyoccupied building through windows, airintake vents, or other openings.

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

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

WARNING

Gas fuel leaks. Explosive fuelvapors can cause severe injury ordeath. Fuel leakage can cause anexplosion. Check the LP vapor gas ornatural gas fuel system for leakage byusinga soapandwater solutionwith thefuel system test pressurized to6--8 ounces per square inch(10--14 inches water column). Do notuse a soap solution containing eitherammonia or chlorine because bothprevent bubble formation. A successfultest depends on the ability of thesolution to bubble.

TP-6515 1/11 7Safety Precautions and Instructions

Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Engine noise. Hazardous noise cancause hearing loss. Generator setsnot equipped with sound enclosurescan produce noise levels greater than105 dBA. Prolonged exposure to noiselevels greater than 85 dBA can causepermanent hearing loss. Wear hearingprotection when near an operatinggenerator set.

Hazardous Voltage/Moving Parts

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Hazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.

If the generator set is used forstandby power, install an automatictransfer switch to prevent inadvertentinterconnection of standby andnormal sources of supply.

WARNING

Welding the generator set.Can cause severe electricalequipment damage.

Never weld components of thegenerator set without firstdisconnecting the battery, controllerwiring harness, and engine electroniccontrol module (ECM).

CAUTION

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Welding on the generator set. Cancause severe electrical equipmentdamage. Before welding on thegenerator set perform the followingsteps: (1) Remove the battery cables,negative (--) lead first. (2) Disconnectall engine electronic control module(ECM) connectors. (3) Disconnect allgenerator set controller and voltageregulator circuit board connectors.(4) Disconnect the engine battery-charging alternator connections.(5) Attach the weld ground connectionclose to the weld location.

Connecting the battery and thebattery charger. Hazardous voltagecan cause severe injury or death.Reconnect the battery correctly,positive to positive and negative tonegative, to avoid electrical shock anddamage to the battery charger andbattery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death. Installa transfer switch in standby powerinstallations to prevent the connectionof standby and other sources of power.Electrical backfeed into a utilityelectrical system can cause severeinjury or death to utility personnelworking on power lines.

Airborne particles.Can cause severe injury orblindness.

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

WARNING

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not use lifting eyes.Lift the generator set using lifting barsinserted through the lifting holes onthe skid.

WARNING

TP-6515 1/118 Safety Precautions and Instructions

Hot Parts

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

Do not work on the generator set untilit cools.

WARNING

Servicing the exhaust system. Hotparts can cause severe injury ordeath. Do not touch hot engine parts.The engine and exhaust systemcomponents become extremely hotduring operation.

Servicing the engine heater. Hotparts can cause minor personalinjury or property damage. Install theheater before connecting it to power.Operating the heater before installationcan cause burns and componentdamage. Disconnect power to theheater and allow it to cool beforeservicing the heater or nearby parts.

NoticeNOTICE

Canadian installations only. Forstandby service connect the output ofthe generator set to a suitably ratedtransfer switch in accordance withCanadian Electrical Code, Part 1.

TP-6515 1/11 9Introduction

Introduction

This manual provides operation and maintenanceinstructions for residential/commercial generator setsequipped with ADC-RES controls. The generator setmodels covered by this manual are listed on the frontcover.

This generator set is approved for use in stationaryapplications in locations served by a reliable utilitypower source. Have the generator set installed by anauthorized distributor/dealer or service technician.Refer to TP-6514, Installation Manual, for installationinstructions.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

The equipment service requirements are very importantto safe and efficient operation. Inspect the parts oftenand perform required service at the prescribedintervals. Obtain service from an authorized servicedistributor/ dealer to keep equipment in top condition.

NameplateThe following illustration shows a typical generator setnameplate. Copy the model, serial, and specificationnumbers from the nameplate into the spaces providedin the product information section on the inside frontcover of this manual. SeeSection 1.5 for the nameplatelocation.

Emission InformationThe Kohlerr Model CH640 engine used on the model8.5RES generator set, CH740 engine used on the12RES generator set, and CH980 engine used on the17/18RES generator set are certified to operate usingnatural gas or propane fuel.

The Emission Compliance Period referred to on theEmissionControl orAir Index label indicates thenumberof operating hours for which the engine has been shownto meet CARB or EPA emission requirements. Thefollowing table provides the engine compliance period(in hours) associated with the category descriptor,which may be found on the certification label.

Emission Compliance Period

EPA Category C250 hours

Category B500 hours

Category A1000 hours

CARB Moderate125 hours

Intermediate250 hours

Extended500 hours

Figure 1 Emission Compliance Period

Refer to the certification label for engine displacement.

The exhaust emission control system for the CH640,CH740, and CH980 engines is EM for U.S. EPA,California, and Europe.

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

TP-6515 1/1110 Service Assistance

Service Assistance

For professional advice on generator set powerrequirements and conscientious service, pleasecontact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators—Electric.

D Visit the Kohler Power Systems website atKohlerPower.com.

D Lookat the labels and stickers on yourKohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems3 rue de Brennus93200 Saint DenisFrancePhone: (33) 1 49 178300Fax: (33) 1 49 178301

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

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

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

Latin AmericaLatin America Regional OfficeLakeland, Florida, USAPhone: (863) 619-7568Fax: (863) 701-7131

TP-6515 1/11 11Section 1 Specifications

Section 1 Specifications

1.1 IntroductionThe generator set specification sheets provide specificgenerator and engine information. Refer to the specsheet for data not supplied in this manual. Consult thegenerator set service manual, engine operationmanual, and engine service manual for additionalspecifications. Obtain copies of the latest spec sheets,manuals, diagrams, and drawings from your localdistributor/ dealer.

1.2 GeneratorThe generator uses Kohler’s unique PowerBoosttvoltage regulation system, which provides instantresponse to load changes.

