KOHLER Generator Manual L0402312

User Manual: KOHLER KOHLER Generator Manual KOHLER Generator Owner's Manual, KOHLER Generator installation guides

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Operation and
Installation
Residential/Commercial

Generator Sets

Models:

8.5RES
12RES
Controller:
Advanced

Digital Control

KOHLERo
POWERSYSTEMS

POWERSYSJEMS

NATIONALLY

TP-6195

REGISTERED

1/04

California

Proposition

WARNING

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

Product Identification

Information

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

Generator

Set Identification

Record the product identification
generator set nameplate(s).

numbers from the

Controller Description

Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation

Specification Number
Serial Number

Serial Number
Accessory Description

Identification

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

Numbers

Model Designation

Accessory Number

Controller

Table of Contents
Product Identification
Safety Precautions
Introduction

Information

and Instructions

........................................................

........................................................................

Section I Specifications
1.1
1.2

and Features

......................................................

I
t
ti
1

Specifications .........................................................
Generator ............................................................

1
1

1.3

Engine ...............................................................

1.4
1.5

Advanced Digital Control ...............................................
Service Views ........................................................

1
2

Section 2 Operation
2.1
2.2
2.3

2.4

2.5
Section 3 Scheduled

.......................................................................
Prestart Checklist .....................................................

3
3

Exercising the Generator Set ...........................................
Generator Set Operation ...............................................
2.3.1
Controls and Indicators ........................................
2.3.2
Starting the Generator Set ......................................
2.3.3
Stopping the Generator Set .....................................
2.3.4
Fault Shutdowns ..............................................

3
3
4
4
4
5

2.3.5
Resetting the Controller after a Fault Shutdown ....................
2.3.6
Continuous Power Mode .......................................
Circuit Protection ......................................................
2.4.1
Line Circuit Breaker ...........................................
2.4.2
Fuses .......................................................

6
6
7
7
7

Battery Charger .......................................................
2.5.1
Battery Charger Operation ......................................

7
8

Maintenance

..........................................................

3.1
3.2

Routine Maintenance ..................................................
Service Schedule .....................................................

3.3

Lubrication System ....................................................
3.3.1
Low Oil Pressure Shutdown ....................................
3.3.2
Oil Check ....................................................

11
11
11

3.3.3
Engine Oil Recommendation ....................................
3.3.4
Oil Change Procedure .........................................
Spark Plugs ..........................................................
Air Cleaner Element and Precleaner .....................................
3.5.1
Precleaner Service ............................................

11
11
12
12
12

3.5.2
Paper Element Service .........................................
Cooling System .......................................................

12
13

3.7
3.8

Exhaust System ......................................................
Battery ...............................................................
3.8.1
Cleaning the Battery ...........................................
3.8.2
Checking Battery Electrolyte Level ...............................
3.8.3
Checking Electrolyte Specific Gravity ............................

14
14
15
15
16

3.9
3.10

Battery
Storage
3.10.1
3.10.2
3.10.3
3.10.4
3.10.5

17
17
17
17
17
17
18

3.4
3.5

3.6

1/04

Inside front cover

...............................................................................

Service Assistance

TP-6195

............................................

Charger .......................................................
Procedure ....................................................
Lubricating System ............................................
Fuel System ..................................................
Cylinder Lubrication ...........................................
Exterior Preparation ...........................................
Battery .......................................................

9
9

Table of Contents

Table of Contents, continued
Section 4 Troubleshooting .................................................................
4.1
Introduction
..........................................................
4.2
4.3

Generator Set Troubleshooting ..........................................
Fault Codes ..........................................................

19
20

4.4
4.5

Controller Troubleshooting
.............................................
Battery Charger Troubleshooting
........................................

20
20

Section 5 Wiring Diagrams
5.1
5.2
Section

6 Installation

................................................................

Specification Numbers .................................................
Controller Wiring Diagram Reference ....................................

21
21

......................................................................

6.1

General ..............................................................

6.2
6.3

Weight ...............................................................
Generator Set Inspection ...............................................

25
25

6.4
6.5
6.6
6.7

Mounting .............................................................
Exhaust Requirements .................................................
Air Requirements
.....................................................
Power Supply .........................................................

25
25
27
27

6.8

Fuel System ..........................................................
6.8.1
Fuel Supply ..................................................
6.8.2
Fuel Pipe Size ................................................
6.8.3
Fuel Conversion ..............................................
Electrical Connections .................................................
6.9.1
AC Load Lead Connections .....................................

27
27
28
28
31
31

6.9.2
Remote Start Connection (optional) ..............................
6.9.3
Continuous Power Mode Jumper ................................
6.9.4
Battery .......................................................
6.9.5
Battery Charger ...............................................
Accessories ..........................................................
6.10.1
Common Fault and Run Relay Board ............................
6.10.2
Carburetor Heater .............................................

32
32
33
34
35
35
36

6.12

Controller Configuration ................................................
6.11.1
System Configuration ..........................................
6.11.2
Advanced Configuration Mode ..................................
Prestart Installation Check ..............................................

37
37
37
37

6.13

Warranty Registration

6.9

6.10

6.11

Appendix A Abbreviations

Table of Contents

19
19

..................................................

..................................................................

A-1

TP-6195

1/04

Safety Precautions and Instructions
IMPORTANT
INSTRUCTIONS.

SAFETY
Electromechanical

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

DANGER
Danger indicates the presence of a
hazard
that will cause
severe
personal injury, death, or substantial
property damage.

WARNING
Warning indicates the presence of a
hazard
that can
cause
severe
personal injury, death, or substantial
property damage.

CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE

Accidental

Starting

_1_ WARNING

Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working
on the generator
set.
Remove the negative (-) lead first
when disconnecting
the battery.
Reconnect the negative (-) lead last
when reconnecting the battery.
Disabling
the
generator
set.
Accidental
starting
can
cause
severe injury or death.
Before
working on the generator
set or
connected equipment, disable the
generator set asfollows: (1) Movethe
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (-) lead first.
Reconnect the negative (-) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer
switch,
remote
start/stop
switch, or engine start command from a
remote computer.

Battery
_1_ WARNING

Notice communicates
installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician
to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication
to
improve
operator
recognition.
Replace missing or
damaged decals.

TP-6195

1/04

_1_ WARNING

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

Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
Battery
electrolyte
is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always
wear splashproof
safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive.
Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing
solution on the spilled
battery acid and continue to add the
neutralizing
solution to the spilled
battery acid until all evidence of a
chemical
reaction
(foaming)
has
ceased. Flush the resulting liquid with
water and dry the area.

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

Safety Precautions and Instructions

Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body
before touching
batteries by first touching a grounded
metal surface awayfrom the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections.
Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits.
Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or
equipment
damage.
Disconnect
the
battery
before
generator
set
installation
or
maintenance.
Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative
(-) lead first when
disconnecting the battery. Reconnect
the negative
(-) lead last when
reconnecting
the battery.
Never
connect the negative (-) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition
terminals together.

shorting

the

Safety Precautions and Instructions

Engine Backfire/Flash
Fire

Exhaust System
A

WARNING

_1_ WARNING

Fire.
Can cause severe injury or death.

Carbon monoxide.
Can
cause
severe
fainting, or death.

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

The
exhaust
system
must be
leakproof and routinely inspected.

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

Generator set operation.
Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid

Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Combustible materials. A fire can
cause
severe
injury
or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
SeleCt a fire extinguisher rated ABC or
BC
for
electrical
fires
or
as
recommended by the local fire code or
an authorized
agency.
Train all
personnel
on
fire
extinguisher
operation
and
fire
prevention
procedures.

nausea,

breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building. Never operate the generator
set where exhaust gas could seep
inside or be drawn into a potentially
occupied building through windows, air
intake vents, or other openings.
Carbon
monoxide
symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases.
Carbon monoxide
poisoning symptoms include but are
not limited to the following:
• Light-headedness, dizziness
• Physical fatigue, weakness in
joints and muscles
• Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
• Stomachache, vomiting, nausea
if experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep.
Alert others to the
possibility
of
carbon
monoxide
poisoning.
Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.

