KOHLER Generator Manual L0402312

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

Open the PDF directly: View PDF .
Page Count: 56

Operation and

Installation

Residential/Commercial Generator Sets

Models:

8.5RES

12RES

Controller:

Advanced Digital Control

KOHLERo

POWERSYSTEMS

mPOWERSYSJEMS

NATIONALLY REGISTERED

TP-6195 1/04

California Proposition 65

& WARNING

Engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth

defects, or other reproductive harm.

Product Identification Information

Product identificationnumbers determine service parts.

Record the product identification numbers in the spaces

below immediately after unpacking the products so that

the numbers are readily available for future reference.

Record field-installed kit numbers after installing the

kits.

Generator Set Identification Numbers

Record the product identification numbers from the

generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Controller Identification

Record the controller description from the generator set

operation manual, spec sheet, or sales invoice.

Controller Description

Engine Identification

Record the product identification information from the

engine nameplate.

Manufacturer

Model Designation

Serial Number

Accessory Number Accessory Description

Table of Contents

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

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

Introduction ............................................................................... t

Service Assistance ........................................................................ ti

Section I Specifications and Features ...................................................... 1

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

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

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

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

1.5 Service Views ........................................................ 2

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

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

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

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

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

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

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

2.3.4 Fault Shutdowns .............................................. 5

2.3.5 Resetting the Controller after a Fault Shutdown .................... 6

2.3.6 Continuous Power Mode ....................................... 6

2.4 Circuit Protection ...................................................... 7

2.4.1 Line Circuit Breaker ........................................... 7

2.4.2 Fuses ....................................................... 7

2.5 Battery Charger ....................................................... 7

2.5.1 Battery Charger Operation ...................................... 8

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

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

3.2 Service Schedule ..................................................... 9

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

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

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

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

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

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

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

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

3.5.2 Paper Element Service ......................................... 12

3.6 Cooling System ....................................................... 13

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

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

3.8.1 Cleaning the Battery ........................................... 15

3.8.2 Checking Battery Electrolyte Level ............................... 15

3.8.3 Checking Electrolyte Specific Gravity ............................ 16

3.9 Battery Charger ....................................................... 17

3.10 Storage Procedure .................................................... 17

3.10.1 Lubricating System ............................................ 17

3.10.2 Fuel System .................................................. 17

3.10.3 Cylinder Lubrication ........................................... 17

3.10.4 Exterior Preparation ........................................... 17

3.10.5 Battery ....................................................... 18

TP-6195 1/04 Table of Contents

Table of Contents, continued

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

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

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

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

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

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

Section 5 Wiring Diagrams ................................................................ 21

5.1 Specification Numbers ................................................. 21

5.2 Controller Wiring Diagram Reference .................................... 21

Section 6 Installation ...................................................................... 25

6.1 General .............................................................. 25

6.2 Weight ............................................................... 25

6.3 Generator Set Inspection ............................................... 25

6.4 Mounting ............................................................. 25

6.5 Exhaust Requirements ................................................. 25

6.6 Air Requirements ..................................................... 27

6.7 Power Supply ......................................................... 27

6.8 Fuel System .......................................................... 27

6.8.1 Fuel Supply .................................................. 27

6.8.2 Fuel Pipe Size ................................................ 28

6.8.3 Fuel Conversion .............................................. 28

6.9 Electrical Connections ................................................. 31

6.9.1 AC Load Lead Connections ..................................... 31

6.9.2 Remote Start Connection (optional) .............................. 32

6.9.3 Continuous Power Mode Jumper ................................ 32

6.9.4 Battery ....................................................... 33

6.9.5 Battery Charger ............................................... 34

6.10 Accessories .......................................................... 35

6.10.1 Common Fault and Run Relay Board ............................ 35

6.10.2 Carburetor Heater ............................................. 36

6.11 Controller Configuration ................................................ 37

6.11.1 System Configuration .......................................... 37

6.11.2 Advanced Configuration Mode .................................. 37

6.12 Prestart Installation Check .............................................. 37

6.13 Warranty Registration .................................................. 37

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

Table of Contents TP-6195 1/04

Safety Precautions and Instructions

IMPORTANT SAFETY

INSTRUCTIONS. Electromechanical

equipment, including generator sets,

transfer switches, switchgear, and

accessories, can cause bodily harm

and pose life-threatening danger when

improperly installed, operated, or

maintained. To prevent accidents be

aware of potential dangers and act

safely. Read and follow all safety

precautions and instructions. SAVE

THESE INSTRUCTIONS.

This manual has 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, orsubstantial

property damage.

CAUTION

Caution indicates the presence of a

hazard that will or can cause minor

personal injury orproperty damage.

NOTICE

Notice communicates installation,

operation, or maintenance information

that is safety related but not hazard

related.

Safety decals affixed to the equipment

in prominent places alert the operator

or service technician to potential

hazards and explain how to act safely.

The decals are shown throughout this

publication to improve operator

recognition. Replace missing or

damaged decals.

Accidental Starting

_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 switchto 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

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and

clothing. Battery acid may cause

blindness and burn skin.

_1_ WARNING

Explosion.

Can cause severe injury or death.

Relays in the battery charger

cause arcs or sparks.

Locate the battery in a well-ventilated

area. Isolate the battery charger from

explosive fumes.

Battery electrolyte is a diluted

sulfuric acid. Battery acid can cause

severe injury or death. Battery acid

can cause blindness and burn skin.

Always wear splashproof safety

goggles, rubber gloves, and boots

when servicing the battery. Do not

open a sealed battery or mutilate the

battery case. If battery acid splashes in

the eyes or on the skin, immediately

flush the affected area for 15 minutes

with large quantities of clean water.

Seek immediate medical aid in the case

of eye contact. Never add acid to a

battery after placing the battery in

service, as this may result in hazardous

spattering of battery acid.

Battery acid cleanup. Battery acid

can cause severe injury or death.

Battery acid is electrically conductive

and corrosive. Add 500 g (1 lb.) of

bicarbonate of soda (baking soda) to a

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.

TP-6195 1/04 Safety Precautions and Instructions I

Battery gases. Explosion can cause

severe injury or death. Battery gases

can cause an explosion. Do not smoke

or permit flames orsparks 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 agrounded

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 by shorting the

terminals together.

Engine Backfire/Flash

Fire

_1_ WARNING

Fire.

Can cause severe injury or death.

Do not smoke or permit flames or

sparks near fuels or the fuel system.

Servicing the air cleaner. A sudden

backfire can cause severe injury or

death. Do not operate the generator

set with the air cleaner removed.

Servicing the fuel system. A flash

fire can cause severe injury or death.

Do not smoke or permit flames or

sparks near the carburetor, fuel line,

fuel filter, fuel pump, or other potential

sources of spilled fuels or fuel vapors.

Catch fuels in an approved container

when removing the fuel line or

carburetor.

Combustible materials. A fire can

cause severe injury or death.

Generator set engine fuels and fuel

vapors are flammable and explosive.

Handle these materials carefully to

minimize the risk of fire or explosion.

Equip the compartment or nearby area

with a fully charged fire extinguisher.

SeleCt a fire extinguisher rated ABC or

BC for electrical fires or as

recommended by the local fire code or

an authorized agency. Train all

personnel on fire extinguisher

operation and fire prevention

procedures.

Exhaust System

AWARNING

Carbon monoxide.

Can cause severe nausea,

fainting, or death.

The exhaust system must be

leakproof and routinely inspected.

Generator set operation. Carbon

monoxide can cause severe nausea,

fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless,

nonirritating gas that can cause death if

inhaled for even a short time. Avoid

breathing exhaust fumes when working

on or near the generator set. Never

operate the generator set inside a

building. Never operate the generator

set where exhaust gas could seep

inside or be drawn into a potentially

occupied building through windows, air

intake vents, or other openings.

Carbon monoxide symptoms.

Carbon monoxide can cause severe

nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in

exhaust gases. Carbon monoxide

poisoning symptoms include but are

not limited to the following:

• 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.

II Safety Precautions and Instructions TP-6195 1/04

Fuel System Hazardous Noise

_1_ WARNING _1_ CAUTION

Explosive fuel vapors.

Can cause severe injury or death.

Use extreme care when handling,

storing, and using fuels.

Hazardous noise.

Can cause hearing loss.

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.

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

ADANGER

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.

Operate the generator set only when

all guards and electrical enclosures

are in place.

_1_ WARNING

Hazardous voltage.

Backfeed to the utility system can

cause property damage, severe

injury, or death.

if the generator set is used for

standby power, install an automatic

transfer switch to prevent inadvertent

interconnection of standby and

normal sources of supply.

_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 complywith applicable codes

and standards. Never contact

electrical leads or appliances when

standing in water or on wet ground

because these conditions increase the

risk of electrocution.

TP-6195 1/04 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 battery-

charging alternator connections.

(5) Attach the weld ground connection

close to the weld location.

instilling the battery charger.

Hazardous voltage can cause

severe injury or death. An

ungrounded battery charger may

cause electrical shock. Connect the

battery charger enclosure to the ground

of apermanent 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.

Heavy Equipment

_1_ WARNING

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.

Hot Parts

_1_ WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until

it cools.

Servicing the generator. Hot parts

can cause severe injury or death.

Avoid touching the generator set field

orexciter 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. Installthe

heater before connecting it to power.

Operating the heater before installation

can cause burns and component

damage. Disconnect power to the

heater and allow it to cool before

servicing the heater or nearby parts.

Moving Parts

_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

Rotating parts.

Can cause severe injury or death.

Operate the generator set only when

all guards, screens, and covers are in

place.

_1_ WARNING

Airborne particles.

Can cause severe injury or

blindness.