PowerBoostt ensures reliable motor starting andconsistent voltage levels. PowerBoostt utilizes avoltage excitation system that employs a windingindependent of the main output windings to provideexcitation voltage.

1.3 EngineThe generator set has a four-cycle, twin cylinder, air-cooled Kohlerr engine. The engine operates on clean-burning natural gas or propane (LP) vapor. Enginefeatures include:

D Efficient overhead valve design and full pressurelubrication for maximum power, torque, and reliabilityunder all operating conditions.

D Dependable, maintenance-free electronic ignition.

D Precision-formulated cast iron construction of partssubjected to the most wear and tear.

D Field-convertible multi-fuel systems that allow fuelchangeover from natural gas to LP vapor (and vice-versa) while maintaining CARB emissioncertification.

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

1.4 Advanced Digital ControlThe generator set is equipped with the KohlerrADC-RES Advanced Digital Control. Controllerfeatures include the following:

D Compact controller

D Integrally mounted to the generator set

D LED display:D Engine runtime, hoursD AC voltageD Frequency (Hz)D Battery voltageD Crank cycle statusD Setup informationD Application software version

D LED display communicates faults:D High battery voltageD High engine temperatureD Low battery voltageD Low oil pressureD Overcrank safetyD OverfrequencyD OverspeedD OvervoltageD UnderfrequencyD Undervoltage

D Membrane keypad for configuration and adjustmentD Password-protected user access to menusD Voltage, gain, and speed adjustmentD System configuration (system voltage/frequencysettings 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 tofull-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 1/1112 Section 1 Specifications

1.5 Service Views for Maintenance

ADV-7466-

1. Muffler2. Oil check3. Oil fill4. Air cleaner5. Fuses6. RS-232 connector (for application program updates)7. Controller user interface (see Figure 2-1)8. Generator set master switch (RUN-OFF/RESET-AUTO)9. Line circuit breaker (single-phase models)*10. Field-connection terminal block location (single-phase

models)*11. Spark plug locations (both sides)12. Oil drain hose

13. Oil drain valve14. Oil filter15. Exhaust16. Equipment ground17. Relay board location (optional)18. Battery charger (single-phase models)[19. DSAI lead location (12 kW models)20. Fuel block21. Gas regulator assembly22. Fuel solenoid valve23. Fuel inlet24. Air intake25. Engine starting battery location (battery purchased separately)

1 2 3 4

14 13

25

9

816

18 21

22

23

24

15

11

10

19 2017

12

5 6 7

24

* See Figure 1-3 for additional components for 3-phase models.[ See Figure 2-9 for 3-phase battery charger locations.

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

TP-6515 1/11 13Section 1 Specifications

1 2 54 21

16

63

13 26

17

20

1415

24

ADV-7341A-B

10

2725

9

18 22

28

Control detail, top view 8

11

7

12

1. Muffler2. Oil check3. Oil fill4. Air cleaner5. Spark plug locations (both sides)6. Oil filter7. Oil cooler location8. ADC-RES Advanced Digital Control user interface9. Generator set master switch (RUN-OFF/RESET-AUTO)10. Line circuit breaker (single-phase models )*11. Fuses12. RS-232 connector (for application program updates)13. Engine starting battery location (battery purchased separately)14. Oil drain hose15. Nameplate location (on base)

16. Oil drain valve17. Exhaust outlet18. Relay board location (optional)19. Carburetor heater access opening20. LP fuel orifice location (inside hose fitting)21. Gas regulator assembly22. DSAI leads23. Fuel solenoid valve24. Fuel inlet25. Air intake26. Battery cables27. Battery charger (single-phase models)[28. Field-connection terminal block location (single-phase models)*29. 120 VAC receptacles for battery charger and optional

carburetor heater (single-phase models)

See controldetail 19

29

23

25

25

* See Figure 1-3 for additional components for 3-phase models.[ See Figure 2-9 for 3-phase battery charger locations.

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

TP-6515 1/1114 Section 1 Specifications

1

GM66010

1. Emergency stop switch2. Field-connection terminal block and circuit breakers3. Cable inlet area

2

3

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

TP-6515 1/11 15Section 2 Operation

Section 2 Operation

2.1 Prestart ChecklistTo ensure continued satisfactory operation, perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In addition, some checks requireverification after the unit starts.

Air Cleaner. Check for a clean and installed air cleanerelement to prevent unfiltered air from entering theengine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consultthe battery manufacturer’s instructions regardingbattery care and maintenance.

Exhaust System. Check for exhaust leaks andblockages. Check the muffler condition and check fortight exhaust system connections.

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

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check that the exhaust outlet is unobstructed.

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

Operating Area. Check for obstructions that couldblock the flow of cooling air. Keep the air intake areaclean. Do not leave rags, tools, or debris on or near thegenerator set.

2.2 Exercising Generator SetOperate the generator set without load once each weekfor 20 minutes. If the generator set is not connected toan automatic transfer switch (ATS) with an exerciseoption, exercise the unit in the presence of an operator.

The operator should perform all of the prestart checksbefore starting the exercise procedure. Start thegenerator set according to the starting procedure in thecontroller section of this manual. While the generatorset is operating, listen for a smooth-running engine andvisually inspect the generator set for fluid or exhaustleaks. Check the air inlets and outlets and remove anyitems restricting the air flow.

2.3 ADC-RES Controls andIndicators

Figure 2-1 illustrates the ADC-RES user interface andother items on the generator set junction box.Figure 2-2 describes the ADC-RES controls andindicators.

1. LED display2. Up and down arrow buttons3. Generator set master switch4. Line circuit breaker (single-phase models)5. Fuses6. RS-232 connector (for application program upgrade)7. Select button (use for setup and adjustment only)

1

7

3

2

4

5

6

Figure 2-1 ADC-RES Controls

2.3.1 LED Display

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

D Move the master switch to RUN.

D With the master switch in AUTO, send a remote startcommand (close the remote start contact acrossleads 3 and 4).