TP-6195

1/04

Fuel System
_1_ WARNING

Hazardous

Noise

_1_ CAUTION

Explosive fuel vapors.
Can cause severe injury or death.

Hazardous noise.
Can cause hearing loss.

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

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

The fuel system.
Explosive fuel
vapors can cause severe injury or
death.
Vaporized fuels are highly
explosive.
Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated
area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines.
Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Gas fuel leaks.
Explosive fuel
vapors can cause severe injury or
death.
Fuel leakage can cause an
explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6-8 ounces
per
square
inch
(10-14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. Asuccessful
test depends on the ability of the
solution to bubble.

TP-6195

1/04

_1_ WARNING

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

Hazardous Voltage/
Electrical Shock
A

DANGER

Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.

_1_ WARNING

Hazardous voltage Moving
Can cause severe injury or death.

Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
if the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection
of standby
and
normal sources of supply.

_1_ CAUTION

Welding the generator set.
Can
cause
severe
electrical
equipment damage.
Never weld components
of the
generator
set
without
first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
Grounding
electrical
equipment.
Hazardous
voltage
can
cause
severe injury or death. Electrocution
is possible whenever electricity is
present.
Open the main circuit
breakers of all power sources before
servicing the equipment. Configurethe
installation to electrically ground the
generator set, transfer switch, and
related equipment
and electrical
circuitsto comply with applicable codes
and
standards.
Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.

Operate the generator set only when
all guards and electrical enclosures
are in place.

Safety Precautions and Instructions

Ill

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

Heavy Equipment

instilling
the
battery
charger.
Hazardous
voltage
can
cause
severe
injury
or death.
An
ungrounded
battery charger may
cause electrical shock. Connect the

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

battery charger enclosure to the ground
of a permanent wiring system. As an
alternative,
install
an
equipment
grounding conductor with circuit
conductors and connect it to the
equipment grounding terminal or the
lead on the battery charger. Install the
battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.
Connecting
the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect
the
battery
correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies).
Have
a qualified
electrician install the battery(ies).
Short

circuits.

Hazardous

voltige/current
can cause severe
injury or death.
Short circuits can
cause bodily injury and/or equipment
damage.
Do not contact electrical
connections with tools or jewelry while
making
adjustments
or
repairs.
Remove all jewelry before servicing the
equipment.
Electrical backfeed to the utility.
Hazardous
backfeed voltage can
cause severe injury or death, install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical
backfeed
into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.

Safety Precautions and Instructions

_1_ WARNING

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

Moving Parts
_1_ WARNING

Hazardous voltage Moving
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.

_1_ WARNING

Hot Parts
_1_ WARNING

Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.

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

_1_ WARNING

Do not work on the generator set until
it cools.
Servicing the generator. Hot parts
can cause severe injury or death.
Avoid touching the generator set field
or exciter armature. When shorted,the
generator set field and exciter armature
become hot enough to cause severe
burns.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust
system
components
become extremely hot
during operation.
Servicing the engine heater.
Hot
parts can cause minor personal
injury or property damage. Install the
heater before connecting it to power.
Operating the heater before installation
can cause burns and component
damage.
Disconnect power to the
heater and allow it to cool before
servicing the heater or nearby parts.

Airborne particles.
Can cause
severe
blindness.

injury

Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
Tightening the hardware.
Flying
projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator set engine and can cause
personal
injury.
Retorque
all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotorthrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise
can loosen
the
hardware.

TP-6195

1/04

Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.

Notice

NOTICE
Electrostatic
discharge
damage.
Electrostatic
discharge
(ESD)
damages electronic circuit boards.
Prevent
electrostatic
discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), net a direct short, to
ground.

NOTICE
This generator
set has been
rewired from its nameplate voltage
to

246242

NOTICE
Voltage reconnection.
Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate.
Order
voltage reconnection
decal 246242
from
an
authorized
service
distributor/dealer.
NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not
substitute
with
inferior
grade
hardware.
Screws and nuts are
available in different hardness ratings.
To indicate
hardness,
American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.
NOTICE
Canadian installations
only.
For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

TP-6195

1/04

Safety Precautions and Instructions

Notes

Safety Precautions

and Instructions

TP-6195

1/04

Introduction
This manual provides operation and installation
instructions for model 8.5RES and 12RES generator
sets equipped with the Kohler _ Advanced Digital
Control (ADC 2100).
Information in this publication represents data available
at the time of print. The manufacturer may provide this
manual for models not listed on the front cover. Kohler
Co. reserves the right to change this publication and the
products represented without notice and without any
obligation or liability whatsoever.

EPA and California
Certification

An engine or generator set with the following
identification labels is certified to meet Small Off-Road
Engine emission standards for EPA!CARB. All model
8.5RES and 12RES generator sets with multhfuel
systems are emission-certified.
IMPORTANT

ENGINE INFORMATION

THIS ENGINE MEETS U,S. EPA PH1 AND
CALIFORNIA 2006 EMISSION REGS FOR
Si SMALL OFF-ROAD ENGINES

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

FAMILY

KHXS*7252NA

OISPL {CC)
MODEL NO.
SPEC, NO,
SERIAL

NO,

EMISSION

COMPUANCE

EPA:

PERIOD:

CARB:

THIS ENGINE IS CERTIFIED
ON: LPG / NATURAL GAS

EXTENDED
TO OPERATE

REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE
SPECS AND ADJUSTMENTS,

The generator set is approved for use in stationary
applications in locations served by a reliable utility
power source.

FOR SALES AND SERVICE tN US/CANADA,
CALL:
1-800-544-2444
KotllerEng_nes.com

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

KOH_ERCO KOHLER,WISCONSIN USA
tp6195

Figure

dealer to keep equipment in top condition.

Emission

Emissions
IMPORTANT

Nameplate

Label, 8.5RES

Engine (CH20)

ENGINE INFORMATION

THIS ENGINE MEETS U,S. EPA PH1 AND
CALIFORNIA 2006 EMISSION REGS FOR
Si SMALL OFF-ROAD ENGINES

The following illustration shows a typical generator set
nameplate. Copy the model, serial, and specification
numbers from the nameplate into the spaces provided in

FAMILY

KHXS*7252NA

OISPL {CC)
MODEL NO.
SPEC,
SERIAL

the product information section on the inside front cover
of this manual. See Section 1.5, Service Views, for the
nameplate location.

NO,

EMISSION
EPA:

725

NO,
COMPUANCE

PERIOD:

CARB:

THIS ENGINE IS CERTIFIED
ON: LPG / NATURAL GAS

EXTENDED
TO OPERATE

REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE
SPECS AND ADJUSTMENTS,

KOHLER,o

FOR SALES AND SERVICE tN US/CANADA,
CALL:
1-800-544-2444
KotllerEng_nes.com

KOHLER CO. KOHLER Wl. USA
MODEL:

SERIAL:

RPEC:

SERVICE DUTY:
HZ:

I ...........
GEN, MODEL:
BAI"r, V
INSULATION:NEMA CLASS
KWVARIES WITH BTU CON]ENT OF FUEL

TP-6195

1/04

KOH_ERCO KOHLER,WISCONSIN USA

RPM:
tp6195

I
Figure 2

Emissions Label, 12 RES Engine (CH740)

Introduction

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

O
_T

CLE_,N

NOTE:

10
L_AST

GLE_I

THE LOWER TH_ Afl_ tNI_EX, THE LE,9._POtLU_ON

TH_$ ENGINE I_ O_RT]F_ED TO _E EMI,%_ION CX_MpL_ANT
FOR TH£ FOLLOWING USE:
r3 MOD_ATE

1_11kC'_ERMaDIATE
_ EXUDED
CHECK OWNE_
MANU_
FOR FURTHER D_W'A_LS
THIS LAI_EL TO BE R_MOV_O By THE ULIff_ATE pURCHASER
CAUTION_EL

Emission Compliance Period (hours)

BE,_OR E _TAWCING ENGINE,

CARB
tp6185

Figure 3

Air Index Label, 8.5/12RES

Moderate,
125

intermediate,
250

Extended,
500

Refer to the certification label for engine displacement.