Wear protective goggles and clothing

when using power tools, hand tools,

or compressed air.

Tightening the hardware. Flying

projectiles can cause severe injury

or death. Loose hardware can cause

the hardware or pulley to release from

the generator set engine and can cause

personal injury. Retorque all

crankshaft and rotor hardware after

servicing. Do not loosen the crankshaft

hardware or rotorthrubolt when making

adjustments or servicing the generator

set. Rotate the crankshaft manually in

aclockwise direction only. Turning the

crankshaft bolt or rotor thrubolt

counterclockwise can loosen the

hardware.

IV Safety Precautions and Instructions 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

This generator set has been

rewired from its nameplate voltage

to I I

246242

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 ahigh resistance (about

1 megohm), net a direct short, to

ground.

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 V

Notes

Vl 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.

Read this manual and carefully follow all procedures

and safety precautions to ensure proper equipment

operation and to avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the

beginning of this manual. Keep this manual with the

equipment for future reference.

The generator set is approved for use in stationary

applications in locations served by a reliable utility

power source.

The equipment service requirements are very important

to safe and efficient operation. Inspect the parts often

and perform required service at the prescribed intervals.

Obtain service from an authorized service distributor/

dealer to keep equipment in top condition.

Nameplate

The following illustration shows a typical generator set

nameplate. Copy the model, serial, and specification

numbers from the nameplate into the spaces provided in

the product information section on the inside front cover

of this manual. See Section 1.5, Service Views, for the

nameplate location.

KOHLER,o

KOHLER CO. KOHLER Wl. USA

MODEL: SERIAL:

RPEC:

SERVICE DUTY:

HZ: RPM:

I ........... I

GEN, MODEL: BAI"r, V

INSULATION:NEMA CLASS

KWVARIES WITH BTU CON]ENT OF FUEL

EPA and California Emission

Certification

An engine or generator set with the following

identification labels is certified to meet Small Off-Road

Engine emission standards for EPA!CARB. All model

8.5RES and 12RES generator sets with 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

FAMILY KHXS*7252NA

OISPL {CC)

MODEL NO.

SPEC, NO,

SERIAL NO,

EMISSION COMPUANCE PERIOD:

EPA: CARB: EXTENDED

THIS ENGINE IS CERTIFIED TO OPERATE

ON: LPG /NATURAL GAS

REFER TO OWNER'S MANUAL FOR SAFETY,

MAINTENANCE SPECS AND ADJUSTMENTS,

FOR SALES AND SERVICE tN US/CANADA,

CALL: 1-800-544-2444

KotllerEng_nes.com

KOH_ERCO KOHLER,WISCONSIN USA

tp6195

Figure 1 Emissions Label, 8.5RES Engine (CH20)

Figure 2

IMPORTANT ENGINE INFORMATION

THIS ENGINE MEETS U,S. EPA PH1 AND

CALIFORNIA 2006 EMISSION REGS FOR

Si SMALL OFF-ROAD ENGINES

FAMILY KHXS*7252NA

OISPL {CC) 725

MODEL NO.

SPEC, NO,

SERIAL NO,

EMISSION COMPUANCE PERIOD:

EPA: CARB: EXTENDED

THIS ENGINE IS CERTIFIED TO OPERATE

ON: LPG /NATURAL GAS

REFER TO OWNER'S MANUAL FOR SAFETY,

MAINTENANCE SPECS AND ADJUSTMENTS,

FOR SALES AND SERVICE tN US/CANADA,

CALL: 1-800-544-2444

KotllerEng_nes.com

KOH_ERCO KOHLER,WISCONSIN USA

tp6195

Emissions Label, 12 RES Engine (CH740)

TP-6195 1/04 Introduction i

f

O 2 4 58 10

_T CLE_,N L_AST GLE_I

NOTE: 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 BE,_OR E _TAWCING ENGINE,

tp6185

Figure 3 Air Index Label, 8.5/12RES

This engine/generator is certified to operate using

natural gas or propane fuel.

The Emission Compliance Period referred to on the

Emission Control or Air Index label indicatesthe number

of operating hours for which the engine has been shown

to meet CARB emission requirements. The following

table provides the engine compliance period (in hours)

associated with the category descriptor found on the

certification label.

Emission Compliance Period (hours) I

CARB Moderate, intermediate, Extended, I

125 250 500

Refer to the certification label for engine displacement.

The exhaust emission control system for the 8.5RES

(CH20) and 12RES (CH740) is EM.

Service Assistance

For professional advice on generator power

requirements and conscientious service, please contact

your nearest Kohler distributor or dealer.

• Consult the Yellow Pages under the heading

Generators--Electric

• Visit the Kohler Power Systems website at

KohlerPowerSystems.com

•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

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 264-6422

Fax: (65) 264-6455

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

ii Service Assistance TP-6195 1/04

Section 1 Specifications and Features

1.1 Specifications

The generator set specification sheets provide specific

generator and engine information. Refer to the spec

sheet for data not supplied in this manual. Consult the

generator set service manual, engine operation manual,

and engine service manual for additional specifications.

Obtain copies of the latest spec sheets, manuals,

diagrams, and drawings from your local

distributor/dealer.

1.2 Generator

The generator uses Kohler's unique PowerBoosV"

voltage regulation system, which provides instant

response to load changes.

PowerBoost TM 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.

1.3 Engine

The generator set has a four-cycle, twin cylinder, air-

cooled Kohler _ engine. The engine operates on

clean-burning natural gas or propane (LP) vapor.

Engine features include:

•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).

1.4 Advanced 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

• Crank cycle status

• Diagnostics

• LED display communicates faults:

• Auxiliary fault

• High battery voltage

• High engine temperature

• Low battery voltage

• Low oil pressure

• Overcrank safety

• Overspeed

• Overfrequency

• Overvoltage

• Underfrequency

• Undervoltage

• Membrane keypad for configuration and adjustment

• 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 to maintain

steady-state speed at all loads

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

1.5 Service Views

2 3 4 5 6 7 18 19 20

22

22

/

15 14 13 12 11

1. Enclosure

2. Muffler

3. Oil check

4. 0il fill

5. Air cleaner

6. Spark plug locations (both sides)

7. Controller

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

9. Nameplate

10. Line circuit breaker

11. Engine starting battery location

12. Oil drain hose

13. Oil drain valve

14. Oil filter

15. Alternator cooling air intake

16. Exhaust

17. Spark arrestor

18. DSAM leads

19. Multi-fuel block

20. Gas regulator assembly

21. Fuel solenoid valve

22. Air intake

23. Battery charger

24. Relay board

Figure 1-1 Generator Set Service View

AD_6_3_

2 Section 1 Specifications and Features TP-6195 1/04

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the

following checks or inspections before or at each

startup, as designated, and at the intervals specified in

the service schedule. In addition, some checks require

verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner

element to prevent unfiltered air from entering the

engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

the battery manufacturer's instructions regarding

battery care and maintenance.

Exhaust System. Check for exhaust leaks and

blockages. Check the muffler and piping condition and

check for tight exhaust system connections.

Inspect the exhaust system components (exhaust

manifold, exhaust line, flexible exhaust, clamps, muffler,

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 the exhaust clamps

and/or hangers as needed.

• Check that the exhaust outlet is unobstructed.

• Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components.

Carbon and soot residue indicates an exhaust leak.

Seal leaks as needed.

Oil Level. Maintain the oil level at or near, not over, the

full mark on the dipstick.

Operating Area. Check for obstructions that could

block the flow of cooling air. Keep the air intake area

clean. Do not leave rags, tools, or debris on or near the

generator set.

x:op:001:002

2.2 Exercising the Generator Set

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.

During the exercise period apply a minimum of 35% load

based on the nameplate standby rating.

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.

2_

\\

_'ED D_T_._

COnE nEFImTION

_,_ A_JII i _ull

Cmn_l*

Hn Hlgll _ "a11_Ip

He Hlllh_en I_ lllmp

L_L LOW 4_1411mn4 Lllt_

LOC LU= of CNMn=

LOp LOW G41Ll_'lOFJr4p

C4_ _r Ct, lnk

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

uU_ Oser voltep

Under _u*_'i,

_FmSllmr

RUN _ AU'TO

o o

x4

J

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 ADC 2100 Controller User Interface

TP-6195 1/04 Section 2 Operation 3

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 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 inthree

attempts, the system shuts down on an overcrank fault.

Local Starting

Move the generator set master switch to the RUN

position to immediately start the generator set.

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:

1.

2.

The ATS or other device disconnects the load from

the generator set.

If the ATS is equipped with an engine cooldown

time delay, the generator set continues to run for a

preset engine cooldown time.

Note: There is no engine cooldown time delay on

the ADC controller.

3. The ATS or other device opens the connection

between controller leads 3 and 4. The generator

set shuts down.

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

LED display Runtime hours Displays total generator set runtime hours while the generator set is running.

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. See Section 2.3,4.

Software version See TP-6196, Generator Set Service Manual.

number

Keypad Select and arrow The keypad is used for controller setup and adjustment only. Have setup and adjustments

buttons performed only by an authorized distributor/dealer, The setup and adjustment functions are

password-protected.

Generator set master Three-position Switch functions as the generator set operation and controller reset switch,

switch switch

Figure 2-2 ADC 2100 Controls and Indicators

4 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 after a battery voltage fault condition is

corrected.

The shutdown switches on the generator set

automatically reset when the problem is corrected. The

high engine temperature switch automatically resets

when the generator set cools. However, the fault does

not clear until the controller is reset.

The controller displays a fault code but the generator set

does not shut down under the conditions shown in

Figure 2-4.

Code Fault

AF Auxiliary fault

input shutdown

Description

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

Check the cause of theauxiliary fault.