The LED display indicates generator set status asshown inFigure 2-2. When the generator set is running,engine runtime hours are shown unless the arrowbuttons are used to step through the other displays asdescribed in Section 2.3.2.

When the master switch is in AUTO, the display mayturn off 48 hours after generator set shutdown. SeeSection 2.4, Controller Power.

TP-6515 1/1116 Section 2 Operation

Control or Indicator Item Description

LED display Runtime hours Displays total generator set runtime hours while the generator set is running andwhen no other codes are displayed.

Meteringdisplay

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

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

Softwareversion number

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

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

Keypad Select andarrow buttons

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

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

Generator set masterswitch

Three-positionswitch

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

Figure 2-2 ADC-RES Controls and Indicators

2.3.2 Controller Keypad

The three buttons on the controller keypad are Select,Up, and Down. See Figure 2-1.

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

The buttons on the controller keypad are also used forsystem configuration and adjustment. The systemconfiguration is factory-set and should not requirechanges under normal operating conditions. Contactan authorized distributor/dealer or service technician ifadjustments are required.

2.3.3 Generator Set Master Switch

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

D Generator set master switch in AUTO

D Step through using up or down arrow buttons

D After 10 seconds, display returns to runtime hours

tp6515

Engine RuntimeXXX.X hours

Output VoltageVAC

Output FrequencyHz

Battery VoltageVDC

Figure 2-3 Data Displays


2.4 Controller PowerThe ADC-RES is powered by the generator set enginestarting battery.

Note: The generator sets are equipped with factory-installed battery chargers to prevent batterydischarge. The battery charger must beconnected to utility power.

2.4.1 Standby Mode

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

The controller can be set to go into sleepmode if there isno start signal for 48 hours.

2.4.2 Sleep Mode

Controllers with application code version 1.13 or higherare shipped with the sleep mode disabled and J1939communication enabled. The controller will remain instandby mode whenever the master switch is in AUTOand the engine is not running.

Communication parameter Cn can be changed todisable communication and enable the sleep mode ifremote communication is not required. See InstallationManual TP-6514 for instructions to change parameterCn.

Sleep Mode. If the controller communication isdisabled and the generator set master switch is in theAUTO position, the controller powers downautomatically after 48 hours of inactivity. The controllerdisplay is dark and battery draw is minimized. A remotestart signal from a transfer switch or a remote start/stopswitch connected to controller leads 3 and 4 reactivatesthe controller. Moving the generator set master switchto 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 RUNposition to immediately start the generator set.

Auto (Automatic) Starting

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

Crank Cycle

The controller attempts to start the generator set threetimes (three crank cycles, 15 seconds crank and15 seconds off). See Figure 2-2 for display informationduring the crank cycle. If the generator set does notstart in three attempts, the system shuts down on anovercrank fault. See Section 2.6.

2.5.2 Stopping Generator Set

Local Stopping

1. Run the generator set with no load for at least2 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 AUTOposition, open the contact across engine start leads 3and 4 to signal the generator set to stop.

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

1. The ATS disconnects the load from the generatorset.

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

Note: There is no engine cooldown time delay onthe ADC-RES controller.

3. The ATS opens the connection between controllerleads 3 and 4. The generator set shuts down. Thecontroller enters standby mode and displaysengine runtime hours.


Emergency Stopping (TRES Models Only)

Push the red emergency stop switch for immediategenerator set shutdown in the case of an emergency.See Figure 2-4 for the emergency stop switch location.

The emergency stop switch shuts down the generatorset immediately. The controller display shows AF(auxiliary fault) when the emergency stop button isactivated.

Use the generator set master switch for normalshutdowns.

1

GM66010

1. Emergency stop switch

Figure 2-4 Emergency Stop Switch, TRES Models

2.5.3 Resetting Emergency Stop Switch(TRES Models only)

Use the following procedure to reset the generator setafter shutdown by the emergency stop switch. SeeSection 2.6.3 to reset the generator set after a faultshutdown.

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

2. Investigate and correct the cause of theemergency stop.

3. Rotate the emergency stop switch knob clockwiseand release it. Check that the knob returns to thedeactivated (out) position.

4. Move the generator set master switch to the RUNor AUTO position to restart the generator set.Verify that the controller display no longer shows afault code. The generator set engine will not startuntil the reset procedure is complete.


2.6 Faults

2.6.1 Shutdowns

Under the fault shutdown conditions listed in Figure 2-5,the generator set shuts down automatically and thecontroller displays a fault code. The generator setcannot be restarted until the fault condition is correctedand the controller is reset. SeeSection 2.6.3 to reset thecontroller after a fault shutdown.

The shutdown switches on the generator set willautomatically reset when the problem is corrected. Forexample, the high engine temperature switch resetsautomatically 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 setdoes not shut down on a high battery voltagewarning ora low battery voltage warning. The controller resetsautomatically after a battery voltage fault condition iscorrected.

2.6.3 Resetting Controller after a FaultShutdown

Always identify and correct the cause of a faultshutdown before resetting the controller. Check thefault code displayed on the ADC-RES and refer toFigure 2-5 to identify and correct the fault conditionbefore proceeding.

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

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

2. Disconnect the generator set from the load usingthe line circuit breaker or ATS. See the safetyprecautions at the beginning of this manual beforeproceeding.

3. Identify and correct the cause of the faultshutdown. See the safety precautions at thebeginning of thismanual before proceeding. Referto Section 4, Troubleshooting.

4. Start the generator set bymoving the generator setmaster switch to RUN. Test operate the generatorset to verify that the cause of the shutdown hasbeen corrected.

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

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

7. Move the generator setmaster switch to the AUTOposition for startup by remote transfer switch orremote start/stop switch.

Note: The controller’s LED display remains offuntil an engine start command is received.


Code Fault Description Check

AF Auxiliary faultinput shutdown

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

Not used on RES models.