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

using

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

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

Service Assistance
For
professional
advice
on generator
power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
• Consult the Yellow
Generators--Electric

Pages

• Visit the Kohler Power
KohlerPowerSystems.com

under

Systems

the

heading

website

• Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product
• Call toll free in the US and Canada 1-800-544-2444
• Outside the US and Canada, call the nearest regional
office
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems
ZI Senia 122
12, rue des Hauts FIouviers
94517 Thiais Cedex
France
Phone: (33) 1 41 735500
Fax:
(33) 1 41 735501

China
North China
Phone: (86)
(86)
(86)
Fax:
(86)

Regional Office, Beijing
10 6518 7950
10 6518 7951
10 6518 7952
10 6518 7955

East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax:
(86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax:
(91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax:
(813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax:
(863) 701-7131

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

Service

Assistance

TP-6195

1/04

Section 1 Specifications
1.1

Specifications

1.4

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

Advanced

and Features

Digital Control

The generator set is equipped with the Kohler ®
Advanced Digital Control (ADC 2100).
Controller
features include the following:
• Compact controller
• Integrally mounted to the generator set
• LED display:
• Runtime hours

1.2

Generator

• Crank cycle status
• Diagnostics

The generator uses Kohler's unique PowerBoosV"
voltage regulation system, which provides instant
response to load changes.
PowerBoost
ensures reliable motor starting and
consistent voltage levels.
PowerBoosV"
utilizes a
voltage excitation system that employs a winding
independent of the main output windings to provide
excitation voltage.
TM

1.3

• LED display communicates faults:
• Auxiliary fault
• High battery voltage
• High engine temperature
• Low battery voltage
• Low oil pressure
• Overcrank safety
• Overspeed

Engine

• Overfrequency

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

• Overvoltage
• Underfrequency
• Undervoltage
• Membrane keypad for configuration and adjustment

• Efficient overhead valve design and full pressure
lubrication for maximum power, torque, and reliability
under all operating conditions.
• Dependable, maintenance-free

electronic ignition.

• Precision-formulated cast iron construction of parts
subjected to the most wear and tear.
• Field-convertible multi-fuel systems that allow fuel
changeover from natural gas to LP vapor (and
vice-versa)
while maintaining
CARB emission
certification.
• Digital spark-advance module (DSAM) optimizes
ignition timing for the selected fuel (12RES).

• Password-protected

user access to menus

• Voltage, gain, and speed adjustment
• System configuration
(system voltage, phase,
and frequency settings, battery voltage, and
generator set model)
• Master control switch: Run/Off-Reset/Auto
Remote two-wire start!stop capability
Superior electronics protection from corrosion and
vibration
• Potted electronics
• Sealed connections
Digital
isochronous
governor
steady-state speed at all loads

maintain

Digital voltage regulation: -+1.5% RMS no-load to
full-load
• Automatic start for programmed cranking cycle

TP-6195

1/04

Section 1 Specifications

and Features

1.5

Service Views

/
15
1.
2.
3.
4.
5.

Enclosure
Muffler
Oil check
0il fill
Air cleaner

AD_6_3_

15. Alternator
16. Exhaust

Generator set master switch (RUN\OFF/RESET_AUTO)
Nameplate
Line circuit breaker
Engine starting battery location
Oil drain hose

Figure 1-1

11
13. Oil drain valve
14. Oil filter

6. Spark plug locations (both sides)
7. Controller
8.
9.
10.
11.
12.

cooling air intake

17. Spark arrestor
18. DSAM leads
19. Multi-fuel block
20.
21.
22.
23.
24.

Gas regulator assembly
Fuel solenoid valve
Air intake
Battery charger
Relay board

Generator Set Service View

Section 1 Specifications

and Features

TP-6195

1/04

Section 2 Operation
2.1

Prestart Checklist

2.2

Exercising

the Generator

Set

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

Operate the generator set under load once each week
for one hour. If the generator set does not have a
programmed exercise mode or an automatic transfer
switch (ATS) with an exercise option, exercise the unit in
the presence of an operator.

Air Cleaner. Check for a clean and installed air cleaner

During the exercise period apply a minimum of 35% load
based on the nameplate standby rating.

element to prevent unfiltered
engine.

air from

entering the

Air Inlets. Check for clean and unobstructed air inlets.
Battery. Check for tight battery connections. Consult
the battery manufacturer's
instructions regarding
battery care and maintenance.
Exhaust System.
Check for exhaust leaks and
blockages. Check the muffler and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, exhaust line, flexible exhaust, clamps, muffler,
and outlet pipe) for cracks, leaks, and corrosion.

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

2.3

Generator

Set Operation

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

• Check for corroded or broken metal parts and replace
them as needed.

J
• Check for loose, corroded, or missing clamps and
hangers.
Tighten or replace the exhaust clamps
and/or hangers as needed.

• Check that the exhaust outlet is unobstructed.

_'ED

D_T_. _

COnE
nEFImTION
_,_
A_JII i
_ull
Cmn_l*
Hn
Hlgll
_ "a11_Ip
He
Hlllh_en I_ lllmp

• Visually inspect for exhaust leaks (blowby). Check
for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.

L_L

LOW 4_1411mn4 Lllt_

LOC

LU= of CNMn=

LOp
C4_

LOW G41Ll_'lOFJr4p
_r
Ct, lnk

uU_

Under
_u*_'i,
Oser voltep

= _; ."',..?='
_FmSllmr

Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.
x:op:001:002

RUN

1/04

AU'TO

o
x

GM28707A-C

1. LED display
2. Select button (use for setup and adjustment only)
3, Up and down arrow buttons (use for setup and adjustment
only)
4, Generator set master switch

Figure 2-1

TP-6195

ADC 2100 Controller User Interface

Section 2 Operation

2.3.1

Controls

and Indicators

Figure 2-2 describes the controls and indicators located
on the generator set controller.
The LED display indicates generator set status as
shown in Figure 2-2. The display is activated by a start
or run command and remains active until the generator
set master switch is moved to the OFF/RESET position
or power to the controller is removed.
If the
factory-installed continuous power mode jumper has
been disconnected, the LED display turns off 48 hours
after generator set shutdown. See Section 2.3.6.
The buttons on the controller keypad are used only for
system configuration and adjustment. The controller is
factory-set and should not require configuration or
adjustment under normal operating conditions. Contact
an authorized distributor/dealer or service technician if
adjustments are required.

2.3.2

Starting

the Generator

start/stop switch. (A remote start/stop switch can be
connected to controller leads 3 and 4. See the wiring
diagrams in Section 5).

2.3.3

Stopping

the Generator

Set

The following procedures describe the actions required
to stop the generator set.
Local Stopping
1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.
2. Move the generator set master switch to the
OFF/RESET position. The engine stops.
Automatic Stopping
With the generator set master switch in the AUTO
position and an automatic transfer switch (ATS) or other
automatic device connected to controller leads 3 and 4:

Set

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

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

2. If the ATS is equipped with an engine cooldown
time delay, the generator set continues to run for a
preset engine cooldown time.
Note: There is no engine cooldown time delay on
the ADC controller.

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

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

Auto (Automatic) Starting
Move the generator set master switch to the AUTO
position to allow startup by the ATS or the remote

Control

or Indicator

Item

Description

Runtime hours

Displays total generator

Crank indication

Displays CC1, CC2, or CC3 to indicate the first, second or third attempt to start the
engine. The last digit flashes during the crank cycle rest periods.

Fault codes

Flashes a 2- or 3-letter fault code to indicate various fault conditions.

Software version
number

See TP-6196,

Keypad

Select and arrow
buttons

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

Generator set master
switch

Three-position
switch

Switch functions as the generator set operation and controller

LED display

Figure 2-2

set runtime hours while the generator set is running.

See Section 2.3,4.

