Instruction/ maintenance manual of the product 12RES Kohler
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Residential/Commercial Generator Sets Models: 8.5RES 12RES Controller: Advanced Digital Control (ADC 2100) TP-6331 5/04 Operation.
Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts.
T able of Contents TP-6331 5/04 T able of Contents Product Identification Information Inside front cover ............................................ Safety Precautions and Instructions I ........................................................ Introduction i .
T able of Contents, continued TP-6331 5/04 T able of Contents Section 4 T roubleshooting 19 ................................................................. 4.1 Introduction 19 .......................................................... 4.2 Generator Set T roubleshooting 19 .
TP-6331 5/04 I Safety Precautions and Instructions Safety Precautions and Instructions IMPORT ANT 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.
TPTPS-6331 5/04 II Safety Precautions and Instructions Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.
TP-6331 5/04 III Safety Precautions and Instructions Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe injury or death.
TPTPS-6331 5/04 IV Safety Precautions and Instructions Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative ( - - ) lead first.
TP-6331 5/04 V Safety Precautions and Instructions Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair , clothing, and test leads away from the belts and pulleys when the generator set is running.
TPTPS-6331 5/04 VI Safety Precautions and Instructions Notes.
TP-6331 5/04 i Introduction Introduction This manual provides operation and maintenance instructions for model 8.5RES and 12RES generator sets equipped with the Kohler r Advanced Digital Control (ADC 2100). This generator set is approved for use in stationary applications in locations served by a reliable utility power source.
TP-6331 5/04 ii Service Assistance tp6195 Figure 3 Air Index Label, 8.5/12RES This engine/generator is certified to operate using natural gas or propane fuel.
TP-6331 5/04 1 Section 1 Features Section 1 Features 1.1 Specifications The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications.
TP-6331 5/04 2 Section 1 Features 1.5 Generator Set Components 12 3 6 57 1 9 13 14 4 11 21 16 18 12 9 20 ADV- 6823 -A 1. Enclosure 2. Muffler 3. Oil check 4. Oil fill 5. Air cleaner 6. Spark plug locations (both sides) 7. ADC 2100 8. Generator set master switch (RUNOFF/RESETAUTO) 9.
TP-6331 5/04 3 Section 2 Operation Section 2 Operation 2.1 Prestart Checklist T o 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.
TP-6331 5/04 4 Section 2 Operation 2.3.1 Controls and Indicators Figure 2-2 describes the controls and indicators located on the ADC 2100. The LED display indicates generator set status as shown in Figure 2-2.
TP-6331 5/04 5 Section 2 Operation 2.4 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.
TP-6331 5/04 6 Section 2 Operation Code Fault Description Check HB High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 10 seconds when the engine is not running.
TP-6331 5/04 7 Section 2 Operation 2.6 Battery Charger The generator set is equipped with a 6-amp float/equalize battery charger to maintain the engine starting battery . The charger ’s power cord must be connected to a 120 V AC power source. Figure 2-5 illustrates the battery charger .
TP-6331 5/04 8 Section 2 Operation Notes.
TP-6331 5/04 9 Section 3 Scheduled Maintenance Section 3 Scheduled Maintenance 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 .
TP-6331 5/04 10 Section 3 Scheduled Maintenance 3.2 Service Schedule Procedure System Component or Procedure See Section Visually Inspect Check Change Clean T est Frequency Fuel Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Y early Lubrication 3.
TP-6331 5/04 11 Section 3 Scheduled Maintenance 3.3 Lubrication System See Section 3.2, Service Schedule, for oil change and oil filter replacement intervals. See Section 1.5, Service Views, for the oil drain, oil check, oil fill, and oil filter locations.
TP-6331 5/04 12 Section 3 Scheduled Maintenance b. Clean the gasket sealing surface of the oil filter adapter . c. Apply a light coat of clean oil to the rubber seal of the new oil filter . d. Install the new oil filter following the instructions provided with the filter .
TP-6331 5/04 13 Section 3 Scheduled Maintenance traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry . 5. Saturate the precleaner with new engine oil. Squeeze out all of the excess oil. 6. Reinstall the precleaner over the paper element.
TP-6331 5/04 14 Section 3 Scheduled Maintenance 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.
TP-6331 5/04 15 Section 3 Scheduled Maintenance Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance.
TP-6331 5/04 16 Section 3 Scheduled Maintenance 3.10 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly , see Section 4, Troubleshooting, for possible causes.
TP-6331 5/04 17 Section 3 Scheduled Maintenance 3.1 1.3 Cylinder Lubrication 1. Remove the spark plugs. 2. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the plugs.
TP-6331 5/04 18 Section 3 Scheduled Maintenance Notes.
TP-6331 5/04 19 Section 4 Troubleshooting Section 4 T roubleshooting 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 .
TP-6331 5/04 20 Section 4 Troubleshooting 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.
TP-6331 5/04 Appendix A-1 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.
TP-6331 5/04 A-2 Appendix ISO International Organization for Standardization J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 10 bytes) kg kilogram kg/cm 2 ki.
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E 2004 by Kohler Co. All rights reserved. TP-6331 5/04 KOHLER CO. Kohler , Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.
An important point after buying a device Kohler 12RES (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kohler 12RES yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kohler 12RES - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kohler 12RES you will learn all the available features of the product, as well as information on its operation. The information that you get Kohler 12RES will certainly help you make a decision on the purchase.
If you already are a holder of Kohler 12RES, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kohler 12RES.
However, one of the most important roles played by the user manual is to help in solving problems with Kohler 12RES. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kohler 12RES along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