Check the position of the emergencystop button. (TRES models only)

HE High enginetemperatureshutdown

Shutdown occurs if the engine coolant temperatureexceeds the maximum temperature for more than5 seconds. This function becomes active after the enginereaches the crank disconnect speed.

Check for blocked air inlets andexhaust outlets.

LOP Low oilpressureshutdown

Shutdown occurs if a low oil pressure condition exists formore than 5 seconds. This function becomes active30 seconds after the engine has reached crank disconnectspeed (30 second inhibit).

Note: The low oil pressure shutdown does not protectagainst low oil level. Check the oil level at the engine.

Check for leaks in the lubricationsystem.

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

OC Overcrankshutdown

Shutdown occurs after 3 unsuccessful starting attempts.The crank cycle is set for three starting attempts of 15seconds cranking and 15 seconds rest.

Check the fuel supply, spark plug, andbattery.

Check for loose connections.

Contact an authorizeddistributor/dealer for service ifproblem continues.

Locked rotor The generator set also shuts down on OC if no enginerotation is sensed during cranking. Shuts down 3 secondsafter the fault is detected.

OF Overfrequencyshutdown

Shutdown occurs when the governed frequency exceeds110% of the system’s frequency setpoint for more than 5seconds. This function becomes active 10 seconds afterengine start (10 second inhibit).


OS Overspeedshutdown

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


OU Overvoltageshutdown

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


UF Underfrequencyshutdown

Shutdown occurs if the governed frequency falls below54 Hz for more than 5 seconds.

Shutdown also occurs if the governed frequency falls below56.5 Hz for more than 60 seconds.

This function becomes active 10 seconds after engine start.(10 second inhibit).

Reduce the load and restart thegenerator set.


UU Undervoltageshutdown

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

Reduce the load and restart thegenerator set.


HB High batteryvoltage warning

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

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

Check the battery rating andcondition.

Check the battery charger operation.

LB Low batteryvoltage warning

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

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

Check the battery rating andcondition.

Check the battery charger operation.

Charge or replace the battery.

Figure 2-5 ADC-RES Fault Codes


2.7 Battery Charger

2.7.1 RES Battery Charger

RES model generator sets are equipped with a 6-ampfloat/equalize battery charger to maintain the enginestarting battery. The charger’s power cord must beconnected to a 120 VAC power source. Figure 2-6illustrates the battery charger.

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

INDICATORRed:

Red & Green:

Green:

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

CAUTION:To reduce the risk of elect rical shock,connect only to properly gr ounded outlet.

Allowable Battery Types: Lead Acid a nd Gel Cell

INPUT: 115 VAC 50/60Hz @ 1.6A

OUTPUT: 12 VDC @ 6 Amps

MAX. BAT.: 180 Amp Hr. Max.

DATE:

6 AMPAUTOMATICBATTERY CHARGER

RC US LISTEDBATTERY CHARGER

53AB2608KH

1

1. LED indicators2. AC power cord3. Fuse4. Battery leads, 12 VDC

4 2

3

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

Battery Charger Operation

Figure 2-7 illustrates the three-stage charging method.Red and green LEDs indicate charger operation. Thechart in Figure 2-8 describes the LED indicatoroperation during each stage of the charging process.See Section 4.4 for battery charger troubleshootinginformation, if necessary.

Figure 2-7 Charging Method

Display Operating Condition

Red ONGreenOFF

When the red LED is on, it indicates thebattery is discharged and the battery chargeris recharging at the BULK rate (stage 1).This charging rate is 6 amps. While the redLED is on, the voltage measured (with thebattery charger on) will be 11.8--14 volts.

If the red LED stays on for more than24 hours, refer to Section 4.4 in this manual.

Red ONGreen ON

When both the green and the red LEDs areon, the battery charger is charging at anABSORPTION rate of between 1.5 and 5amps (stage 2). This mode of charginggradually tops off your battery, and reducesharmful sulfating. While both LEDs are on,the voltage measured (with the batterycharger on) should be approximately14.0--14.5 VDC.

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

Red OFFGreen ON

When the green LED is on, the batterycharger is charging at a FLOAT orMAINTENANCE rate of less than 1.5 amps(stage 3). Your battery is now 90% chargedand ready for use. This float charging currentwill gradually decrease to as low as 0.1 ampsas the battery reaches 100% charge. It willnow be kept at full charge withoutovercharging.

If the green LED stays on when your batteryis known to be low, refer to Section 4.4 in thismanual.

Figure 2-8 Battery Charger LED Indicator Functions


2.7.2 TRES Battery Charger

Three-phasemodel TRES generator sets are equippedwith a 2.5-amp battery charger to maintain the enginestarting battery. Utility power must be supplied to thegenerator set for the battery charger.

The battery charger is located in or near the controllerjunction box. See Figure 2-9 for the battery chargerlocation.

A green LEDon the side of the battery charger indicatesbattery charger operation. See Figure 2-10.

Two internal fuses protect the battery charger. SeeSection 4.4 for battery charger troubleshootinginformation, if necessary.

1

ADV-7713

1. Battery charger

12 kW

17/18 kW

1

Figure 2-9 Battery Charger Location, TRES(3-phase) Models

2

pdf1. Carburetor heater power connection2. LED3. Cover (open for fuse access)

1 3

Figure 2-10 Battery Charger for 3-Phase Models

TP-6515 1/11 23Section 3 Scheduled Maintenance

Section 3 Scheduled Maintenance

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or connected equipment, disable the generatorset as follows: (1) Move the generator setmaster switch to theOFFposition. (2) Disconnect the power to the battery charger.(3) Remove the battery cables, negative (--) lead first.Reconnect the negative (--) lead last when reconnecting thebattery. Follow these precautions to prevent starting of thegenerator set by an automatic transfer switch, remotestart/stop switch, or engine start command from a remotecomputer.

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

Do not work on the generator set untilit cools.