HE High engine Shutdown occurs if the engine coolant temperature exceeds Check for blocked air inlets and exhaust

temperature the maximum temperature for more than 5 seconds, This outlets,

shutdown protective becomes active after the engine reaches the crank

disconnect speed,

LOP Low oil pressure Shutdown occurs if a low oil pressure condition exists 7 Check for leaks in the lubdcation system,

shutdown seconds after the engine has reached crank disconnect speed. Check the oil level and add oil if the level

Note: The low oil pressure shutdown does not protect against is low.

low oil level, Check the oil level at the engine,

OC Overcrank Shutdown occurs after 3 unsuccessful starting attempts. The Check the fuel supply, spark plug, and

shutdown crank cycle is set for three starting attempts of 15 seconds battery.

cranking and 15 seconds rest. Check for loose connections.

The generator set also shuts down after 1 crank attempt if no Contact an authorized distributor/dealer for

speed signal is sensed, Shuts down 1 second after the fault is service if problem continues.

detected.

OF Overfrequency Shutdown occurs when the governed frequency exceeds 110% Contact an authorized distributor/dealer for

shutdown of the system's frequency setpoint for more than 1 second, service if problem continues.

This protective becomes active 30 seconds after engine start.

OS Overspeed Shutdown occurs if the engine speed exceeds 115% of the Contact an authorized distributor/dealer for

shutdown normal running speed for more than 1 second, service if problem continues.

OU Overvoltage Shutdown occurs if the voltage exceeds 120% of the voltage Contact an authodzed distributor/dealer for

shutdown regulator setpoint for more than 1 second, service if problem continues.

UF Underfrequency Shutdown occurs when the governed frequency falls 1 Hz Reduce the load and restart the generator

shutdown below the system's frequency setpoint for more than 1 second, set,

Contact an authodzed distributor/dealer for

service if problem continues.

UU Undervoltage Shutdown occurs if the voltage falls below 80% of the voltage Reduce the load and restart the generator

shutdown regulator setpoint for more than 1 second. This protective 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 Check

HB High battery Check the battery rating and condition.

voltage warning

LB Low battery

voltage warning

Description

Fault code is displayed ifthe engine starting battery voltage rises

above 16 VDC for a 12 VDC system or above 30 VDC for a

24 VDC system for more than 10 seconds when the engine is not

running, This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a

voltage within the limits for more than 10 seconds.

Fault code is displayed ifthe engine starting battery voltage falls

below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC

system for more than 10 seconds when the engine is not running.

This fault condition does not inhibit engine starting.

The fault condition clears when the battery voltage returns to a

voltage within the limits for more than 10 seconds.

Check the battery charger operation.

Check the battery rating and condition.

Check the battery charger operation.

Charge or replace the battery.

Figure 2-4 ADC Fault Warning Codes

TP-6195 1/04 Section 2 Operation 5

2.3.5 Resetting the Controller after a

Fault Shutdown

Always identify and correct the cause of a fault

shutdown before resetting the controller. Use the

following procedure to reset the generator set controller

after a fault shutdown.

1. Move the generator set master switch to

OFF/RESET.

2. Disconnect the generator set from the load using

the line circuit breaker or ATS. See the safety

precautions at the beginning of this section before

proceeding.

3. Identify and correct the cause of the fault

shutdown. See the safety precautions at the

beginning of this section before proceeding. Refer

to Section 4, Troubleshooting.

4. Start the generator set by moving the generator set

master switch to RUN. Test operate the generator

set to verify that the cause of the shutdown has

been corrected.

5. Move the generator set master switch to

OFF/RESET.

6. Reconnect the generator set to the load using the

line circuit breaker or ATS.

7. Move the generator set master switch to the AUTO

position for startup by remote transfer switch or

remote start/stop switch.

Note: The controller's LED display remains off

until an engine start command is received.

Opening and closing a remote start/stop contact also

resets the controller.

2.3.6 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 to disconnect the

jumper.

6 Section 2 Operation TP-6195 1/04

2.4 Circuit Protection

Ifthe 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

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.

Model

8.5RES

12RES

Figure 2-5

Circuit Breaker

Rating, Amps

40

50

Line Circuit Breakers

2.4.2 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.

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.

Part

Fuse Label Number

Auxiliary Winding F1 292937

Relay Interface F2 223316

Board

Controller F3 358337

Battery Charger -- AGS 10

Location

Lead 55

Lead PF2

Lead PF1

Battery charger DC

lead. See Section 2.5.

Figure 2-6 Fuses

2.5 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.

2F4

3

1. LED indicators

2, Battery leads, 12 VDC

3, Fuse

4, AC power cord

Figure 2-7 6-Amp Float!Equalize Battery Charger

TP-6195 1/04 Section 2 Operation 7

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 When the red LED is on, it indicates the battery is discharged and the battery charger is recharging at the

Green OFF 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 When both the green and the red LEDs are on, the battery charger is charging at an ABSORPTION rate

Green ON of between 1,5 and 5 amps (stage 2), This mode of charging gradually tops off your battery, and reduces

harmful sulfating. While both LEDs are on, the voltage measured (with the battery charger on) should be

approximately 14,0-14.5 VDC.

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

Red OFF When the green LED is on, the battery charger is charging at a FLOAT or MAINTENANCE rate of less

Green ON than 1.5 amps (stage 3), Your battery is now 90% charged and ready for use. This float charging current

will gradually decrease to as low as 0.1 amps as the battery reaches 100% charge. It will now be kept at

full charge without overcharging,

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

Figure 2-9 Battery Charger LED Indicator Functions

8Section 2 Operation TP-6195 1/04

Section 3 Scheduled Maintenance

_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

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

Hot engine and exhaust system.

Can cause severe injury or death.

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.

_1_ WARNING

Hazardous voltage. Moving r.

Can cause severe injury or death.

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 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 inthe 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 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.

TP-6195 1/04 Section 3 Scheduled Maintenance 9

System Component or Procedure

Fuel

Flexible lines and connections

Main tank supply level

Fuel piping

Lubrication

Oil level

Crankcase breather*

Change oil

Replace filter*

Cooling

Air ducts, louvers

Exhaust Line

Leakage

Insulation, fire hazards

Hangers and supports

DO Electrical System

See

Section

3.3

3.6

3.7

3.8

Visually

Inspect

X

X

X

X

X

X

X

Procedure

Check Change

R

X

X

X

X

Clean

X

Test

Battery charger operation, charge rate (if equipped)

Remove corrosion, clean and dry battery and rack

Clean and tighten battery terminals

Battery electrolyte level and specific gravity-;

AC Electrical System

Visible wear or damage

Wire abrasions where subject to motion

Tighten control and power wiring connections

Wire-cable insulation breakdown *

Engine and Mounting

Visible wear or damage

Air cleaner service

Spark plugs

Replace stepper motor coupling and bushing *

Compartment condition

Remote Control System

Remote control

Run generator set

Generator

Visible wear or damage

Exercise generator set

Rotor and stator *

Measure and record resistance readings of

windings with insulation tester (Megger, with

SCR assembly or rectifier disconnected)

General Condition of Equipment

Evidence of vibration, leakage, excessive noise,

temperature, or deterioration

Interior of sound enclosure

•Contact your local distributor/dealer for parts or service,

Not necessary for maintenance-free batteries,

X

X

X X

X

X

X

X

X

3.5

3.4

X

2.1 X

2.2

X

R

X

X

X X

X

X Action

R Replace as necessary

X

X

X

X

X

Figure 3-1 Service Schedule

Frequency

Quarterly

Weekly

Yearly

8 hours or

before use

Yearly or 500 hours

Yearly or 100 hours

Yearly or 200 hours

Yearly

Weekly

Yearly

Yearly

Monthly

Yearly

Yearly

Yearly

Quarterly

Six Months

Yearly

3 Years or 500 hours

Weekly

Yearly or 100 hours

Yearly or 300 hours

500 hours

Weekly

X Monthly

X Weekly

Quarterly

X Weekly

Yearly

X 3 Years

Weekly

Quarterly

10 Section 3 Scheduled Maintenance TP-6195 1/04

3.3 Lubrication System

See Section 3.2, Service Schedule, for oil change and

oil filter replacement intervals. See Section 1.5, Service

Views, for the oil drain, oil check, oil fill, and oil filter

locations.

For extended operation, check the oil level every 8

hours. Maintain the oil level at or near, not over, the full

mark on the dipstick.

3.3.1 Low Oil Pressure Shutdown

The low oil pressure shutdown feature protects the

engine against internal damage if the oil pressure drops

below 24.1 kPa +-13.8kPa (3.5 psi -+1.5 psi) because of

oil pump failure or other malfunction. The shutdown

feature does not protect against damage caused by

operating with the oil level below the safe range; it is not

a low oil level shutdown. Check the oil level regularly,

and add oil as needed.

3.3.2 Oil Check

The generator set is shipped with oil. Before operating a

new generator set, check the engine oil in the

crankcase. See 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 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.

°F -20 0 20 32 40 60 80 100

°C -30 -20 -10 0 10 20 30 40

Temperature Range Expected Before Next Oil Change

Figure 3-2 Engine Oil Selection

3.3.4 Oil Change Procedure

Drain the oil while it is still warm.

1. Drain the oil.

a. Place the generator set master switch in the

OFF position.

b. Disconnect the power to the battery charger.

c. Disconnect the generator set engine starting

battery, negative (-) lead first.

d. Remove the housing side panel.

e. Remove the oil drain hose from its retaining

clip. Remove the cap from the oil drain hose

and lower the hose into an oil collection

container.

f. Open the oil drain valve on the engine.

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

h. Close the oil drain valve.

