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Kohler 12RES Operation

Residential/commercial generator sets
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Operation
Residential/Commercial Generator Sets
Models:
12RES
Similar Models (no longer available):
8.5/17/18RES
12/18TRES
Controller:
Advanced Digital Control ADC-RES
TP-6515 2/21g

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Summary of Contents for Kohler 12RES

  • Page 1 Operation Residential/Commercial Generator Sets Models: 12RES Similar Models (no longer available): 8.5/17/18RES 12/18TRES Controller: Advanced Digital Control ADC-RES TP-6515 2/21g...

  • Page 2: Product Identification Information

    WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Product Identification Information Product identification numbers determine service parts.

  • Page 3: Table Of Contents

    3.4.1 Air Cleaner, 8.5/12RES ........
  • Page 4 Table of Contents, continued Battery Charger ............Circuit Protection .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. WARNING Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, WARNING can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be Explosion. aware of potential dangers and act Can cause severe injury or death.
  • Page 6 Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms. severe injury or death. Battery gases fire can cause severe injury or death. Carbon monoxide can cause severe can cause an explosion. Do not smoke Do not smoke or permit flames or nausea, fainting, or death.
  • Page 7 Hazardous Noise Electrical backfeed to the utility. CAUTION Hazardous backfeed voltage can cause severe injury or death. Install Welding the generator set. CAUTION a transfer switch in standby power cause severe electrical installations to prevent the connection equipment damage. of standby and other sources of power. Electrical backfeed into...
  • Page 8 Hot Parts Notice NOTICE WARNING Canadian installations only. standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools.

  • Page 9: Introduction

    Specification Sheet, 18RES G4- 133 Information in this publication represents data available Installation Manual, Generator Set, at the time of print. Kohler Co. reserves the right to 8.5/18RES, 12/18TRES TP-6792 change this publication and the products represented without notice and without any obligation or liability...
  • Page 10 8.5RES generator set, CH740 engine used on the numbers from the nameplate into the spaces provided in 12RES generator set, and CH980 engine used on the the product information section on the inside front cover 17/18RES generator set are certified to operate using of this manual.

  • Page 11: Service Assistance

    Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7952 Fax: (86) 10 6518 7955 Look at the labels and decals on your Kohler product East China Regional Office, Shanghai or review the appropriate literature or documents Phone: (86) 21 6288 0500 included with the product.
  • Page 12 Notes Service Assistance TP-6515 2/21...

  • Page 13: Section 1 Specifications

    Section 1 Specifications 1.1 Introduction 1.4 Advanced Digital Control The generator set specification sheets provide specific The generator set is equipped with the Kohler generator and engine information. Refer to the spec ADC-RES Advanced Digital Control. Controller sheet for data not supplied in this manual. Consult the...

  • Page 14: Accessories

    0 C (32 F). Note: Battery heaters compatible with Kohler-supplied lead-acid batteries.* For other battery types, check the battery manufacturer’s instructions for any restrictions regarding the use 1. Battery heater wrap of battery heaters.

  • Page 15: Service Views For Maintenance

    1.6 Service Views for Maintenance ADV-7466- 1. Muffler 14. Oil filter 2. Oil check 15. Exhaust 3. Oil fill 16. Equipment ground 4. Air cleaner 17. Relay board location (optional) 5. Fuses 18. Battery charger (single-phase models) 6. RS-232 connector (for application program updates) 19.
  • Page 16 0.006 - C- - B- - A- - B- ADV-9747- 1. Muffler 14. Oil filter 2. Oil check 15. Exhaust 3. Oil fill 16. Equipment ground 4. Air cleaner 17. Relay board location (optional) 5. Fuses 18. Battery charger 6. RS-232 connector (for application program updates) 19.
  • Page 17 Control detail, top view See control detail ADV-7341A-B 1. Muffler 16. Oil drain valve 2. Oil check 17. Exhaust outlet 3. Oil fill 18. Relay board location (optional) 4. Air cleaner 19. Carburetor heater access opening 5. Spark plug locations (both sides) 20.
  • Page 18 GM66010 1. Emergency stop switch 2. Field-connection terminal block and circuit breakers 3. Cable inlet area Figure 1-4 Additional Components, TRES (3-phase) Models Section 1 Specifications TP-6515 2/21...

  • Page 19: Section 2 Operation

    Section 2 Operation 2.1 Operating Area Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to DANGER the generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide.

  • Page 20: Exercising Generator Set

    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.

  • Page 21: Controller Keypad

    Control or Indicator Item Description LED display Runtime hours Displays total generator set runtime hours while the generator set is running and when no other codes are displayed. Metering Displays AC voltage (output), frequency, and battery voltage. Press the up or display down arrow when runtime hours are displayed to step through these displays.

  • Page 22: Controller Power

    2.5 Controller Power 2.6 Generator Set Operation The ADC-RES is powered by the generator set engine 2.6.1 Starting Generator Set starting battery. Note: The generator sets are equipped with factory- Local Starting installed battery chargers to prevent battery Move the generator set master switch to the RUN discharge.

  • Page 23: Emergency Stopping (Tres Models Only)

    2.6.3 Emergency Stopping (TRES Resetting Emergency Stop Switch (TRES Models only) Models Only) Use the following procedure to reset the generator set Push the red emergency stop switch for immediate after shutdown by the emergency stop switch. See generator set shutdown in the case of an emergency. Section 2.7.3 to reset the generator set after a fault See Figure 2-4 for the emergency stop switch location.