WARNING

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Servicing the generator setwhen it is operating. Exposedmoving parts can cause severe injury or death. Keephands, feet, hair, clothing, and test leads away from the beltsand pulleys when the generator set is running. Replaceguards, screens, and covers before operating the generatorset.

3.1 Scheduled MaintenanceRefer to the following service schedules and the runtimehours displayed on the ADC-RES display to scheduleroutine maintenance. Intervals are shown in hours ofoperation and/or time intervals (i.e. weekly, monthly,quarterly, etc.) Have an authorized distributor/dealerservice the generator set at the designated intervals inthe service schedule for the life of the generator set.Service units subject to extreme weather, longoperating hours, or dusty or dirty conditions morefrequently.

Contact an authorized distributor/dealer for parts.

TP-6515 1/1124 Section 3 Scheduled Maintenance

3.1.1 Service Schedule, 8.5/12 kW Models

System Component or ProcedureSee

Section

Procedure

FrequencyVisuallyInspect Check Change Clean Test

FuelFlexible lines and connections X R Quarterly

Main tank supply level X Weekly

Fuel piping X Yearly

Lubrication 3.2

Oil level X X 8 hours orbefore use

Crankcase breather hose X Yearly or 500 hours

Change oil X Yearly or 100 hours

Replace filter X Yearly or 200 hours

Cooling 3.5

Air ducts, louvers X X Yearly

Exhaust Line 3.6

Leakage X X Weekly

Insulation, fire hazards X Yearly

Obstructions or combustible materials near exhaustoutlet X Weekly

DC Electrical System 3.7

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 inspectboots X X Yearly

Battery electrolyte level and specific gravity * X Yearly

AC Electrical SystemTighten 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 MountingVisible wear or damage X Weekly

Air cleaner and precleaner service [ 3.4 R Yearly or 100 hours

Spark plugs 3.3 X Yearly or 300 hours

Replace stepper motor coupling and bushing D 500 hours

GeneratorVisible wear or damage X Quarterly

Exercise generator set X Weekly

Brushes and collector ring D D Yearly

Measure and record resistance readings ofwindings with insulation tester (Meggerr, withSCR assembly or rectifier and load leadsdisconnected) *

D 3 Years

General Condition of EquipmentEvidence of vibration, leakage, excessive noise,temperature, or deterioration X X X Weekly

Interior of sound enclosure X X Quarterly

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

X ActionD Authorized distributor/dealer onlyR Replace as necessary


3.1.2 Service Schedule, 17/18 kW Models

System Component or ProcedureSee

Section

Procedure

FrequencyVisuallyInspect Check Change Clean Test

FuelFlexible lines and connections X R Quarterly

Main tank supply level X Weekly

Fuel piping X Yearly

Lubrication 3.2

Oil level X 8 hours orbefore each use

Change oil X Yearly or 150 hours

Replace filter X Yearly or 150 hours

Crankcase breather hose X Yearly or 500 hours

Oil cooler X X Yearly or 100 hours

Cooling 3.5

Air ducts, louvers X X Yearly

Exhaust System 3.6

Leakage X X Weekly

Insulation, fire hazards X Yearly

Obstructions or combustible materials nearexhaust outlet

X Weekly

DC Electrical System 3.7

Battery charger operation, charge rate X Monthly

Remove corrosion, clean and dry battery andrack

X X Yearly

Clean and tighten battery terminals and inspectboots

X X Yearly

Battery electrolyte level and specific gravity * X Yearly

AC Electrical SystemTighten 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 MountingVisible wear or damage X Weekly

Air cleaner service [ 3.4 150 300 Yearly or hours shown

Spark plugs 3.3 150 300 Yearly or hours shown

Replace stepper motor coupling and bushing D 500 hours

GeneratorVisible wear or damage X Quarterly

Exercise generator set W Weekly

Brushes and collector ring D D Yearly

Measure and record resistance readings ofwindings with insulation tester (Meggerr, withSCR assembly or rectifier and load leadsdisconnected)

D 3 Years

General Condition of EquipmentEvidence of vibration, leakage, deterioration,unusual or excessive noise or temperature X X X Weekly

Interior of sound enclosure X X Quarterly

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

X = ActionD Authorized distributor/dealer onlyR Replace as necessary


3.2 Lubrication SystemSee the service schedules in Section 3.1 for oil changeand oil filter replacement intervals. See the serviceviews inSection 1.5 for the oil drain, oil check, oil fill, andoil filter locations.

3.2.1 Low Oil Pressure Shutdown

The low oil pressure (LOP) shutdown feature protectsthe engine against internal damage if the oil pressuredrops below a minimum pressure because of oil pumpfailure or other malfunction.

Note: The LOP shutdown feature does not protectagainst damage caused by operating when theoil level is low; it is not a low oil level shutdown.Check the oil level regularly, and add oil asneeded.

3.2.2 Oil Check

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

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

Check the oil level before each use. For extendedoperation, check the oil level every 8 hours. Do notcheck the oil level when the generator set is running.Shut down the generator set and wait several minutesbefore checking the oil.

6515

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

3.2.3 Engine Oil Recommendation

Use 5W-30 API (American Petroleum Institute) ServiceClass SG, SH, or SJ synthetic oil. Synthetic oil oxidizesand thickens less than other oils and leaves the engineintake valves and pistons cleaner.

3.2.4 Oil Change Procedure

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

Drain the oil while it is still warm.

1. Drain the oil.

a. Place the generator set master switch in theOFF position.

b. Disconnect the power to the battery charger.

c. Disconnect the generator set engine startingbattery, negative (--) lead first.

d. Remove the housing side panel.

e. Clean the area around the dipstick and oil fillcap.

f. Remove the oil drain hose from its retainingclip. Remove the cap from the oil drain hoseand lower the hose into an oil collectioncontainer.

g. Open the oil drain valve on the engine.

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

i. Close the oil drain valve. Replace the cap onthe oil drain hose. Replace the oil drain hose inits retaining clip.

j. Replace the dipstick.