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 it

counterclockwise with an oil filter wrench.

b. Clean the gasket sealing surface of the oil filter

adapter.

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

of the new oil filter.

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.

c. Check that the generator set master switch is in

the OFF position.

TP-6195 1/04 Section 3 Scheduled Maintenance 11

d. Reconnect the generator set engine starting

battery, negative (-) lead last.

e. Reconnect the power to the battery charger.

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

allow the oil pressure to reach the operating

range.

g. Stop the generator set, wait 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.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

3.4 Spark Plugs

Reset the spark plug gap or replace the plugs with new

plugs as necessary.

1. Clean the area around the base of the spark plug to

keep dirt and debris out of the engine.

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.

Figure 3-3 Checking the Spark Plug Gap

Figure 3-4 Adjusting the Spark Plug Gap

1-514

1-511

3.5 Air Cleaner Element and

Precleaner

The engine has a replaceable high-density paper air

cleaner element with an oiled foam precleaner. See

Figure 3-5.

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.

3.5.1 Precleaner Service

Use the following procedure to wash and reoil the

precleaner as indicated in the service schedule. Wash

and reoil the precleaner more often under extremely

dusty or dirty conditions.

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the power to the battery charger.

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 oil.

Squeeze out all of the excess oil.

6. Reinstall the precleaner over the paper element.

7. Reinstall the air cleaner cover. Secure the cover

with the cover retaining knob.

8. Reconnect the power to the battery charger.

9. Reconnect the generator set engine starting

battery, negative (-) lead last.

3.5.2 Paper Element Service

Use the following procedure to replace the paper

element at the intervals specified in the service

schedule. Replace the paper element more often under

extremely dusty or dirty conditions.

12 Section 3 Scheduled Maintenance TP-6195 1/04

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the power to the battery charger.

3. Disconnect the generator set engine starting

battery, negative (-) lead first.

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 starting

battery, negative (-) lead last.

3.6 Cooling System

The engine fan draws cooling air through the openings

in the sides and end near the battery. The alternator fan

draws cooling air through openings on the side walls of

the enclosure. The cooling air mixes with the engine

exhaust and is discharged at the exhaust outlet. See

Figure 3-6. To prevent generator set damage caused by

overheating, keep the housing cooling inlets and outlets

clean and unobstructed at all times.

Note: Do not blockthe generator set cooling air inlets or

mount other equipment above them.

Overheating and severe generator damage may

OCCUr.

3

5

6

7

1. Cover knob

2. Air cleaner cover

3. Element cover nut

4, Element cover

5, Foam precleaner

6, Air cleaner element

7, Air cleaner base

Figure 3-5 Air Cleaner Components

586536

1

\\

_@_ POWER_TE/&_ [_

1, Exhaust outlet

2, Alternator air intake (both sides)

3, Engine air intake

\ \

2 3 tp6195

Figure 3-6 Cooling Air Intake and Exhaust

TP-6195 1/04 Section 3 Scheduled Maintenance 13

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

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.

14 Section 3 Scheduled Maintenance 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.

jl 2

EZ-273000-J

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

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

Figure 3-7 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery Connection

3.8.1 Cleaning the Battery

To prevent dirt and grime buildup, occasionally wipe the

battery with a damp cloth.

To prevent corrosion, maintain tight, dry electrical

connections at the battery terminals. To remove

corrosion from battery terminals, disconnect the cables

from the battery and scrub the terminals with a wire

brush. Clean the battery and cables with a solution of

baking soda and water. 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 Battery Electrolyte

Level

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.

1

©

1. Filler caps

2. Electrolyte level

Figure 3-8 Checking Electrolyte Level

2

5810321

TP-6195 1/04 Section 3 Scheduled Maintenance 15

3.8.3 Checking Electrolyte Specific

Gravity

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 Battery

Beads Floating Condition

5 Overcharged

4 Full Charge

3 Adequate Charge

1, 2 Low Charge

0 Battery Dead

Figure 3-9 Electrolyte Testing Chart

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).

°C °F

71.1 160

65.6 150

60.0 140

54.4 130

48.9 120

43.3 110

37.8 100

32.2 90

26.7 80

21.1 70

15.6 60

10 50

4,4 40

-1.1 30

-6.7 20

-122 10

Correction

+032

+030

+028

+026

+024

+022

+020

+018

+016

+014

+012

+010

+008

+006

+004

+002

0

002

004

-. 006

008

010

012

014

016

018

020

022

024

026

028

Example 1:

Temperature below 26,7°C (80°F)

Hydrometer Reading 1.250

Electrolyte Temperature

-6,7°C (20°F)

Subtract .024 Specific Gravity

Corrected Specific Gravity is 1,226

Example 2:

Temperature above 26.7°C (80°F)

Hydrometer Reading 1,235

Electrolyte Temperature

37.8°C (100°F)

Add ,008 Specific Gravity

Corrected Specific Gravity is

1,243

The temperature correctionamounts to about .004 (4points)of

specific gravity for each 5,5°C (10°F) change in electrolyte

temperature, 5810322

Figure 3-10 Specific Gravity Temperature Correction

16 Section 3 Scheduled Maintenance TP-6195 1/04

3.9 Battery Charger

The generator set is equipped with a 6-amp

float/equalize battery charger to maintain the engine

starting battery. The charger's DC leads are

factory-wired. Figure3-11 illustrates the battery

charger.

1

2

3_

5

zJ

1. LED indicators

2. Mounting flanges

3. Battery leads, 12 VDC

4. Fuse

5, AC powerco_

Figure 3-11 6-Amp Float/Equalize Battery Charger

Periodically tighten all connections. No other

maintenance on the battery charger is required.

3.10 Storage Procedure

Perform the following storage procedure before

removing the generator set from service for three

months or longer. Follow the engine manufacturer's

recommendations for storage, if available.

Note: Run the generator set monthly whenever

possible.

3.10.1 Lubricating System

1. Operate the generator set until it reaches operating

temperature, or about 15 minutes.

2. Stop the generator set.

3. While the engine is still warm, drain the engine

lubrication oil from the engine crankcase.

4. Refill the engine crankcase with oil. See Section

3.3.3 for oil recommendations.

5. Run the generator set for a few minutes to

distribute the clean oil.

6. Stop the generator set.

3.10.2 Fuel System

1. Start the generator set.

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

supply.

3. Run the generator set until the engine stops.

4. Place the generator set master switch in the

OFF/RESET position.

3.10.3 Cylinder Lubrication

1.

2.

Remove the spark plugs.

Pour one tablespoon of engine oil into each spark

plug hole. Install the spark plugs and ground the

spark plug leads. Do not connect the leads to the

plugs.

3. Toggle the generator set master switch to crank the

engine two or three revolutions to lubricate the

cylinders.

3.10.4 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.

4. Spread a light film of oil over unpainted metallic

surfaces to prevent rust and corrosion.

TP-6195 1/04 Section 3 Scheduled Maintenance 17

3.10.5 Battery

Perform battery storage last.

1. Place the generator set master switch in the

OFF/RESET position.

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

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

cleaning procedure.

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

5. Connect the battery to a float/equalize battery

charger, or charge the battery monthly using a

trickle charger. Follow the battery charger

manufacturer's recommendations.

18 Section 3 Scheduled Maintenance 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

The generator set

does not crank.

The generator set

cranks but does not

start, starts hard, lacks

power, or operates

erratically.

No AC output.

Low output or

excessive drop in

voltage.

Generator set stops

suddenly.

Figure 4-1

Possible Cause

Battery weak or dead

Battery charger fuse blown

Battery connections reversed or poor

Controller fuse (F3) blown

Relay interface board fuse (F2) blown

Generator set master switch in the OFF position

Air cleaner clogged

Battery weak or dead

Battery connection poor

Spark plug wire connection loose

Low oil pressure shutdown

Fuel pressure insufficient

Engine malfunction

AC circuit breaker in the OFF position

AC circuit breaker tripping because of overload

AC circuit breaker tripping because of short circuit

Generator set overloaded

Low oil pressure shutdown

Out of fuel

Overcrank shutdown

Controller fuse (F3) blown

Overspeed shutdown

Generator set master switch in the OFF/RESET

)oaltion

Remote stop command received from a remote switch

or ATS

Engine malfunction

Auxiliary winding fuse (F1) blown

General Troubleshooting Chart

Corrective Action

Check power to the battery charger.

Recharge or replace the battery.

Replace the fuse, Contact an authorized distributor/dealer

for service if fuse blows repeatedly,

Check the connections,

Replace the fuse, Contact an authorized distributor/dealer

for service if fuse blows repeatedly,

Replace the fuse, Contact an authorized distributor/dealer

for service if fuse blows repeatedly,

Move the master switch to the RUN position,

Clean and/or replace the air cleaner.

Check power to the battery charger.

Recharge or replace the battery.

Clean and tighten the battery connections,

Check the spark plug wires,

Check the oil level,

Check the fuel supply and valves,

Contact the distributor/dealer.

Place the circuit breaker in the ON position.

Reduce the load on the generator set.

Contact an authorized distributor/dealer for service,

Reduce the load,

Check the oil level,

Check fuel supply.

Reset the controller. If the overcrank fault occurs again,

contact the distributor/dealer,

Replace the fuse, If the fuse blows again, contact the

distributor/dealer.

Reset the controller. If the overspeed fault occurs again,

contact the distributor/dealer,

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

Check the remote switch position,

Contact the distributor/dealer.

Replace the fuse, Contact an authorized distdbutor/dealer

for service if fuse blows repeatedly,

TP-6195 1/04 Section 4 Troubleshooting 19

4.3 Fault Codes

The Advanced Digital Control displays fault codes to aid

in troubleshooting. Fault codes, descriptions, and

recommended actions are listed in Figure 2-3.