Generator Set Service Manual.

reset switch,

ADC 2100 Controls and Indicators

Section 2 Operation

TP-6195

1/04

2.3.4

Fault Shutdowns

The generator set shuts down automatically under the
fault conditions listed in Figure 2-3 and the controller
displays a fault code. The generator set cannot be
restarted until the fault condition is corrected and the
controller is reset. See Section 2.3.5 to reset the
controller after a fault shutdown. The controller resets
automatically
corrected.

after a battery voltage fault condition is

The shutdown
switches on the generator
set
automatically reset when the problem is corrected. The
high engine temperature switch automatically resets
when the generator set cools. However, the fault does
not clear until the controller is reset.
The controller displays a fault code but the generator set
does not shut down under the conditions shown in
Figure 2-4.

Code

Fault

Description

Check

Auxiliary fault
input shutdown

Input from a customer-supplied switch that closes when the
fault is active. The generator set shuts down and will not start
when the fault is active (input is grounded),

Check the cause of the auxiliary fault.

High engine
temperature
shutdown

Shutdown occurs if the engine coolant temperature exceeds
the maximum temperature for more than 5 seconds, This
protective becomes active after the engine reaches the crank
disconnect speed,

Check for blocked air inlets and exhaust
outlets,

LOP

Low oil pressure

Shutdown occurs if a low oil pressure condition exists 7

Check for leaks in the lubdcation

shutdown

seconds after the engine has reached crank disconnect

Overcrank
shutdown

speed.

system,

Check the oil level and add oil if the level

Note: The low oil pressure shutdown does not protect against
low oil level, Check the oil level at the engine,

is low.

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

Check the fuel supply, spark plug, and
battery.

cranking and 15 seconds rest.

Check for loose connections.

The generator set also shuts down after 1 crank attempt if no
speed signal is sensed, Shuts down 1 second after the fault is
detected.

Contact an authorized distributor/dealer
service if problem continues.

for

Overfrequency
shutdown

Shutdown occurs when the governed frequency exceeds 110%
of the system's frequency setpoint for more than 1 second,
This protective becomes active 30 seconds after engine start.

Contact an authorized distributor/dealer
service if problem continues.

for

Overspeed
shutdown

Shutdown occurs if the engine speed exceeds 115% of the
normal running speed for more than 1 second,

Contact an authorized distributor/dealer
service if problem continues.

for

Overvoltage
shutdown

Shutdown occurs if the voltage exceeds 120% of the voltage
regulator setpoint for more than 1 second,

Contact an authodzed distributor/dealer
service if problem continues.

for

Underfrequency
shutdown

Shutdown occurs when the governed frequency falls 1 Hz
below the system's frequency setpoint for more than 1 second,

Reduce the load and restart the generator
set,
Contact an authodzed distributor/dealer
service if problem continues.

Undervoltage
shutdown

for

Shutdown occurs if the voltage falls below 80% of the voltage
regulator setpoint for more than 1 second. This protective

Reduce the load and restart the generator
set,

becomes active 30 seconds after engine start.

Contact an authorized distributor/dealer

for

service if problem continues.

Figure

2-3

ADC

Fault

Shutdown

Codes

Code

Fault

Description

Check

High battery
voltage warning

Fault code is displayed if the engine starting battery voltage rises
above 16 VDC for a 12 VDC system or above 30 VDC for a
24 VDC system for more than 10 seconds when the engine is not
running, This fault condition does not inhibit engine starting.

Check the battery rating and condition.
Check the battery charger operation.

The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 seconds.
LB

Low battery
voltage warning

Fault code is displayed if the engine starting battery voltage falls
below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC
system for more than 10 seconds when the engine is not running.
This fault condition does not inhibit engine starting.

Check the battery rating and condition.
Check the battery charger operation.
Charge or replace the battery.

The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 seconds.

Figure 2-4
TP-6195

1/04

ADC Fault Warning Codes
Section 2 Operation

2.3.5

Resetting the Controller
Fault Shutdown

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

after a

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

set

master

switch

Note: The controller's LED display remains off
until an engine start command is received.
Opening and closing a remote start/stop contact also
resets the controller.

2.3.6
2. Disconnect the generator set from the load using
the line circuit breaker or ATS. See the safety
precautions at the beginning of this section before
proceeding.
3. Identify and correct the cause of the fault
shutdown.
See the safety precautions at the
beginning of this section before proceeding. Refer
to Section 4, Troubleshooting.
4. Start the generator set by moving the generator set
master switch to RUN. Test operate the generator
set to verify that the cause of the shutdown has
been corrected.
5. Move the generator
OFF/RESET.

set

master

switch

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

Continuous

Power Mode

The controller is powered by the generator set engine
starting battery. A jumper on the back of the controller
maintains power to the controller at all times.
Controllers are shipped with the jumper connected.
Note: The 8.5 and 12 RES generator sets are equipped
with factory-installed battery chargers to prevent
battery discharge.
Disconnecting the jumper allows the controller to power
down automatically 48 hours after the generator set
shuts down if the generator set master switch is in the
AUTO position. A remote start signal (from a transfer
switch or a remote start/stop switch connected to
controller leads 3 and 4) or moving the generator set
master switch to the RUN position turns the controller
back on.
See Section 6.9.3 for instructions
jumper.

Section 2 Operation

to disconnect the

TP-6195

1/04

2.4

Circuit Protection

2.5

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

2.4.1

Line Circuit

Breaker

A line circuit breaker interrupts the generator output in
the event of a fault in the wiring between the generator
and the load. The line circuit breaker location is shown

Battery Charger

The generator set is equipped with a 6-amp
float/equalize battery charger to maintain the engine
starting battery. The charger's power cord must be
connected to a 120 VAC power source. Figure 2-7
illustrates the battery charger.
The battery charger uses an AGS 10 inline fuse. The
fuse is located in the battery lead. See Figure 2-7.

in Figure 1-1. See Figure 2-5 for the circuit breaker
ratings. If the circuit breaker trips, reduce the load and
switch the breaker back to the ON position. With the
breaker in the OFF position the generator set runs but
the generator output is disconnected from the load.
Circuit Breaker
Model

Rating, Amps

8.5RES

12RES

Figure 2-5

2.4.2

Line Circuit

2
Breakers

F 4

Fuses

The engine harness contains two 1O-amp and one
20-amp inline fuses. See Figure 2-6. Another 10-amp
fuse protects the battery charger.
1. LED indicators

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

2, Battery leads, 12 VDC
3, Fuse
4, AC power cord

Figure 2-7

6-Amp Float!Equalize Battery Charger

Part
Fuse

Label

Number

Location

Auxiliary Winding

292937

Lead 55

Relay Interface
Board

223316

Lead PF2

Controller

358337

Lead PF1

Battery Charger

AGS 10

Battery charger DC
lead. See Section 2.5.

Figure 2-6

TP-6195

1/04

Fuses

Section 2 Operation

2.5.1

Battery Charger

Operation

Figure 2-8 illustrates the three-stage charging method.
Red and green LEDs indicate charger operation. The
chart in Figure2-9
describes the LED indicator
operation during each stage of the charging process.

Figure 2-8

Charging Method

Display

Operating

Condition

Red ON
Green OFF

When the red LED is on, it indicates the battery is discharged and the battery charger is recharging at the
BULK rate (stage 1). This charging rate is 6 amps, While the red LED is on, the voltage measured (with
the battery charger on) will be 11.8-14 volts.
If the red LED stays on for more than 24 hours, refer to Section 4,5 in this manual,

Red ON
Green ON

When both the green and the red LEDs are on, the battery charger is charging at an ABSORPTION rate
of between 1,5 and 5 amps (stage 2), This mode of charging gradually tops off your battery, and reduces
harmful sulfating. While both LEDs are on, the voltage measured (with the battery charger on) should be
approximately 14,0-14.5 VDC.

Red OFF
Green ON

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

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

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

Figure 2-9

Battery Charger

Section 2 Operation

LED

Indicator

Functions

TP-6195

1/04

Section 3 Scheduled

_1_ WARNING

Hazardous voltage. Moving
r.
Can cause severe injury or death.