2. Replace the oil filter.

a. Clean the area around the oil filter. Remove theoil filter by rotating it counterclockwise with anoil filter wrench.

b. Clean the gasket sealing surface of the oil filteradapter.

c. Apply a light coat of clean oil to the rubber sealof the new oil filter.

d. Install the newoil filter following the instructionsprovided with the filter.


3. Fill with oil.

a. Fill the engine to the F mark on the dipstick.The engine oil capacity is shown in Figure 3-2.See Section 3.2.3, Engine OilRecommendation, for oil selection.

Generator Set Oil Capacity, L (qt.)

8.5/12RES 1.9 (2.0)

17/18RES 2.8 (3.0)

Figure 3-2 Engine Oil Capacity

b. Reinstall the dipstick and the oil fill cap.

c. Check that the generator setmaster switch is inthe OFF position.

d. Reconnect the generator set engine startingbattery, negative (--) lead last.

e. Reconnect the power to the battery charger.

f. Start and run the generator set for a minute toallow the oil pressure to reach operating range.

g. Stop the generator set, wait 1 minute, and thenrecheck the oil level. Add oil to bring the levelup to the F mark on the dipstick.

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

3.2.5 Oil Cooler, 17/18 kW

Inspect and clean the oil cooler at the intervals indicatedin the service schedule. The oil coolermust be kept freeof debris.

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

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

162 590 011. Oil cooler

Figure 3-3 Oil Cooler Location


3.3 Spark PlugsReset the spark plug gap or replace the plugs with newplugs as necessary.

1. Clean the area around the base of the spark plug tokeep 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 isquestionable.

3. Check the spark plug gap using a wire feelergauge. See Figure 3-4 for the recommendedspark plug gap. Adjust the gap by carefullybending the ground electrode. See Figure 3-5 andFigure 3-6.

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

Generator Set Spark Plug Gap

8.5 kW 0.51 mm (0.020 in.)

12/17/18RES 0.76 mm (0.030 in.)

Figure 3-4 Spark Plug Gap

1--514

Figure 3-5 Checking the Spark Plug Gap

1--511

Figure 3-6 Adjusting the Spark Plug Gap

3.4 Air Cleaner Service

3.4.1 Air Cleaner, 8.5/12RES

The engine has a replaceable high-density paper aircleaner element with an oiled foam precleaner. SeeFigure 3-7.

1

2

3

4

5

6

7

586536

1. Cover knob2. Air cleaner cover3. Element cover nut4. Element cover5. Foam precleaner6. Air cleaner element7. Air cleaner base

Figure 3-7 Air Cleaner Components

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

Note: Operating the engine with loose or damaged aircleaner components could allow unfiltered airinto the engine causing premature wear andfailure.

Precleaner Service

Use the following procedure to wash and reoil theprecleaner as indicated in the service schedule. Washand reoil the precleaner more often under extremelydusty or dirty conditions.

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


2. Disconnect the power to the battery charger.

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

4. Loosen the cover retaining knob and remove thecover. Remove the precleaner from the paperelement. Wash the precleaner in warm water withdetergent. Rinse the precleaner thoroughly until alltraces of detergent are eliminated. Squeeze outexcess water (do not wring). Allow the precleanerto air dry.

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

6. Reinstall the precleaner over the paper element.

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

8. Reconnect the power to the battery charger.

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

Paper Element Service

Use the following procedure to replace the paperelement at the intervals specified in the serviceschedule. Replace the paper elementmore often underextremely dusty or dirty conditions.


2. Disconnect the power to the battery charger.

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

4. Loosen the cover retaining knob and remove thecover.

5. Remove theelement cover nut, element cover, andthe paper element with precleaner.

6. Remove the precleaner from the paper element.

Note: Do not wash the paper element or clean itwith pressurized air, as this will damage theelement.

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

8. Check the air cleaner base. Make sure it is secureand not bent or damaged. Also check the elementcover for damage and fit. Replace all damaged aircleaner components. Remove any loose dirt ordebris from the air cleaner base. Wipe the basecarefully so that no dirt drops into the intake throat.

Check the condition of the rubber seal on the aircleaner stud and replace the seal if necessary.

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

10. Reconnect the power to the battery charger.

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

3.4.2 Air Cleaner, 17/18RES

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

1

tp6515

1. Knobs (qty.2)2. Cover

3. Paper element4. Air filter latch

3

4

2

Figure 3-8 Air Cleaner Components

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

Note: Operating the engine with loose or damaged aircleaner components could allow unfiltered airinto the engine causing premature wear andfailure.


Paper Element Service

Replace the paper element at the intervals indicated inthe service schedule. See Section 3.1.2 for the serviceschedule. See Figure 3-8 for the air cleanercomponents.

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

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

3. Do not wash the paper element or use pressurizedair, as this will damage the element. Replace adirty, bent, or damaged element. Handle newelements carefully; do not use if the sealingsurfaces are bent or damaged.

4. When servicing the air cleaner, check the aircleaner baseand latch.Makesure it is securedandnot bent or damaged. Also, check the elementcover for damage or improper fit. Replace alldamaged air cleaner components.

Note: If any loose dirt or debris fell on the air cleanerbase when the element was removed, carefullyremove it and wipe the base clean. Be carefulthat none of it drops into the intake throat.

5. Reinstall the paper element onto the air cleanerbase. Make sure the element is flat and properlyseated. Rotate the latch clockwise, over themolded lip on the element.

6. Install the air cleaner cover and securewith the tworetaining knobs.

7. When element replacement is necessary, ordergenuine Kohler parts.

3.5 Cooling SystemThe engine fan draws cooling air through the openingsin the sides and end near the battery. The alternator fandraws cooling air through openings on the side walls ofthe enclosure. The cooling air mixes with the engineexhaust and is discharged at the exhaust outlet. SeeFigure 3-9. To prevent generator set damage causedby overheating, keep the housing cooling inlets andoutlets clean and unobstructed at all times.