Identify and correct the cause of the fault condition.

Then reset the controller after a fault shutdown. See

Section 2.3.5.

4.5 Battery Charger

Troubleshooting

Use the battery charger's LED indicators and the table in

Figure 4-3 to troubleshoot battery charger operation

problems.

4.4 Controller Troubleshooting

Figure 4-2 contains troubleshooting, diagnostic, and

repair information for the Advanced Digital Control.

Problem

Controller LED display

is off

Possible Cause Corrective Action

No power to the controller:

Continuous power mode jumper is disconnected

and the generator set has not run for 48 hours or

longer.

Controller fuse (F3) is blown.

Low or no battery voltage.

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.

Replace the fuse. If the fuse blows again, contact the

distributor/dealer.

Check connections.

Check generator set battery and battery charger. See

Figure 4-1.

Generator set master switch is in the OFF/RESET Move generator set master switch to the AUTO or RUN

)osition. position,

Generator set master switch in AUTO but no start No action required (see Section 2.3.1). Controller display

command has been received since last controller will activate when a remote start command is received or

reset, the generator set master switch is moved to the RUN

position, Use the remote switch to start generator set and

activate the controller display, if desired.

Figure 4-2 Controller Troubleshooting 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 Battery charger has reduced its output voltage below Remove the source of the overload or short. Disconnect the

24 hours the normal level due to a DC overload or a DC short, 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 Turn off all DC equipment while charging.

the battery charger can replace.

Red and green Onboard DC systems are drawing between 1.5 and Turn off all DC equipment while charging.

LEDs stay on for 5 amps.

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 Open DC output fuse. Replace AGS-10 fuse.

on when the

battery is known Faulty or contaminated terminal connections. Clean and tighten or repair all terminal connections.

to be low One or more defective or damaged cells. Load test the battery and replace, if necessary.

Neither of the No AC power available at the battery charger. Connect AC power or reset the AC breaker on the main panel.

LEDs turn on

when the AC Component failure. Replace battery charger.

power is applied

Figure 4-3 Battery Charger Troubleshooting

20 Section4 Troubleshooting TP-6195 1/04

Section 5 Wiring Diagrams

5.1 Specification Numbers

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 5-1 Generator Set Specification Numbers

5.2 Controller Wiring Diagram

Reference

Figure5-2 lists the wiring diagram numbers and

locations.

Drawing

Wiring Diagram Description Number Page

Schematic Diagram

Sheet 1 ADV-6835A 22

Sheet 2 ADV-6835B 23

Point-to-Point Wiring Diagram GM29358 24

Figure 5-2 Controller Wiring Diagrams

TP-6195 1/04 Section 5 Wiring Diagrams 21

(/)

CD

O

C_

3

CQ

(o

-I

(,o

C_

"n

€:

U1

P

ro

m

09

09

o

:T

cO

0

C.Q

C.Q

cO

>

,<

Co

>

e I zI s I 5

IIFI

14.,"

!L ....................

i_ FUSLF:n_YOE_Pl-la _;_. p1_-1F_EL_L_ndNFLyO0"_L

MODE / FI JUMP_I _-_

LOWI_R JUMF_RIT02 _ _,o

COfmNUOLm POVW JUMPIER_TO 3

mUm_M_ P_VI_

O_ _E_T_r

_m _ LLm_

_,U_'aW,UNe Z*eUT

_U_y,mU_ r4_T

_EL_ 0_'._ ZaNUO

_Rr4_ IA rl_

:1_17,_tM u_w

•1_1n_=t_.o

_4 I

71;* N

_N

ra-

m

I 2 I 1

D

_C_Y

IGNITK_411Mlr_3

.... l-

_U_ F_,L _S NECT _TO N CO NOT G(_NNE_T

L_B_D

C8(#) -QRCU[T B;qF_R

D(#) - DIODE

G1"8-CO_ _RA_IJRE 9BNDBR

FV - RJGLV_-'_

QND - C_mR_L_ B_( GROUND

I_N - I_NmON C_411_L

LO - COmI_OL_R BOX LO8TU_

LOP -LOW O_LP_SURE 8VdT_H

kip-M_E_ oFqCI_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 MART8 pARK U 0 _4JLE

_TAT -_ATOR

_J_l - 811_RPGRUOTOR

_NE BUICK GROUND

_"=_"_ _ _c

_.5/12 KW RE_

I

-4

"0

CO

03

¢#

O

t_

3

o_

co

'11

C

&

IX)

m

0

0

CO

>

,<

¢.0

W

ADC 2100 CONTROLLER

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

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 POWER MODE SELECT

P7-3 GROUND

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)

RELAY iNTERFACE BOARD

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

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 FUEL {70A)

P14-8 GROUND

P14-9 STARTER (71 A)

ADO2100

)

OFF_ESET

RUN_

1"1FN

_FP

b3

O

O_

9)

3

cn

O

b3

(,O

"11

=3'

C

U1

P

ro

m

-o

o

g

_o

o

"o

W

ENGINE

I

P1 CONMEDNC_NS

RN*I _N (_4_ lU

a _ 21 m UMmUb_

4 IB _N*C

Nf_I N_

Rm _1-'_ _

_1_1,)¢ ¢ EU<_

RN_ _T p1-_

;[ ......

FORGB_TO_

CONNECll_U,S _EE:

/_DV-SaW 8INGLE pHASE.

A1_2100 COt_RO_ER BCX

N01_ F_fl P7 JUMPER

CONNE_ON88BE ADV-_.

LOW POW_ MOCE SHOWN. P14 CC_NECIIONS

m_#1 _ _1-I=

Jl 6 P18

P15 CONr_cCT1GN8

.°1/ _-

pJ

S_TGH.

BI7I8I5_4I

I 2 I 1

JUNG31ON BOX ._ m_m,_]

Ft*_- _PE Ctt25 Ctt20

TtJp_L _,_ C_MECT _TO N DO _OT C_MNE_T

L_G_S DO NOT C_',_EOT DO NOT CONNECT

LEGEND _CREW &8TN_r_ER.

_- CIRCUIT BR_ SM - ETAR_i M_TOR

O(J_- [_ODE _R -_ARTER RI_J_y

GTS -G_]LANT T_4PlS:L_TdRIE SBNDER _s _ START_ 5OU_K_D

EBGf_ -ENGINE BLOCK GROUND 68P1( -SMART SPARK MODLlU_

F(_ - NI6E _rAT - _rA_

F:V_ _UEL VAL'vl_ _- S_p_I MOTOR

GND - _NTR_L_R B_X _qOUND

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 _AOV_

3

Section 6 Installation

6.1 General

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

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.

6.4 Mounting

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 Exhaust Requirements

_1_ WARNING

Carbon monoxide.

Can cause severe nausea,

fainting, or death.

The exhaust system must be

leakproof and routinely inspected.

Generator set operation. Carbon monoxide can cause

severe nausea, fainting, or death. Carbon monoxide is an

odorless, colorless, tasteless, nonirritating gas that can cause

death ifinhaled for even ashorttime. 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.

TP-6195 1/04 Section 6 Installation 25

I'O

6_

0

0

-.I

G_

'11

C

@

t_

6"_

0

C

_Q

cJ

c

O.

3

0

cJ

,< B

i'o

8Y65432 I

Note: Dimensions in[]are ininch _qu_vaFents.

8 7

INLET

_INLET

STU6 UP

{lJ2" NpT FEMALE1

OIL FILL CAP_ _AIR FILTER

OIL DIPSTICK RUNIOFFIRESET/AUTO

O J

I 123 [ 44 2 ] = EOU I PMENT GROUND

\ \ \ /IILOCAX,ON

:!

533 [_1_0] CENTER OF

_RAVITY _/0 BATTERY]

FRONT VIE3i_

<DOOR & _IDE PANEL

REMOVED TO _HO_ DETAIL}

ELECTRICAL CONNECTION--

TO CIRCUIT BREAKER

--LOAD

CIRCUIT BREAKER

6ATTERY CHARGER

IINCLUDEDI

6ATTERY LOCATIOr_--

IBATTERY NOT INCLU_EDI

_BATTER¥ CA6LES

IINCLUDEDI

_--_IL DRAIN VALVE

ii i_ _ _ i_ _EI_HT _ _ 4_ CEr_TEROF _R_VIT_

RS VIEW _A

<END PARCEL REMOVED

TO SHOW DETAIL}

_.,o_ _,_ DIMB_JSION PRINT

2 I

WEIGHT _I0 BATTER_: 18_K_ [40_L_]

5 T

_DDED: _D 5_ TOP _IE_ _ DET_IL_ _D_ED:

E_IZS2]

Figure 6-2 gives the exhaust flow and temperature at

rated load. Mount the generator set so that the hot

exhaust does not blow on plants or other combustible

materials.

Exhaust System

Exhaust flow at rated kW, m3/min. (cfm)

8,5RES

12RES

Exhaust temperature at rated kW, dry

exhaust, °C (°F)

Figure 6-2

60 Hz 50 Hz

3.3 (115) 2.7 (96)

3,8 (135) 3,2 (113)

816 (1500)

Exhaust Flow and Temperature

6.6 Air Requirements

The generator set requires correct air flow for cooling

and combustion. The inlet and outlet openings in the

sound enclosure provide the cooling and combustion

air. Figure 6-3 shows the locations of the cooling air

intake and exhaust vents. Inspect the air inlet and outlet

openings inside and outside the housing to ensure that

the air flow is not blocked.