  • Page 24: Faults

    2.7 Faults Use the following procedure to reset the generator set controller after a fault shutdown. 2.7.1 Shutdowns 1. Move the generator set master switch to OFF/ RESET. Under the fault shutdown conditions listed in Figure 2-5, the generator set shuts down automatically and the 2.
  • Page 25 Code Fault Description Check Auxiliary fault Indicates a shutdown initiated by pushing the emergency Check the position of the emergency input shutdown stop switch. (TRES models only) stop button. (TRES models only) Not used on RES models. High engine Shutdown occurs if the engine coolant temperature Check for blocked air inlets and temperature exceeds the maximum temperature for more than...

  • Page 26: Battery Charger

    2.8 Battery Charger Battery Charger Operation Figure 2-7 illustrates the three-stage charging method. 2.8.1 RES Battery Charger Red and green LEDs indicate charger operation. The chart in Figure 2-8 describes the LED indicator RES model generator sets are equipped with a 6-amp operation during each stage of the charging process.

  • Page 27: Tres Battery Charger

    2.8.2 TRES Battery Charger Three-phase model TRES generator sets are equipped with a 2.5-amp battery charger to maintain the engine starting battery. Utility power must be supplied to the generator set for the battery charger. The battery charger is located in or near the controller junction box.
  • Page 28 Notes Section 2 Operation TP-6515 2/21...

  • Page 29: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance DANGER WARNING Hazardous voltage. Moving parts. Accidental starting. Will cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working generator set.

  • Page 30: Service Schedule, 8.5/12 Kw Models

    3.1.1 Service Schedule, 8.5/12 kW Models Procedure Visually Inspect Check Change Clean Test Section System Component or Procedure Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather hose Yearly or 500 hours Change oil...

  • Page 31: Service Schedule, 17/18 Kw Models

    3.1.2 Service Schedule, 17/18 kW Models Procedure Visually Inspect Section Check Change Clean Test System Component or Procedure Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before each use Change oil Yearly or 150 hours Replace filter...

  • Page 32: Lubrication System

    3.2 Lubrication System 3.2.3 Engine Oil Recommendation Use 5W-30 API (American Petroleum Institute) Service See the service schedules in Section 3.1 for oil change Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and oil filter replacement intervals. See the service and thickens less than other oils and leaves the engine views in Section 1.6 for the oil drain, oil check, oil fill, and intake valves and pistons cleaner.

  • Page 33: Oil Cooler, 17/18 Kw

    See Figure 3-3 for the oil cooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the Generator Set Oil Capacity, L (qt.) top mounting screw and loosen the two side screws, 8.5/12RES 1.9 (2.0) then lift off the cylinder shroud. 17/18RES 2.8 (3.0)

  • Page 34: Spark Plugs

    3.4 Air Cleaner Service Reset the spark plug gap or replace the plugs with new 3.4.1 Air Cleaner, 8.5/12RES plugs as necessary. The engine has a replaceable high-density paper air 1. Clean the area around the base of the spark plug to cleaner element with an oiled foam precleaner.

  • Page 35: Air Cleaner, 17/18Res

    2. Disconnect the power to the battery charger. Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary. 3. Disconnect the battery, negative (- ) lead first. 9. Reinstall the paper element, precleaner, element 4.

  • Page 36: Cooling System

    Keep dry field 7. When element replacement is necessary, order grass, foliage, and combustible landscaping material a genuine Kohler parts. minimum of 1.5 m (5 ft.) from the exhaust outlet. Periodically inspect the exhaust system components for cracks, leaks, and corrosion.

  • Page 37: Battery

    3.7 Battery Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance. WARNING All generator set models use a negative ground with a 12-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.

  • Page 38: Circuit Protection

    Controller 223316 Model Circuit Breaker Rating, Amp Battery charger — 223316 (RES) 8.5RES 12RES Figure 3-12 Fuses 12TRES 17/18RES 18TRES Figure 3-11 Line Circuit Breaker Rating Section 3 Scheduled Maintenance TP-6515 2/21...

  • Page 39: Storage Procedure

    3.10 Storage Procedure 3.10.3 Cylinder Lubrication 1. Remove the spark plugs. Perform the following storage procedure before removing the generator set from service for three 2. Pour one tablespoon of engine oil into each spark months or longer. Follow the engine manufacturer’s plug hole.
  • Page 40 Notes Section 3 Scheduled Maintenance TP-6515 2/21...

  • Page 41: Section 4 Troubleshooting

    Section 4 Troubleshooting 4.1 Introduction 4.2 Controller Troubleshooting Use the following charts to diagnose and correct Figure 4-1 contains troubleshooting, diagnostic, and common problems. First check for simple causes such repair information for the ADC-RES controller. as a dead engine starting battery, loose connections, or an open circuit breaker.
  • Page 42 Problem Possible Cause Corrective Action The generator set Fault shutdown Check for a fault code on the controller display. See does not crank. Section 2.7. Battery weak or dead Check power to the battery charger. Recharge or replace the battery. Battery charger fuse blown Replace the fuse.

  • Page 43: Battery Charger Troubleshooting

    4.4 Battery Charger Troubleshooting Use the battery charger’s LED indicators and the table in Figure 4-3 or Figure 4-4 to troubleshoot battery charger operation problems. Problem Cause Solution Red LED stays on One or more inoperative or damaged cells. Load test the battery and replace, if necessary for more than Battery charger has reduced its output Remove the source of the overload or short.
  • Page 44 Notes Section 4 Troubleshooting TP-6515 2/21...

  • Page 45: Appendix A Abbreviations

    (2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6515 2/21 Appendix 45...
  • Page 46 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
  • Page 47 Notes...
  • Page 48 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-6515 2/21g For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com 2007 Kohler Co. All rights reserved.

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