Note: Donot block the generator set cooling air inlets ormount other equipment above them. Overheatingand severe generator damage may occur.

tp61952

1. Exhaust outlet2. Alternator air intake (both sides)3. Engine air intake

3

1

3

Figure 3-9 Cooling Air Intake and Exhaust

3.6 Exhaust SystemRemove all combustible materials from the exhaustlocation. Combustible materials include buildingmaterials as well as natural surroundings. Keep dryfield grass, foliage, and combustible landscapingmaterial a minimum of 1.5 m (5 ft.) from the exhaustoutlet.

Periodically inspect the exhaust systemcomponents forcracks, leaks, and corrosion.

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check that the exhaust outlet is clear.


3.7 Battery

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

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid can causeblindness and burn skin. Always wear splashproof safetygoggles, rubber gloves, and boots when servicing the battery.Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediatelyflush the affected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case of eyecontact. Never add acid to a battery after placing the battery inservice, as this may result in hazardous spattering of batteryacid.

Battery acid cleanup. Battery acid can cause severeinjury or death. Battery acid is electrically conductive andcorrosive. Add 500 g (1 lb.) of bicarbonate of soda (bakingsoda) to a container with 4 L (1 gal.) of water and mix theneutralizing solution. Pour the neutralizing solution on thespilled battery acid and continue to add the neutralizingsolution to the spilled battery acid until all evidence of achemical reaction (foaming) has ceased. Flush the resultingliquid with water and dry the area.

Battery gases. Explosion can cause severe injury ordeath. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur near a battery at any time,particularly when it is charging. Do not dispose of a battery in afire. To prevent burns and sparks that could cause anexplosion, avoid touching the battery terminals with tools orother metal objects. Remove all jewelry before servicing theequipment. Discharge static electricity from your body beforetouching batteries by first touching a grounded metal surfaceaway from the battery. To avoid sparks, do not disturb thebattery charger connections while the battery is charging.Always turn the battery charger off before disconnecting thebattery connections. Ventilate the compartments containingbatteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injuryor death. Short circuits can cause bodily injury and/orequipment damage. Disconnect the battery before generatorset installation or maintenance. Remove all jewelry beforeservicing the equipment. Use tools with insulated handles.Remove the negative (--) lead first when disconnecting thebattery. Reconnect the negative (--) lead last whenreconnecting the battery. Never connect the negative (--)battery cable to the positive (+) connection terminal of thestarter solenoid. Do not test the battery condition by shortingthe terminals together.

Refer to this section for general battery information andmaintenance. Also consult the battery manufacturer’sinstructions for battery maintenance.

All generator set models use a negative ground with a12-volt engine electrical system. Consult the generatorset nameplate for the engine electrical system voltage.Consult the generator spec sheet for battery capacityrecommendations for replacement purposes. Wiringdiagrams provide battery connection information. SeeFigure 3-10 for typical battery connections.

EZ-273000-J

1 2

1. To positive (+) terminal on starter solenoid.2. To ground (--) terminal on or near starter motor.

Figure 3-10 12-Volt Engine Electrical System SingleStarter Motor, Typical BatteryConnection

Clean the battery and cables and tighten batteryterminals using the service schedulerecommendations. To prevent corrosion,maintain tight,dry electrical connections at the battery terminals. Toremove corrosion from battery terminals, disconnectthe cables from the battery and scrub the terminals witha wire brush. Clean the battery and cables with asolution of baking soda and water. After cleaning, flushthe battery and cables with clean water and wipe themwith a dry, lint-free cloth.

After reconnecting the battery cables, coat the batteryterminals with petroleum jelly, silicone grease, or othernonconductive grease.

3.8 Battery ChargerThe generator set is equipped with a battery charger tomaintain the engine starting battery. The charger’s DCleads are factory-wired. Periodically check and tightenall connections.

See Section 2.7, Battery Charger.


3.9 Circuit ProtectionIf the generator set circuit breaker trips or the fuses blowrepeatedly, see Section 4, Troubleshooting, forpossible causes.

3.9.1 Line Circuit Breaker

A line circuit breaker interrupts the generator output inthe event of a fault in the wiring between the generatorand the load. The line circuit breaker location is shownin Figure 1-2. The circuit breaker rating is shown inFigure 3-11. If the circuit breaker trips, reduce the loadand switch the breaker back to theONposition. With thebreaker in the OFF position the generator set runs butthe generator output is disconnected from the load.

Model Circuit Breaker Rating, Amp

8.5RES 40

12RES 50

12TRES 20

17/18RES 80

18TRES 25

Figure 3-11 Line Circuit Breaker Rating

3.9.2 Fuses

Three panel-mounted fuses protect the alternator andelectrical controls. See Section 1.5 for fuse locations.Another 10-amp fuse protects the battery charger.

See Figure 3-12 for fuse part numbers. Always identifyand correct the cause of a blown fuse before restartingthe generator set. Refer to Section 4, Troubleshooting,for conditions that may indicate a blown fuse. Replaceblown fuses with identical replacement parts.

Fuse Rating, Amp Label Part Number

Auxiliary winding 20 F1 292937

Relay interfaceboard

10 F2 223316

Controller 10 F3 223316

Battery charger(RES)

10 — 223316

Figure 3-12 Fuses


3.10 Storage ProcedurePerform the following storage procedure beforeremoving the generator set from service for threemonths or longer. Follow the engine manufacturer’srecommendations for storage, if available.

Note: Run the generator set monthly wheneverpossible.