_,_ 3

1\\\

\ \

\ \\

23

1. Exhaust outlet tp6195

2. Alternator air intake (both sides)

3. Engine air intake

Figure 6-3 Cooling Air Intake and Exhaust

Cooling Air

Requirements

Cooling air,

m3/min. (cfm)

Total inlet air

requirement,

m3/min. (cfm)

Combustion air,

m3/min. (cfm)

8.5RES

60 Hz 50 Hz

26,9 (950) 22.4 (790)

27,8 (980) 23,2 (820)

0,94 (33,4) 0,8 (28,0)

12RES

60 Hz 50 Hz

26,9 (950) 22.4 (790)

28.0 (990) 23,4 (825)

1,1 (39,2) 0,9 (32,6)

Figure 6-4 Cooling Air Requirements

6.7 Power Supply

Utility power must be supplied to the generator set

location. Provide a 110- or 120-volt outlet connected to

the utility power supply for the battery charger

(standard) and carburetor heater (optional). Figure 6-5

lists the battery charger power requirements.

,°put 1

Rated AC voltage 90-135 VAC, 50/60 Hz

Current draw 1_ amp at full output

Figure 6-5 Battery Charger Power Requirements

6.8 Fuel System

The generator set operates using natural gas or LP

vapor fuel. The multi-fuel system allows conversion

from natural gas to LP vapor (or vice-versa) in the field

while maintaining emissions-standard compliance. A

trained technician or authorized distributor/dealer can

convert the fuel system. Generator sets with multi-fuel

systems are CARB- and EPA-certified for both natural

gas and LP vapor fuels.

6.8.1 Fuel Supply

Comply with local, state, and federal codes regarding

the correct storage of fuel. Because of variable climates

and geographical considerations, contact an authorized

service distributor/dealer for fuel system planning and

installation.

Figure6-1 shows the location of the fuel inlet

connection. Bring the fuel supply lines through the rear

access opening. Use flexible sections to prevent fuel

line breakage caused by vibration. Remove the housing

end panel and hold the fuel solenoid valve with a wrench

when tightening the fuel connections. Protect all fuel

lines from machinery or equipment contact, adverse

weather conditions, and environmental damage.

Verify that the output pressure from the primary gas

utility (or LP tank) pressure regulator is 1.7-2.7 kPa

(7-11 in. water column) and that the utility gas meter

flow rate is sufficient to supply the generator set plus all

other gas-consumingappliances. Figure 6-8showsthe

flow rate required for the generator set. Figure 6-6 lists

TP-6195 1/04 Section 6 Installation 27

the recommended fuel ratings for natural gas and LP

vapor fuels. Contact the natural gas utility for flow rate

information or a gas meter upgrade.

Fuel System

Fuel types Natural Gas or LP Vapor

Fuel supply inlet 1/2 NPT

Fuel supply pressure,kPa (in, H20) 1,7-2.7 (7-11)

Nominal Fuel Rating Btu/ft 3 MJ/m 3

Natural gas 1000 37

LP vapor 2500 93

Figure 6-6 Fuel Supply

Fuel 8.5RES 12RES

Consumption,

m3/hr. (cfh) 60 Hz 50 Hz 60 Hz 50 Hz

Natural Gas at % load

109% 3,7 (132) 3,3 (118) 5,9 (209) 4,9 (175)

75% 3,2 (113) 2,9 (101) 4,8 (168) 4,9 (141)

50% 2,6 (93) 2,3 (83) 3,6(127) 3,0(106)

25% 2,2 (77) 1,9 (69) 2,4 (85) 2,0 (71)

LP Vapor at % load

100% 2,0 (72) 1,7 (61) 3,1 (108) 2,5 (89)

75% 1,3 (45) 1,1 (38) 2,5 (87) 2,0 (72)

50% 1.0 (36) 0.9 (31) 1.9 (65) 1.5 (53)

25% 0,8 (29) 0,7 (25) 1,2 (44) 1,0 (36)

LP vapor conversion factors:

8,58 ft3= 1 lb.

36,39 ft3= 1 gal.

Figure 6-7 Fuel Consumption

Gas Flow Rate

Generator Set Model Btu/hro MJ/hr.

8.5RES 132,000 139

12RES 202,000 213

Figure 6-6 Natural Gas Flow Rate

6.8.2 Fuel Pipe Size

Ensure that the natural gas pipe size and length meet

the specifications in Figure 6-9. Measure the pipe

length from the primary gas pressure regulator to the

pipe connection on the generator set fuel inlet. Add

2.4 m (8 ft.) to the measured length for each 90 degree

elbow. Compare the pipe size and length with the chart

in Figure 6-9. If the piping is longer than the maximum

length shown for that size, replace it with the specified

size before proceeding.

Contact the local LP provider for LP installation

information.

Maximum Pipe Length m(ft.)

Pipe Size 8.5RES 12RES

3/4 in. NPT 18.3 (60) 9,2 (30)

1 in, NPT 61 (209) 30 (109)

1 1/4 in, NPT 91,5 (300) 68.6 (225)

Figure 6-9 Maximum Natural Gas Pipe Length

6.8.3 Fuel Conversion

_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

setasfollows: (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 aremote

computer.

28 Section6 Installation TP-6195 1/04

AWARNING

Explosive fuel vapors.

Can cause severe injury or death.

Use extreme care when handling,

storing, and using fuels.

The multi-fuel system allows conversion from natural

gas to LP vapor (or vice-versa) in the field while

maintaining emissions-standard compliance. Atrained

technician or authorized distributor/dealer can convert

the fuel system.

Two fuel connections on the fuel block allow field-

conversion between natural gas and LP vapor. The fuel

metering valves are factory-set and sealed to comply

with applicable emission standards and to provide the

best possible hot and cold starting.

Note: Do not adjust the factory-sealed fuel-metering

adjustments on the fuel block. Changing the

fuel-metering adjustments may violate federal or

state laws.

Use the following procedure to convert from natural gas

to LP vapor, moving the fuel connection from the natural

gas to the LP port, plugging the natural gas port, and

connecting the DSAM leads. See Figure 6-10 for the

fuel system component locations.

Fuel Conversion Procedure

1. Place the generator set master switch in the OFF

position.

2. Disconnect the power to the battery charger.

3. Disconnect the generator set engine starting

battery, negative (-) lead first.

4. Turn off the fuel supply.

5. Remove the hose clamp and fuel hose from the

hose fitting in the fuel block. See Figure 6-11.

6. Remove the hose fitting from the natural gas outlet

port in the fuel block. See Figure 6-11.

1 2

\\

1. DSAM connector location

2. Fuel block

3. Fuel inlet, 1/2 in, NPT female

GM29253

Figure 6-10 Fuel System Locations, Air Inlet Side

1

2

5

4

tp6195

1. Fuel block

2. Fuel metering valves---factory-sealed, do not adjust

3, Fuel inlet, 1/2 in, NPT

4, Hose fitting

5, Plug

Figure 6-11 Fuel Block Connections, Natural Gas

System Shown

TP-6195 1/04 Section 6 Installation 29

7. Remove the plug from the LP port in the fuel block.

See Figure 6-11. Clean the plug with a dry cloth or

brush, apply fresh pipe sealant, and install the plug

into the natural gas outlet port.

8. Clean the hose fitting with a dry cloth or brush,

apply fresh pipe sealant to the threads, and install

the fitting into the LP port.

Note: Do not adjust the fuel metering valves.

9. Slide the hose onto the hose fitting and secure it

with the clamp.

10. For the 12RES only: Connect the digital

spark-advance module (DSAM) leads together for

natural gas. (Disconnect the leads for LP.) See

Figure 6-12.

11. Connect and turn on the new fuel supply.

12. Check that the generator set master switch is in the

OFF position.

13. Reconnect the generator set engine starting

battery leads, negative (-) lead last.

14. Reconnect power to the battery charger.

15. Start the generator set by moving the generator set

master switch to the RUN position.

16. Check for leaks using a gas leak detector.

17. Move the generator set master switch to the AUTO

position.

To convert from LP vapor to natural gas, follow the same

fuel conversion procedure, moving the hose fitting to the

natural gas port and plugging the LP port. For the

12RES model, disconnect the DSAM leads for LP vapor.

See Figure 6-12.

tp6195

1

1, DSAM leads: connect for natural gas, disconnect for LP.

Figure 6-12 Digital Spark Advance Module (DSAM)

Leads (located in generator set air intake

area)

30 Section6 Installation TP-6195 1/04

6.9 Electrical Connections

6.9.1 AC Load Lead Connections

_1_ WARNING

Hazardous voltage.

Backfeed to the utility system can

cause property damage, severe

injury, or death.

if the generator set is used for

standby power, install an automatic

transfer switch to prevent inadvertent

interconnection of standby and

normal sources of supply.

Grounding electrical equipment. Hazardous voltage can

cause severe injury or death. Electrocution is possible

whenever electricity is present. Open the main circuit

breakers of all power sources before servicing the equipment.

Configure the installation to electrically ground the generator

set, transfer switch, and related equipment and electrical

circuits to comply with applicable codes and standards. Never

contact electrical leads or appliances when standing in water

or onwet ground because these conditions increase the risk of

electrocution.

Electrical backfeed to the utility. Hazardous backfeed

voltage can cause severe injury or death. Install atransfer

switch in standby power installations to preventthe 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.

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.

Have an authorized distributor/dealer or a licensed

electrician make the following load connections. Verify

that the electrical installation complies with the National

Electrical Code (NEC) and all applicable local and state

codes.

Connect the AC output leads in the controller

compartment to the AC circuit breaker. Route AC leads

through flexible conduit directly to the AC circuit breaker

box. See Figure 6-1 for the recommended electrical

inlet location. Verify that the leads and conduit do not

interfere with the operation of the generator set or

obstruct the service areas.