Disabling the generator set. Accidental starting can
cause severe injury or death.
Before working on the
generator set or connected equipment, disable the generator
setas follows: (1) Movethegeneratorsetmasterswitchtothe
OFFposition. (2) Disconnectthepowertothebatterycharger.
(3) Remove the battery cables, negative (-) lead first.
Reconnect the negative (-) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

_1_ WARNING

Operate the generator set only when
all guards and electrical enclosures
are in place.
Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.

3.1

Do not work on the generator set until
cools,

Servicing the exhaust system.
Hot parts can cause
severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely
hot during operation.

TP-6195

1/04

Routine Maintenance

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

3.2
Hot engine and exhaust system.
Can cause severe injury or death.

Maintenance

Service Schedule

Perform the tasks listed in the following service
schedule at the designated intervals for the life of the
generator set. For example, an item serviced every
100 hours of operation or 3 months must also be
serviced after 200 hours or 6 months, 300 hours or
9 months and so on. Rough operation, lack of power,
and excessive oil use indicate serious generator set
problems.
Have an authorized distributor/ dealer
perform all generator set service.

Section 3 Scheduled

Maintenance

Procedure

System

Component

See
Section

or Procedure

Visually
Inspect

Check

Change

Clean

Test

Frequency

Fuel
Flexible lines and connections

Quarterly

Main tank supply level

Weekly

Yearly

Oil level

8 hours or
before use

Crankcase breather*

Fuel piping

3.3

Lubrication

Yearly or 500 hours

Change oil

Yearly or 100 hours

Replace filter*

Yearly or 200 hours

3.6

Cooling

Air ducts, louvers
Exhaust

Yearly

3.7

Line

Weekly

fire hazards

Yearly

Hangers and supports

Yearly

Leakage
Insulation,

DO Electrical

3.8

System

Battery charger operation, charge rate (if equipped)

Remove corrosion,

clean and dry battery and rack

Clean and tighten battery terminals
Battery electrolyte
AC Electrical

level and specific gravity-;

Monthly
X

Yearly

System

Visible wear or damage

Quarterly

Wire abrasions where subject to motion

Six Months

3 Years or 500 hours

Tighten control and power wiring connections
Wire-cable insulation
Engine

Yearly

breakdown *

and Mounting
X

Visible wear or damage

Weekly

Air cleaner service

3.5

Yearly or 100 hours

Spark plugs

3.4

Yearly or 300 hours

500 hours

Replace stepper motor coupling and bushing *
Compartment
Remote

condition

Control

Weekly

System

Remote control

Monthly

Run generator set

Weekly

Generator
Visible wear or damage

2.1

Exercise generator

2.2

set

Quarterly
X

Rotor and stator *

Measure and record resistance readings of
windings with insulation tester (Megger, with
SCR assembly or rectifier disconnected)
General

Condition

3 Years

noise,
X

Interior of sound enclosure
• Contact your local distributor/dealer
Not necessary for maintenance-free

Yearly

of Equipment

Evidence of vibration, leakage, excessive
temperature, or deterioration

Figure 3-1

Weekly

X
for parts or service,
batteries,

Action

Replace as necessary

Weekly

Quarterly

Service Schedule

Section 3 Scheduled

Maintenance

TP-6195

1/04

3.3

Lubrication

System

3.3.4

See Section 3.2, Service Schedule, for oil change and
oil filter replacement intervals. See Section 1.5, Service
Views, for the oil drain, oil check, oil fill, and oil filter
locations.
For extended operation, check the oil level every 8
hours. Maintain the oil level at or near, not over, the full
mark on the dipstick.

3.3.1

Low Oil Pressure

Oil Change

Procedure

Drain the oil while it is still warm.
1. Drain the oil.
a. Place the generator set master switch in the
OFF position.
b. Disconnect the power to the battery charger.
c. Disconnect the generator set engine starting
battery, negative (-) lead first.

Shutdown

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

d. Remove the housing side panel.
e. Remove the oil drain hose from its retaining
clip. Remove the cap from the oil drain hose
and lower the hose into an oil collection
container.
f. Open the oil drain valve on the engine.
g. Allow time for the engine oil to drain completely.

3.3.2

Oil Check

h. Close the oil drain valve.

The generator set is shipped with oil. Before operating a
new generator set, check the engine oil in the
crankcase. See 1.5, Service Views. Verify that the oil
level is at the F mark on the dipstick. Add oil that has a
viscosity appropriate for the climate. See Section 3.3.3,
Engine Oil Recommendation.
Do not check the oil level when the generator set is
running. Shut down the generator set and wait several
minutes before checking the oil level.

3.3.3

k Replace the cap on the oil drain hose. Replace
the oil drain hose in its retaining clip.
2. Replace the oil filter.
a. Remove
the oil filter
by rotating
counterclockwise with an oil filter wrench.

b. Clean the gasket sealing surface of the oil filter
adapter.
c. Apply a light coat of clean oil to the rubber seal
of the new oil filter.

Engine Oil Recommendation

Use API (American Petroleum Institute) Service Class
SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and
thickens less than other oils and leaves the engine
intake valves and pistons cleaner. Select the viscosity
based on the air temperature at the time of operation.
See Figure 3-2.

d. Install the new oil filterfollowing the instructions
provided with the filter.
Note: Dispose of all waste materials (engine
oil, fuel, filter, etc.) in an environmentally
safe manner.
3. Fill with oil.
a. Remove the oil fillcap and fillthe engine to the F
mark on the dipstick. The engine oil capacity is
1.9 L (2.0 qt.). See Section 3.3.3, Engine Oil
Recommendation, for oil selection.
b. Reinstall the dipstick and the oil fill cap.

°F -20
°C -30

0
-20

Temperature
Figure 3-2

TP-6195

1/04

20
-10

32 40
60
0
10
20

80
30

100
40

Range Expected Before Next Oil Change
Engine

c. Check that the generator set master switch is in
the OFF position.

Oil Selection

Section 3 Scheduled

Maintenance

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

3.5

Air Cleaner
Precleaner

Element and

e. Reconnect the power to the battery charger.
f. Start and run the generator set for a minute to
allow the oil pressure to reach the operating
range.
g. Stop the generator set, wait I minute, and then
recheck the oil level. Add oil to bring the level
up to the F mark on the dipstick.
4. Check for leaks.
a. Check for oil leaks.

3.4

The engine has a replaceable high-density paper air
cleaner element with an oiled foam precleaner. See
Figure 3-5.
Check for a buildup of dirt and debris around the air
cleaner system. Keep this area clean.
Note: Operating the engine with loose or damaged air
cleaner components could allow unfiltered air
into the engine causing premature wear and
failure.

b. Fix leaks and recheck the oil level.

3.5.1

c. Reinstall the housing side panel.

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

Spark Plugs

Reset the spark plug gap or replace the plugs with new
plugs as necessary.
1. Clean the area around the base of the spark plug to
keep dirt and debris out of the engine.
2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is
questionable.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.76 mm (0.030 in.) by
carefully bending the ground electrode.
See
Figure 3-3 and Figure 3-4.

Precleaner

Service

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

in the

2. Disconnect the power to the battery charger.
3. Disconnect the battery, negative (-) lead first.
4. Loosen the cover retaining knob and remove the
cover. Remove the precleaner from the paper
element. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until all
traces of detergent are eliminated. Squeeze out
excess water (de not wring). Allow the precleaner
to air dry.
5. Saturate the precleaner with new engine
Squeeze out all of the excess oil.

oil.

6. Reinstall the precleaner over the paper element.
7. Reinstall the air cleaner cover. Secure the cover
with the cover retaining knob.
1-514

Figure 3-3

8. Reconnect the power to the battery charger.

Checking the Spark Plug Gap

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

1-511

Figure 3-4

Adjusting the Spark Plug Gap

Section 3 Scheduled

Maintenance

starting

3.5.2

Paper Element

Service

Use the
element
schedule.
extremely

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

TP-6195

1/04

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

switch in the

Note: Do not blockthe generator set cooling air inlets or
mount
other
equipment
above
them.
Overheating and severe generator damage may

2. Disconnect the power to the battery charger.
3. Disconnect the generator
set
battery, negative (-) lead first.

engine

OCCUr.

starting

4. Loosen the cover retaining knob and remove the
cover.
5. Remove the element cover nut, element cover, and
the paper element with precleaner.