3.10.1 Lubricating System

1. Operate thegenerator set until it reachesoperatingtemperature, or about 15 minutes.

2. Stop the generator set.

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

4. Refill engine crankcase with oil. See Section 3.2.3for oil recommendations.

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

6. Stop the generator set.

3.10.2 Fuel System

1. Start the generator set.

2. With the generator set running, shut off the gassupply.

3. Run the generator set until the engine stops.


3.10.3 Cylinder Lubrication

1. Remove the spark plugs.

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

3. Toggle the generator setmaster switch to crank theengine two or three revolutions to lubricate thecylinders.

3.10.4 Exterior Preparation

1. Clean the exterior surface of the generator set.

2. Seal all openings in the engine with nonabsorbentadhesive tape.

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

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

3.10.5 Battery

Perform battery storage last.


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 batterycharger, or charge the battery monthly using atrickle charger. Follow the battery chargermanufacturer’s recommendations.


Notes

TP-6515 1/11 35Section 4 Troubleshooting

Section 4 Troubleshooting

4.1 IntroductionUse the following charts to diagnose and correctcommon problems. First check for simple causes suchas a dead engine starting battery, loose connections, oran open circuit breaker. The charts include a list ofcommon problems, possible causes of the problem,and recommended corrective actions.

If the procedures in this manual do not explain how tocorrect the problem, contact an authorized distributor/dealer. Maintain a record of repairs and adjustmentsperformed on the equipment. Use the record to helpdescribe the problem and repairs or adjustments madeto the equipment.

4.2 Controller TroubleshootingFigure 4-1 contains troubleshooting, diagnostic, andrepair information for the ADC-RES controller.

4.3 Generator Set TroubleshootingFigure 4-2 contains generator set troubleshooting,diagnostic, and repair information. Check for looseconnections before replacing parts.

Fault Codes

TheAdvancedDigital Control displays fault codes to aidin troubleshooting. Fault codes, descriptions, andrecommended actions are listed in Section 2.6.

If a fault code is displayed, identify and correct the causeof the fault condition. Then reset the controller. SeeSection 2.6.3.

Problem Possible Cause Corrective Action

Controller LEDdisplay is off

No power to the controller:

Controller fuse (F3) is blown. Replace the fuse. If the fuse blows again, contact anauthorized distributor/dealer.

Low or no battery voltage. Check connections.Check the engine starting battery and battery charger.See Figure 4-3.

Generator set master switch is in theOFF/RESET position.

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

The controller is in sleep mode. See Section2.4.2.

Controller display will activate when a remote startcommand is received or the generator set master switchis moved to the RUN position. Use the remote switch tostart generator set and activate the controller display, ifdesired. See Section 2.4.

Controllers with application code version 1.13 or highercan be configured to enable or disable the sleep mode.See the generator set Installation Manual forinstructions.

Figure 4-1 ADC-RES Troubleshooting Chart

TP-6515 1/1136 Section 4 Troubleshooting

Problem Possible Cause Corrective ActionThe generator setdoes not crank.

Fault shutdown Check for a fault code on the controller display. SeeSection 2.6.

Battery weak or dead Check power to the battery charger.Recharge or replace the battery.

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

Battery connections reversed or poor Check the connections.Fuse F2 blown Replace the fuse. Contact an authorized distributor/

dealer for service if fuse blows repeatedly.

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

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

The generator setcranks but does notstart, starts hard,lacks power, oroperates erratically.

Air cleaner clogged Clean and/or replace the air cleaner.Battery weak or dead Check power to the battery charger.

Recharge or replace the battery.

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 an authorized distributor/dealer.

No AC output. 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 shortcircuit

Contact an authorized distributor/dealer for service.

Auxiliary winding fuse (F1) blown Replace the fuse. Contact an authorized distributor/dealer for service if fuse blows repeatedly.

Low output orexcessive drop involtage.

Generator set overloaded Reduce the load.

Generator set stopssuddenly.

Low oil pressure shutdown Check the oil level. Check for signs of oil leaks.Out of fuel Check fuel supply.Overcrank shutdown Reset the controller. If the overcrank fault occurs

again, contact an authorized distributor/dealer.

Controller fuse (F3) blown Replace the fuse. If the fuse blows again, contactan authorized distributor/dealer.

Overspeed shutdown Reset the controller. If the overspeed fault occursagain, contact an authorized distributor/dealer.

Generator set master switch in the OFF/RESETposition

Move the switch to the correct position (RUN orAUTO).

Remote stop command received from a remoteswitch or ATS

Check the remote switch position.

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

distributor/dealer for service if fuse blows repeatedly.

Figure 4-2 General Troubleshooting Chart

TP-6515 1/11 37Section 4 Troubleshooting

4.4 Battery ChargerTroubleshooting

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

Problem Cause Solution

Red LED stays onfor more than24 hours

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

Battery charger has reduced its outputvoltage below the normal level due to a DCoverload or a DC short.

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

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

Turn off all DC equipment while charging.

Red and greenLEDs stay on formore than 24 hours

Onboard DC systems are drawing between1.5 and 5 amps.

Turn off all DC equipment while charging.

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

Extremely low AC voltage at the batterycharger.

Apply a higher AC voltage source or reduce the lengthof the extension cord.

Green LED stays onwhen the battery isknown to be low

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.

Neither of the LEDsturn on when theAC power is applied

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

Component failure. Replace battery charger.

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

Problem Cause Solution

Green LED is offand there is nooutput voltage.

No power to the battery charger. Check the power supply to the charger.

Check the upstream circuit breakers and fuses.

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

Abnormal lowvoltage, charger isoperating.

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

Disconnect the battery and verify that the chargeroutput is 13.2 VDC.

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

Test the battery.

The battery isdischarged, but thecharger has powerand is operating.

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

Check inline fuse F4 and replace if necessary.

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

TP-6515 1/1138 Section 4 Troubleshooting

Notes

TP-6515 1/11 Appendix 39

Appendix A Abbreviations

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

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)

exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupterGND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6515 1/1140 Appendix

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gas

NBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

Notes

Notes

E 2007, 2008, 2009, 2011, 2016 by Kohler Co. All rights reserved.

TP-6515 1/11f

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KohlerPower.com

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455

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