See Figure 6-13 and Section 5, Wiring Diagrams, for

the generator set electrical connections. Make the

following AC connections:

1. Connect the output leads going to the transfer

switch (L1/L2 black leads) to the AC circuit breaker

load side.

2. Connect the L0 white leads from the ATS and the

main panel to the neutral terminal.

3. Connect the green lead to the equipment ground

terminal (labeled GRD).

Verify that the electrical installation complies with the

National Electrical Code (NEC) and all applicable local

and state codes.

1

2

VIEW B-B

Bottom of Junction BOX

I\

2,

3

GM29253A-F

1. Line circuit breaker

2, Ground terminal (GRD)

3, Neutral terminal (L0)

Figure 6-13 Field-Installed Wiring Connections

TP-6195 1/04 Section 6 Installation 31

6.9.2 Remote Start Connection

(optional)

Connect leads 3 and 4 from the ADC 2100 controller to

the automatic transfer switch's engine start terminals or

to an optional remote start!stop switch.

6.9.3 Continuous Power Mode Jumper

Ajumper on connector P7 on the back of the controller

causes the controller to remain powered at all times.

See the wiring diagram and schematic drawing in

Section 5. Controllers are shipped from the factory with

the jumper connected. Disconnecting the jumper allows

the controller to power down 48 hours after the

generator set shuts down. See Section 2.3.6.

Note: For most applications, it is not necessary to

disconnect the continuous power mode jumper.

Use the following procedure to disconnect the jumper, if

desired.

Procedure to disconnect the continuous power

mode jumper (optional).

1. Prevent the generator set from starting.

a. Move the generator set master switch to the

OFF/RESET position.

b. Disconnect power to the battery charger.

c. Disconnect the generator set engine starting

battery, negative (-) lead first.

2. Remove the controller from the generator set

housing.

a. Disconnect the engine wiring harness

connector P1 plug (35-pin) from the controller.

Disconnect the J15 and J16 connectors. See

Figure 6-14.

b. Remove the controller from the generator set

housing in order to access the back of the

controller.

3. Remove the controller's back cover to access the

jumper.

a. Note the labels on the three leads connected to

the generator set master switch for

reconnection later. Disconnect the leads at the

pink connectors. See Figure 6-14.

b. Remove the cover screws and remove the

controller's back cover. See Figure 6-14.

4.

5.

6.

7.

8.

9.

10.

Locate the P7 connector near the top of the

controller. See Figure 6-14. Remove the jumper

from pins 1 and 2 of the P7 connector. If the P7

connector has three pins, connect the jumper

across pins 2 and 3 for storage.

Replace the controller's back cover and secure the

cover screws.

Reconnect the three pink connectors to the

generator set master switch.

Reconnect the J 15 and J 16 connectors.

Reconnect the generator set engine starting

battery, negative (-) lead last.

Reconnect power to the battery charger.

Place the generator set master switch in the AUTO

position.

1. Engine wiring harness connector plug (P1)

2. Continuous power mode jumper location (P7)

3, J15 connector

4, J16 connector

5, Generator set master switch connectors

tp6195

Figure 6-14 Advanced Digital Control Connections

32 Section6 Installation TP-6195 1/04

6.9.4 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.

_1_ WARNING

Explosion.

Can cause severe injury or death.

Relays in the battery charger

cause arcs or sparks.

Locate the battery in a well-ventilated

area. Isolate the battery charger from

explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid

can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety

goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If

battery acid splashes in the eyes or on the skin, immediately

flush the affected area for 15 minutes with large quantities of

clean water. Seek immediate medical aid in the case of eye

contact. Never add acid to a battery after placing the battery in

service, as this may result in hazardous spattering of battery

acid.

Battery acid cleanup. Battery acid can cause severe

injury or death. Battery acid is electrically conductive and

corrosive. Add 500 g (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.

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).

TP-6195 1/04 Section 6 Installation 33

Use a 12-volt battery with a minimum rating of 675 cold

cranking amps at 0°E The generator set uses a

negative ground with a 12-volt engine electrical system.

See Figure 6-15 for battery connections. Make sure

that the battery is correctly connected and the terminals

are tight.

Note: The generator set will not start and circuit board

damage may occur if the battery is connected in

reverse.

Figure 6-16 shows the location of the engine starting

battery. Standard battery cables provide easy

connection to the battery. Use the following procedure

to install and connect the battery.

Battery Installation Procedure

1. Ensure that the starting battery is fully charged

before placing the battery in service.

2. Clean the battery posts and/or adapters if

necessary.

3. Install the battery post adapters, if needed.

4. Place the battery in the housing.

5. Verifythat the controller master switch is in the OFF

position.

1 2

J

EZ-273000-J

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

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

Figure 6-15 12-Volt Engine Electrical System Single

Starter Motor Typical Battery Connection

6. Connect the positive (+) lead to the engine starting

battery.

7. Connect the negative (-) lead to the engine starting

battery.

Refer to Section 3.8 for battery maintenance

instructions.

6.9.5 Battery Charger

The generator set requires an external battery charger

to keep the starting battery fully charged. A 6-amp

battery charger is factory-installed in the battery

compartment. The battery charger's DC leads are

factory-connected.

Plug the battery charger's power cord into a 120 VAC

outlet on the load side of the system. Refer to Section

2.5 for battery charger operation information.

1

GM29253

1. Engine starting battery location

Figure 6-16 Battery Location, Air Intake End

34 Section6 Installation TP-6195 1/04

6.10 Accessories

Have accessories installed by an authorized

distributor/dealer or a licensed electrician. Follow the

installation instructions provided with each kit. Use

separate conduit for AC and DC leads to reduce the

possibility of electrical interference. Verify that the leads

and conduit do not interfere with the operation of the

generator set or obstruct the service areas. Verify that

the electrical installation complies with the National

Electrical Code (NEC) and all applicable local and state

codes. See Section 5, Wiring Diagrams, for more

information regarding generator set electrical

connections.

6.10.1 Common Fault and Run Relay

Board

The optional relay board provides two additional relays

to control customer-provided equipment:

• Common fault relay

• Auxiliary run relay

The optional relay board replaces the standard relay

board. The relay board location is shown in Figure 6-17.

Connect customer equipment to the relay board

harness. Figure 6-18 lists the customer connections.

The common fault relay is energized on a fault. The

auxiliary run relay is energized when the generator set is

running. Connect to each relay's normally open or

normally closed contacts depending on the application.

1

2\

GM30414

1. Relay board

2. Relay board harness

Figure 6-17 Common Fault and Run Relay Board

Harness

Lead Connector

Number Pin Number Connection

88 6 Common fault normally open

89 2 Common fault common

90 3 Common fault normally closed

91 4 Run relay normally open

92 1 Run relay common

93 5 Run relay normally closed

I

Figure 6-18 Common Fault and Run Relay Board

Harness Connections

TP-6195 1/04 Section 6 Installation 35

6.10.2 Carburetor Heater

An optional carburetor heater is recommended for

improved cold starting in locations where the ambient

temperature drops below 0°C (32 °F). The carburetor

heater prevents condensation and carburetor icing. The

heater turns on when the temperature at the thermostat

falls below approximately 4°C (40 ° F) and turns off when

the temperature rises above approximately 16°C

(60°F).

The heater requires a continuous source of 120 VAC

power. The heater power cord and thermostat are

located in the generator set housing air intake

area!battery compartment. See Figure 6-16. Plug the

carburetor heater into an outlet that supplies continuous

120 VAC power.

The heater thermostat is installed in the cord.

Figure 6-20 shows the location of the thermostat on the

power cord.

Note: Do not place the heater thermostat inside the

generator set engine compartment. The

thermostat must be exposed to the ambient air.

The thermostat will shut off power to the heater

when the ambient temperature reaches

approximately 60°F (16°C).

tp6195

1. Carburetor heater (air cleaner removed to show heater)

2. Carburetor heater power cord

1 2

\ \\

\ \

\ \

\ \

\ \

\ \

Figure 6-19 Carburetor Heater

3

\\\\\

©

1. Thermostat

2. Connector

3. Heater

Figure 6-20 Carburetor Heater with Thermostat

GM19463

36 Section6 Installation TP-6195 1/04

6.11 Controller Configuration

6.11.1 System Configuration

The system configuration is factory-set and should not

normally require changes in the field. However, the

controller's configuration modes allow setting of the

system voltage/frequency and adjustment of the output

voltage and frequency after reconnection. Have

reconnection and the related adjustments performed by

an authorized distributor/dealer or service technician.

The unit configuration and engine type are factory-set

for each type of generator set and engine, and should

not be changed in the field.

6.11.2 Advanced Configuration Mode

The controller's advanced configuration mode allows a

technician to set the data input type for different

senders, change the battery voltage to 12 or 24 VDC if

the battery voltage is changed in the field, and change

the controller communications setting for field-installed

meters. Have these adjustments performed by an

authorized distributor/dealer or service technician.

6.12 Prestart Installation Check

Review the entire installation section. Inspect all wiring

and connections to verify that the generator set is ready

for operation. Check that there are no obstructions to

the air inlet and outlet. Check all items in the Prestart

Checklist. See Section 2.1.

6.13 Warranty Registration

Complete the startup procedure and installation

checklists supplied with the startup notification form.