6. Remove the precleaner from the paper element.
Note: Do not wash the paper element or clean it
with pressurized air, as this will damage the
element.

7. Replace the element if it is dirty, bent, or damaged.
8. Check the air cleaner base. Make sure it is secure
and not bent or damaged. Also check the element
cover for damage and fit. Replace all damaged air
cleaner components.
Remove any loose dirt or
debris from the air cleaner base. Wipe the base
carefully so that no dirt drops into the intake throat.
Check the condition of the rubber seal on the air
cleaner stud and replace the seal if necessary.
9. Reinstall the paper element, precleaner, element
cover, element cover nut, and the air cleaner cover.
Secure the cover with the cover retaining knob.
10. Reconnect the power to the battery charger.
11. Reconnect the generator set engine
battery, negative (-) lead last.

586536

1.
2.
3.
4,

Cover knob
Air cleaner cover
Element cover nut
Element cover

5, Foam precleaner
6, Air cleaner element
7, Air cleaner base

Figure 3-5

Air Cleaner Components

starting
_@_

POWER_TE/&_

3.6

Cooling

System

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

1/04

3
tp6195

1, Exhaust outlet
2, Alternator air intake (both sides)
3, Engine air intake

Figure 3-6

TP-6195

Cooling Air Intake and Exhaust

Section 3 Scheduled

Maintenance

3.7

Exhaust System

Remove all combustible

materials from the exhaust

location.
Combustible
materials
include building
materials as well as natural surroundings. Keep dry field
grass, foliage, and combustible landscaping material a
minimum of 0.3 m (1 ft.) from the exhaust outlet.
Periodically inspect the exhaust system components
(exhaust manifold, exhaust line, flexible exhaust,
clamps, silencer, and outlet pipe) for cracks, leaks, and
corrosion.
• Check for corroded or broken metal parts and replace
them as needed.
• Check for loose, corroded, or missing clamps and
hangers. Tighten or replace clamps and/or hangers
as needed.
• Check for and remove loose insulation in the exhaust
duct.
• Check that the exhaust outlet is clear.

3.8

Battery
_1_ WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing,
Battery acid may cause blindness and
burn skin,

Battery electrolyte is a diluted sulfuric acid. Battery acid
can cause severe injury or death. Battery acid can cause
blindness and burn skin. Always wear splashproof safety

Section 3 Scheduled

Maintenance

goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If
battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of
clean water. Seek immediate medical aid in the case of eye
contact. Never add acid to a battery after placing the battery in
service, as this may result in hazardous spattering of battery
acid.
Battery acid cleanup.
Battery acid can cause severe
injury or death. Battery acid is electrically conductive and
corrosive. Add 500 g (f lb.) of bicarbonate of soda (baking
soda) to a container with 4 L (f gal.) of water and mix the
neutralizing solution. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.
Battery gases.
Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke
or permit flames or sparks to occur near a battery at any time,
particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury
or death.
Short circuits can cause bodily injury and/or
equipment damage. Disconnect the battery before generator
set installation or maintenance.
Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Remove the negative (-) lead first when disconnecting the
battery.
Reconnect the negative (-) lead last when
reconnecting the battery. Never connect the negative (-)
battery cable to the positive (+) connection terminal of the
starter solenoid. Do not test the battery condition by shorting
the terminals together.

TP-6195

1/04

Refer to this section for general battery information and
maintenance. All generator set models use a negative
ground with a12-volt engine electrical system. Consult
the generator set nameplate for the engine electrical
system voltage. Consult the generator spec sheet for
battery capacity recommendations for replacement
purposes. Wiring diagrams provide battery connection
information.
See Figure3-7
for typical battery
connections.
Check the electrolyte level and specific gravity of
batteries with filler caps. Maintenance-free batteries do
not require electrolyte level checking or specific gravity
testing.
Clean the battery and cables and tighten battery
terminals using the service schedule recommendations.
Clean the battery by wiping it with a damp cloth. Clean
both battery terminals with baking soda. Keep the
electrical connections dry and tight.

from the battery and scrub the terminals with a wire
brush. Clean the battery and cables with a solution of
baking soda and water. Do not allow the cleaning
solution to enter the battery's cells. After cleaning, flush
the battery and cables with clean water and wipe them
with a dry, lint-free cloth.
After reconnecting the battery cables, coat the battery
terminals with petroleum jelly, silicone grease, or other
nonconductive grease.

3.8.2

Checking
Level

Battery

Electrolyte

Check the battery electrolyte level before each startup.
Remove the filler caps and verify that the electrolyte
level reaches the bottoms of the filler holes; see
Figure 3-8. Refill as necessary with distilled water or
clean tap water. Do not add electrolyte. Install and
tighten filler caps. After adding water to the battery in
freezing
temperatures,
run the
generator
set
20-30 minutes to mix the added water and the battery
electrolyte.
Mixing the water and the electrolyte
prevents the added water from freezing and damaging
the battery.

EZ-273000-J

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

Figure 3-7

3.8.1

12-Volt Engine Electrical System Single
Starter Motor, Typical Battery Connection

Cleaning

the Battery

To prevent dirt and grime buildup, occasionally wipe the
battery with a damp cloth.
5810321

To prevent corrosion, maintain tight, dry electrical
connections at the battery terminals.
To remove
corrosion from battery terminals, disconnect the cables

TP-6195

1/04

1. Filler caps
2. Electrolyte level

Figure 3-8

Checking Electrolyte Level

Section 3 Scheduled

Maintenance

3.8.3

Checking Electrolyte Specific
Gravity

°C

°F

71.1

160

65.6

150

Correction

+ 032
+ 030

Use a battery hydrometer to check the specific gravity of
the electrolyte
in each battery cell.
Use the
hydrometer's test instructions, if available, or Figure 3-9
for bead-type testers.
Number of
Beads Floating

Battery
Condition

Overcharged

Full Charge

Adequate Charge

1, 2

Low Charge

+ 028

Example 1:

+ 026
60.0

140

+ 024
+ 022

54.4

130

48.9

120

43.3

110

37.8

100

32.2

Temperature below 26,7°C (80°F)
Hydrometer

Reading 1.250

+ 020
+ 018
+ 016
+ 014
+ 012

Electrolyte Temperature
-6,7°C (20°F)
Subtract .024 Specific Gravity
Corrected Specific Gravity is 1,226

+ 010

Battery Dead

+ 008
+ 006

+ 002

Figure 3-9

Electrolyte

Testing Chart

26.7

Example 2:

+ 004

Temperature above 26.7°C (80°F)
Hydrometer

Reading 1,235

002

Temperature affects specific gravity; correct the
indicated hydrometer readings for temperature. If the
hydrometer does net have a correction table, use
Figure3-10.
A fully charged battery should have a
specific gravity of 1.260 with the electrolyte at 26.7°C
(80°F). Charge the battery if the specific gravity from
cell to cell varies by more than 0.01. Charge the battery
if the specific gravity is less than 1.215 with the
electrolyte at 26.7°C (80°F).

21.1

15.6

004

Electrolyte Temperature
37.8°C (100°F)

-. 006
008
010
10

4,4

012

Add ,008 Specific Gravity
Corrected Specific Gravity is
1,243

014
016
018
- 1.1

- 6.7

020
022
024
026

- 122

028

The temperature correction amounts to about .004 (4 points) of
specific gravity for each 5,5°C (10°F) change in electrolyte
temperature,
5810322
Figure 3-10

Section 3 Scheduled

Maintenance

Specific

Gravity

Temperature

Correction

TP-6195

1/04

3.9

Battery Charger

2. Stop the generator set.

The generator set is equipped
with a 6-amp
float/equalize battery charger to maintain the engine
starting battery.
The charger's
DC leads are
factory-wired.
Figure3-11
illustrates the battery
charger.