Return the form to the distributor/dealer or mail it directly

to:

Kohler Power Systems

Generator Warranty Administrator

M.S. 072

Kohler, Wisconsin 53044

TP-6195 1/04 Section 6 Installation 37

Notes

38 Section6 Installation TP-6195 1/04

Appendix A Abbreviations

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

A, amp ampere

ABDC after bottom dead center

AC alternating current

A!D analog to digital

ADC analog to digital converter

adj. adjust, adjustment

ADV advertising dimensional

drawing

AHWT anticipatory high water

temperature

AISI American iron and Steel

Institute

ALOP anticipatory low oil pressure

alt. alternator

AI aluminum

ANSI American National Standards

Institute

(formerly American Standards

Association, ASA)

AO anticipatory only

API American Petroleum Institute

approx, approximate, approximately

AR as required, as requested

AS as supplied, as stated, as

suggested

ASE American Society of Engineers

ASME American Society of

Mechanical Engineers

assy. assembly

ASTM American Society for Testing

Materials

ATDC after top dead center

ATS automatic transfer switch

auto, automatic

aux. auxiliary

A!V audiovisual

avg. average

AVR automatic voltage regulator

AWG American Wire Gauge

AWM appliance wiring material

bat. battery

BBDC before bottom dead center

BC battery charger, battery

charging

BCA battery charging alternator

BCI Battery Council International

BDC before dead center

BHP brake horsepower

blk. black (paint color), block

(engine)

blk. htr. block heater

BMEP brake mean effective pressure

bps bits per second

br. brass

BTDC before top dead center

Btu British thermal unit

Btu/min. British thermal units per minute

C Celsius, centigrade

cal. calorie

CARB California Air Resources Board

CB circuit breaker

cc cubic centimeter

CCA cold cranking amps

ccw. counterclockwise

CEC Canadian Electdcal Code

cert. certificate, certification, certified

cfh cubic feet per hour

cfm cubic feet per minute

CG center of gravity

CID cubic inch displacement

CL centerline

cm centimeter

CMOS complementary metal oxide

substrate (semiconductor)

cogen, cogeneration

corn communications (port)

coml commercial

Coml/Rec Commercial/Recreational

conn. connection

cont. continued

CPVC chlorinated polyvinyl chlodde

crit. critical

CRT cathode ray tube

CSA Canadian Standards

Association

CT current transformer

Cu copper

cu. in, cubic inch

cw. clockwise

CWC city water-cooled

cyL cylinder

D/A digital to analog

DAC digital to analog converter

dB decibel

dBA decibel (A weighted)

DC direct current

DCR direct current resistance

deg., ° degree

dept. department

din. diameter

DI/EO dual inlet/end outlet

DIN Deutsches Institut fur Normung

e.V.

(also Deutsche ledustrie

Normenausschuss)

DiP dual inline package

DPDT double-pale, double-throw

DPST double-pale, single-throw

DS disconnect switch

DSAM digital spark-advance module

DVR digital voltage regulator

E, emer. emergency (power source)

EDI electronic data interchange

EFR emergency frequency relay

e.g. for example (exempli gratia)

EG electronic governor

EGSA Electrical Generating Systems

Association

EIA Electronic Industries

Association

EI/EO end inlet/end outlet

EMI electromagnetic interference

emiss, emission

eng. engine

EPA Environmental Protection

Agency

EPS emergency power system

ER emergency relay

ES engineering special,

engineered special

ESD electrostatic discharge

est. estimated

E-Stop emergency stop

etc. et cetera (and so forth)

exh. exhaust

ext. external

F Fahrenheit, female

fglass, fiberglass

FHM flat head machine (screw)

fl. oz. fluid ounce

flex. flexible

freq. frequency

FS full scale

ft. foot, feet

ft. Ibs. foot pounds (torque)

ft./rain, feet per minute

g gram

ga. gauge (meters, wire size)

gal. gallon

gen. generator

genset generator set

GFI ground fault interrupter

GND, O ground

gov. governor

gph gallons per hour

gpm gallons per minute

gr. grade, gross

GRD equipment ground

gr. wt. gross weight

H x W x D height by width by depth

HC hex cap

HCHT high cylinder head temperature

HD heavy duty

HET high exhaust temperature,

high engine temperature

hex hexagon

Hg mercury (element)

HH hex head

HHC hex head cap

HP horsepower

hr. hour

HS heat shrink

hsg. housing

HVAC heating, ventilation, and air

conditioning

HWT high water temperature

Hz hertz (cycles per second)

IC integrated circuit

ID inside diameter, identification

IEC International Electrotechnical

Commission

IEEE Institute of Electrical and

Electronics Engineers

IMS improved motor starting

in. inch

in. H20 inches of water

in. Hg inches of mercury

in. Ibs, inch pounds

Inc. incorporated

ind. industrial

int. internal

int./ext, internal/external

I/O input/output

IP iron pipe

TP-6195 1/04 Appendix A-1

ISO InternationalOrganizationfor MS militarystandard

Standardization m/sec, meterspersecond

J joule MTBF meantimebetweenfailure

JIS JapaneseIndustryStandard MTBO meantimebetweenoverhauls

k kilo(1000) mtg. mounting

K kelvin MW megawatt

kA kiloampere mW milliwatt

KB kilobyte(2t°bytes) uF microfarad

kg kilogram N,norm,normal(powersource)

kg/cm2 kilogramspersquare NA notavailable,notapplicable

centimeter nat.gas naturalgas

kgm kilogram-meter NBS NationalBureauofStandards

kg/m3 kilogramspercubicmeter NC normallyclosed

kHz kilohertz NEC NationalElectricalCode

kJ kilojoule NEMA NationalElectrical

km kilometer ManufacturersAssociation

kOhm,k_kilo-ohm NFPA NationalFireProtection

kPa kilopascal Association

kph kilometersperhour Nm newtonmeter

kV kilovolt NO normallyopen

kVA kilovoltampere no.,nos.number,numbers

kVAR kilovoltamperereactive NPS NationalPipe,Straight

kW kilowatt NPSC NationalPipe,Straight-coupling

kWh kilowatt-hour NPT NationalStandardtaperpipe

kWm kilowattmechanical threadpergeneraluse

L liter NPTF NationalPipe,Taper-Fine

LAN localareanetwork NR notrequired,normalrelay

LxWxHlengthbywidthbyheight ns nanosecond

Ib. pound,pounds OC overcrank

Ibm/ft3 poundsmasspercubicfeet OD outsidediameter

LCB linecircuitbreaker OEM odginalequipment

manufacturer

LCD liquidcrystaldisplay

Id.shd. loadshed OF overfrequency

LED lightemitting diode opt. option, optional

Lph liters per hour OS oversize, overspeed

Lpm liters per minute OSHA Occupational Safety and Health

Administration

LOP low oil pressure OV overvoltage

LP liquefied petroleum oz. ounce

LPG liquefied petroleum gas p., pp. page, pages

LS left side PC personal computer

Lwa sound power level, A weighted PCB printed circuit board

LWL low water leval pF picofared

LWT low water temperature PF power factor

m meter, milli (1/1000) ph., _ phase

M mega (106 when used with SI PHC Phillips head edmptite (screw)

units), male

m 3 cubic meter PHH Phillips hex head (screw)

m3/min, cubic meters per minute PHM pan head machine (screw)

mA milliampere PLC programmable logic control

man. manual PMG permanent-magnet generator

max. maximum pot potentiometer, potential

MB megabyte (22° bytes) ppm parts per million

MCM one thousand circular mils PROM programmable reed-only

memory

MCCB molded-case circuit breaker psi pounds per square inch

meggar megohmmeter pt. pint

MHz megahertz PTC positive temperature coefficient

mi. mile PTO power takeoff

rail one one-thousandth of an inch PVC palyvinyl chloride

rain. minimum, minute qt. quart, quarts

misc. miscellaneous qty. quantity

MJ megajoule R replacement (emergency)

mJ millijoule power source

mm millimeter red. radiator, radius

mOhm, m_ RAM random access memory

milliohm RDO relay driver output

MOhm, M_ ref. reference

megohm

MOV metal oxide varistor rem. remote

MPa megapascal Res/Coml Residential/Commercial

mpg miles per gallon RFI radio frequency interference

mph miles per hour

RH round head

RHM round head machine (screw)

rly. relay

FinS root mean square

rnd. round

ROM read only memory

rot. rotate, rotating

rpm revolutions per minute

RS right side

RTV room temperature vulcanization

SAE Society of Automotive

Engineers

scfm standard cubic feet per minute

SCR silicon controlled rectifier

s, sec. second

SI Systeme international d'unites,

International System of Units

SI/EO side in/end out

all. silencer

SN serial number

SPDT single-pole, double-throw

SPST single-pole, single-throw

spec, specsspecification(s)

sq. square

sq. cm square centimeter

sq. in. square inch

SS stainless steel

std. standard

stL steel

tach. tachometer

TD time delay

TDC top dead center

TDEC time delay engine cooldown

TDEN time delay emergency to

normal

TDES time delay engine start

TDNE time delay normal to

emergency

TDOE time delay off to emergency

TDON time delay off to normal

temp. temperature

term. terminal

TIF telephone influence factor

TIn total indicator reading

tal. tolerance

turbo, turbocharger

typ. typical (same in multiple

locations)

UF underfrequency

UHF ultrahigh frequency

UL Underwriter's Laboratories, Inc.

UNC unified coarse thread (was NC)

UNF unified fine thread (was NF)

univ. universal

US undersize, underspeed

UV ultraviolet, undervaltage

V volt

VAC volts alternating current

VAn valtampere reactive

VDC volts direct current

VFD vacuum fluorescent display

VGA video graphics adapter

VHF very high frequency

W watt

WCR withstand and closing rating

w/ with

w/o without

wt. weight

xfmr transformer

A-2 Appendix TP-6195 1/04

TP-6195 1/04

@ 2004 by Kohler Co All rights reserved

KOHLERo

POWERSYSTEMS

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-565-3381, Fax 920-459-1646

For the nearest sales/service outlet in the

US and Canada, phone 1-800-544-2444

KohlerPowerSystems,com

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619169

Phone (66)264*6422, Fax (66)264*6465