3. While the engine is still warm, drain the engine
lubrication oil from the engine crankcase.
4. Refill the engine crankcase with oil. See Section
3.3.3 for oil recommendations.
5. Run the generator set for a few minutes
distribute the clean oil.

1
2

6. Stop the generator set.

3.10.2

Fuel System

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

3_
5
zJ

3. Run the generator set until the engine stops.
4. Place the generator set master switch
OFF/RESET position.

3.10.3
1.

1. LED indicators

4. Fuse

2. Mounting flanges
3. Battery leads, 12 VDC

5, AC powerco_

Figure 3-11 6-Amp Float/Equalize Battery Charger
Periodically tighten all connections.
No
maintenance on the battery charger is required.

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

set

monthly

Lubrication

Remove the spark plugs.

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

other

3.10 Storage Procedure

Note: Run the
possible.

Cylinder

in the

whenever

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

3.10.4

Exterior

Preparation

1. Clean the exterior surface of the generator set.
2. Seal all openings in the engine with nonabsorbent
adhesive tape.
3. Mask all areas to be used for electrical contact.

3.10.1

Lubricating

System

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

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

TP-6195

1/04

Section 3 Scheduled

Maintenance

3.10.5

3. Clean the battery. Refer to Section 3.8.1 for the
cleaning procedure.

Battery

Perform battery storage last.
4. Place the battery in a warm, dry location.
1. Place the generator set master
OFF/RESET position.

switch in the

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

Section 3 Scheduled

Maintenance

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

TP-6195

1/04

Section 4 Troubleshooting
4.1

Introduction

Use the following charts to diagnose and correct
common problems. First check for simple causes such
as a dead engine starting battery, loose connections, or
an open circuit breaker. The charts include a list of
common problems, possible causes of the problem, and
recommended corrective actions.
If the procedures in this manual do not explain how to
correct the problem, contact an authorized distributor/

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

4.2

Generator

Set Troubleshooting

Figure4-1
contains generator set troubleshooting,
diagnostic, and repair information.
Check for loose
connections before replacing parts.

Problem

Possible Cause

Corrective

The generator set
does not crank.

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

Check the connections,

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

reversed or poor

Controller fuse (F3) blown

Replace the fuse, Contact an authorized distributor/dealer
for service if fuse blows repeatedly,

Relay interface board fuse (F2) 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 the RUN position,

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

Spark plug wire connection

No AC output.

Action

Clean and tighten the battery connections,
loose

Check the spark plug wires,

Low oil pressure shutdown

Check the oil level,

Fuel pressure insufficient

Check the fuel supply and valves,

Engine malfunction

Contact the distributor/dealer.

AC circuit breaker in the OFF position

Place the circuit breaker in the ON position.

AC circuit breaker tripping because of overload

Reduce the load on the generator set.

AC circuit breaker tripping because of short circuit

Contact an authorized

Low output or
excessive drop in
voltage.

Generator set overloaded

Reduce the load,

Generator set stops
suddenly.

Low oil pressure shutdown

Check

the oil level,

Out of fuel

Check

fuel

Overcrank shutdown

Reset the controller.
If the overcrank
contact the distributor/dealer,

Controller fuse (F3) blown

Replace the fuse,
distributor/dealer.

Overspeed

Reset the controller.
If the overspeed
contact the distributor/dealer,

Figure 4-1

TP-6195

1/04

shutdown

distributor/dealer

for service,

supply.

If the fuse

blows

fault occurs

again,

fault

contact

occurs

again,

the

again,

Generator set master switch in the OFF/RESET
)oaltion

Move

Remote stop command received from a remote switch
or ATS

Check the remote switch position,

Engine malfunction

Contact the distributor/dealer.

Auxiliary winding fuse (F1) blown

Replace the fuse, Contact an authorized distdbutor/dealer
for service if fuse blows repeatedly,

General Troubleshooting

the switch

to the correct

position

(RUN

or AUTO).

Chart

Section 4 Troubleshooting

4.3

Fault Codes

4.5

The Advanced Digital Control displays fault codes to aid
in troubleshooting.
Fault codes, descriptions, and
recommended actions are listed in Figure 2-3.
Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Section 2.3.5.

4.4

Controller

Battery Charger
Troubleshooting

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

Troubleshooting

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

Possible Cause

Controller LED display
is off

No power to the controller:

Figure

4-2

Corrective Action

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

Controller display will automatically activate when a remote
start command is received or the generator set master
switch is moved to the RUN position. Connect the jumper
to maintain continuous power to the controller, if desired.
See Sections 2.3.6 and 6.9.3.

Controller fuse (F3) is blown.

Replace the fuse.
distributor/dealer.

Low or no battery voltage.

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

If the fuse blows again, contact the

See

Generator set master switch is in the OFF/RESET
)osition.

Move generator
position,

Generator set master switch in AUTO but no start
command has been received since last controller
reset,

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

Controller Troubleshooting

set master switch to the AUTO or RUN

Chart

Problem

Cause

_,olution

Red LED stays

One or more defective or damaged cells.

Load test the battery and replace, if necessary

on for more than
24 hours

Battery charger has reduced its output voltage below
the normal level due to a DC overload 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 and the green LED only should now
light.

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

Turn off all DC equipment

while charging.

Onboard DC systems are drawing between 1.5 and
5 amps.

Turn off all DC equipment

while charging.

Red and green
LEDs stay on for
more than
24 hours

One or more defective or damaged cells.

Load test the battery and replace, if necessary

Extremely low AC voltage at the battery charger.

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

Green LED stays
on when the
battery is known

Open DC output fuse.

Replace AGS-10 fuse.

to be low

One or more defective or damaged cells.

Load test the battery and replace, if necessary.

Neither of the
LEDs turn on

No AC power available at the battery charger.

Connect AC power or reset the AC breaker on the main panel.

when the AC
power is applied

Component failure.

Replace battery charger.

Faulty or contaminated

terminal connections.

Figure 4-3

Battery Charger Troubleshooting

Troubleshooting

Section4

Clean and tighten or repair all terminal connections.

TP-6195

1/04

Section 5 Wiring Diagrams
5.1

Specification

Numbers

5.2

At the time of print, this manual applied to the model
numbers
and specification
(spec)
numbers
in
Figure 5-1. On occasion the manufacturer may provide
this manual with units that are not listed below, such as
when similar new specs are created prior to the updated
reprint or in other cases when the manual is a suitable
substitute for a manual under development.
Model No.

Spec. No.

8.5RES

GM29253-GA1

12RES

GM29253-GA2

Figure

TP-6195

5-1

1/04

Generator

Set Specification

Controller
Reference

Figure5-2
locations.

lists the

Wiring

wiring

Wiring Diagram Description
Schematic Diagram
Sheet 1
Sheet 2
Point-to-Point

Figure 5-2

Wiring Diagram

Diagram

diagram

numbers

Drawing
Number

and

Page

ADV-6835A
ADV-6835B

22
23

GM29358

Controller Wiring Diagrams

Numbers

Section 5 Wiring Diagrams

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LO - COmI_OL_R BOX LO 8TU_
LOP - LOW O_LP_SURE
8VdT_H
kip- M_E_
o FqCI_Jp
p{_) - F,LUO
QC_N¢_ - QUICK CONNEOT
PJB- R_AY IhTERF_
BOkRD
8CR - _ucotl
C_NTI_U_D
F_'_RER
8M - 8T_T_R MOTOR
8R - 8TARTJ_ P,B_y
S9 - STk_:TER SOU_m
8,_u_K- 8 MART 8 pARK U 0 _4JLE
_TAT - _ATOR
_J_l - 811_RPGR UOTOR

RE_

-4
"0

'11
C

ADC 2100 CONTROLLER

RELAY iNTERFACE BOARD

P1 CONNECqqONS
P1-1
START ER RE Lt',Y OUT
P1-2
SPARE OUTPUT
P1-3
COMMON FAULT
P1-4
GOVERNOR 1B
P1-5
GOVERNOR 1A
P1-6
GOVERNOR 2A
P1-7
GOVERNOR 2B
P1-8
COOLANT TEMP SENSOR HiGH
P1-9
COOLANT TEMP SENSOR LOW
P1-10
EXTERNAL CAN H
P1-11 EXTERNALCAN
L
P1-12 AUX SHUTDOWN
P1-13
FUEL RELAY OUT
Pl-14
TAGH OUT
p1-15 OIL PRESSURE SWITCH
P1-16 GROUND
P1-17 VR SENSOR LOW
P1-18 GROUND
P1-19
PRESSURE SENSOR GROUND
P1-20 GROUND
P1-21 GROUND
P1-22 GROUND
P1-23 GROUND
P1-24 VBAT +
P1-25
REMOTE START/STOP 1
P1-26
REMOTE START/STOP2
P1-27 GROUND
P1-28 GOOLANTLEVEL/LOSS
HiGH
P1-29 VRSENSOR HiGH
P1-30
PRESSURE SENSOR SOURCE
P1-31
PRESSURE SENSOR SIGNAL
P1-32 GROUND
P1-33 VBAT ON
P1-34 GROUND
P1-35
RS232 TXD

P13 CONNEGTIONS
P13-1
RUN RELAY GOMMON
P13-2
COMMON FAULTCOMMON
P13-3
COMMON FAULT NO
P13_4
RUN RELAY NO
P13_5
RUN RELAY NC
P13-6
COMMON FAULT NO

IX)

,<
¢.0

W
03
¢#
O
t_

P5 CONNECTIONS
P5-1
N/C
P5-2
RS232 RXD
P5-3
RS232 TXD
P5-4
N/G
P5-5
GROUND
P5-6
N/C
P5_7
N/C
P5_8
N/C
P5_9
N/G
P7CONNEGTIONS
P7-1
_C
P7-2
CONTINUOUS
P7-3
GROUND

POWER MODE SELECT

J16 CONNECqqONS
P16_1 FIELD DRIVE PLUS {G)
P16-2
FLt',SH RELAY OUT
P16-3 AUX WiNDiNG iNPUT {55)
P16_4 FIELD DRIVE MINUS (F+)
P16_5 N/C
P16_6 AUX WiNDiNG iNPUT {66)
J15 CONNEGTIONS
J15_1 AG INPUT {V7/11)
J15_2 AG INPUT {VS)
J15-3 AC INPUT (V9/44)

ADO2100

)

P14 CONNECTIONS
P14-1
FUELJAUX RUN RELAY GONTROL
P14-2
COMMON FAULT RELAY CONTROL
P14-3
STARTER RELAY CONTROL
P14_4
iGNiTiON NEGATIVE
P14_5
FLASH RELAY CONTROL
P14_6
VBAT
P14-7
P14-8

FUEL {70A)
GROUND

P14-9

STARTER (71 A)

1"1FN
_FP

OFF_ESET

RUN_

"11

=3'
C

b3
I

U1
O

P1 CONMEDNC_NS
RN*I

(_4_

A1_2100

a _
4 IB

BCX

N01_ F_fl P7 JUMPER
CONNE_ON88BE
ADV-_.
LOW POW_ MOCE SHOWN.

COt_RO_ER

21 m
UMmUb_
_ N*C

JUNG31ON

BOX

Ft*_- _PE
TtJp_L _,_
L_G_S

Ctt25
C_MECT _ TO N
DO NOT C_',_EOT

m_m,_]

P14 CC_NECIIONS
m_#1

_1-I=

3
cn

m
-o

ENGINE
Jl 6
Nf_I

P18

_o
Rm _1_1,)
_1-'_

RN_

¢ EU<_

Ctt20
DO _OT C_MNE_T
DO NOT CONNECT

p1-_
P15 CONr_cCT1GN8

. °1/

;[ ......

S_TGH.

LEGEND
_
- CIRCUIT BR_
O(J_- [_ODE
GTS - G_]LANT T_4PlS:L_TdRIE SBNDER
EBGf_ - ENGINE BLOCK GROUND
F(_ - NI6E
F:V_ _UEL VAL'vl_
GND - _NTR_L_R
B_X _qOUND

_CREW &8TN_r_ER.
SM - ETAR_i M_TOR
_R - _ARTER RI_J_y
_s _ START_ 5OU_K_D
68P1( - SMART SPARK MODLlU_
_rAT - _rA_
_
- S_p_I
MOTOR

J(_ - CONNE_R'OR
LOp. LOW OIL _RE_;URE _ITCH
Mp - _U_GNE_C PIG_tJp
OCON(#) - QUICK _DM_EGT
_R

- NUG_N CONTROLL_

RE_13RER
FOR SCtt_C

FOR GB_TO_
CONNECll_U,S _EE:
/_DV-SaW 8INGLE pHASE.

(,O

AOV_

Section 6 Installation
6.1

General

6.4

Have an authorized
distributor/dealer
install the
generator set outdoors according to the instructions in
this section. Do not install this generator set indoors.
The generator set installation must comply with state
and local code requirements.
Use the specifications provided here only in the initial
planning. Use the generator set and transfer switch
spec sheets, dimension drawings, and wiring diagrams
for installation.
Contact an authorized service
distributor/dealer for the most current information.

6.2

Weight
_1_ WARNING

Install the generator set outdoors. Maintain a minimum
clearance of 0.9 m (3 ft.) from any building as shown in
Figure 6-1. Do not install the generator set where
exhaust gas could accumulate and seep inside or be
drawn into a potentially occupied building. Mount the
generator set so that the hot exhaust does not blow on
plants or other combustible materials.
See Figure 6-1 for the generator set dimensions and
fuel and electric inlet locations.
The drawing
dimensions are shown in millimeters, with inches in
brackets.
The generator set is shipped on a plastic mounting pad.
Prepare a flat, level mounting area covered with gravel
or compacted soil. Set the plastic mounting pad directly
on the gravel or compacted soil. Do not install the
mounting pad directly on the grass.

6.5
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Liftthe generator set using lifting bars
inserted through the lifting holes on
the skid.

The generator set weighs approximately
186kg
(410 lb.). Use lifting bars inserted through the holes in
the skid to lift the unit. See Figure 6-1 for lifting hole
locations.

6.3

Generator

Set Inspection

Complete a thorough inspection of the generator set.
Check for the following:
1. Inspect the generator set for loose or damaged
parts or wires. Repair or tighten any loose parts
before installation.
2. Check the engine oil. Fill, if necessary, with the
recommended make and grade of oil.
See
Section 3.3.3 for engine oil recommendations.

TP-6195

1/04

Mounting

Exhaust

Requirements

_1_ WARNING

Carbon monoxide.
Can
cause
severe
fainting, or death.

nausea,

The
exhaust
system
must be
leakproof and routinely inspected.
Generator set operation.
Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death ifinhaled for even a short time. Avoid breathing exhaust
fumes when working on or near the generator set. Never
operate the generator set inside a building. Never operate the
generator set where exhaust gas could seep inside or be
drawn intoa potentially occupied buildingthrough windows, air
intake vents, or other openings.

The exhaust system is complete for generator sets
installed outdoors. Do not install this generator set
indoors.

Section 6 Installation

I'O

'11
C

6_
8

@
INLET

{lJ2"

STU6
NpT

UP
FEMALE1

6"_

0
C

_INLET

c
O.
OIL

OIL

FILL

_AIR

I 123 [ 44

CAP_

DIPSTICK

FILTER

RUNIOFFIRESET/AUTO

EOU I PMENT

GROUND

LOCAX,ON

ELECTRICAL
CONNECTION-TO CIRCUIT
BREAKER

--LOAD
CIRCUIT

BREAKER

6ATTERY
CHARGER
IINCLUDEDI
LOCATIOr_-INCLU_EDI

i'o

6ATTERY
IBATTERY
NOT

_BATTER¥
CA6LES
IINCLUDEDI

_--_IL

533
[_1_0]
_RAVITY
_/0

DRAIN

VALVE
RS VIEW
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KOHLER Generator Manual L0402312

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