Kohler 15RES Manual
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Kohler 15RES Manual

Residential generator sets
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Operation
Residential Generator Sets
Models:
15RES
30RES
Controller:
Advanced Digital Control (ADC 2100)
TP-6344 4/09c

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Summary of Contents for Kohler 15RES

  • Page 1 Operation Residential Generator Sets Models: 15RES 30RES Controller: Advanced Digital Control (ADC 2100) TP-6344 4/09c...

  • Page 2: Product Identification Information

    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 identification numbers determine service parts. Controller Identification Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............Safety Precautions and Instructions .
  • Page 4 Notes TP-6344 4/09...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be Explosion. aware of potential dangers and act Can cause severe injury or death.
  • Page 6 metal surface away from the battery. To minimize the risk of fire or explosion. possibility carbon monoxide avoid sparks, do not disturb the battery Equip the compartment or nearby area poisoning. Seek medical attention if charger connections while the battery with a fully charged fire extinguisher.
  • Page 7 Propane (LP)—Adequate ventilation Hazardous Voltage/ Grounding electrical equipment. is mandatory. Because propane is Hazardous voltage cause Moving Parts heavier than air, install propane gas severe injury or death. Electrocution detectors low in a room. Inspect the is possible whenever electricity is DANGER detectors manufacturer’s...
  • Page 8 Connecting the battery and the Servicing the generator set when it WARNING battery charger. Hazardous voltage is operating. Exposed moving parts can cause severe injury or death. can cause severe injury or death. Reconnect battery correctly, Keep hands, feet, hair, clothing, and positive to positive and negative to test leads away from the belts and negative, to avoid electrical shock and...

  • Page 9: Introduction

    Information in this publication represents data available * One Parts Catalog combines generator and engine information. at the time of print. Kohler Co. reserves the right to change this publication and the products represented Figure 1 Generator Set Literature without notice and without any obligation or liability whatsoever.

  • Page 10: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.

  • Page 11: Section 1 Service Views

    Section 1 Service Views Service-Side View GM32850D-R Nonservice-Side View 1. Air cleaner 16. AC circuit breaker panel 2. Oil check 17. Fuses 3. Oil fill (on valve cover) 18. Generator set master switch 4. Fuel/air mixer 19. Advanced Digital Control, ADC 2100 5.
  • Page 12 Notes Section 1 Service Views TP-6344 4/09...

  • Page 13: Section 2 Operation

    Section 2 Operation 2.1 Operating Area 2.2 Prestart Checklist To ensure continued satisfactory operation perform the WARNING 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.

  • Page 14: Exercising Generator Set

    Keypad Select and The keypad is used for controller setup and adjustment only. Have setup and arrow buttons adjustments performed only by an authorized Kohler 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.

  • Page 15: Local Operation

    Note: Have an authorized Kohler distributor/dealer cools. However, the fault on the controller does not clear install and connect the ATS, remote start/stop until the operator resets the controller.
  • Page 16 15 seconds cranking and 15 seconds Check for loose connections. rest. Contact an authorized Kohler distributor/ The generator set also shuts down if no engine dealer for service if problem continues. rotation is sensed during cranking. Shuts down 1 second after the fault is detected.

  • Page 17: Resetting Controller After A Fault Shutdown

    2.4.5 Resetting Controller After a Fault 2.4.6 Controller Power Down Shutdown The ADC 2100 is powered by the generator set’s engine starting battery. Always identify and correct the cause of a fault shutdown before resetting the controller. Use the When the generator set master switch is in the AUTO following procedure to reset the generator set controller position, the controller may power down after a period of after a fault shutdown.
  • Page 18 Notes Section 2 Operation TP-6344 4/09...

  • Page 19: Section 3 Scheduled Maintenance

    Have an authorized battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote Kohler distributor/dealer perform generator set service. start/stop switch, or engine start command from a remote computer.

  • Page 20: Service Schedule

    Check and clean the interior of the enclosure. Clean collector ring and inspect brushes.* (1000 hr.) * Contact your local authorized Kohler distributor/dealer for service. [ Read WARNING found at the beginning of manual regarding moving parts. ] Consult battery manufacturer’s instructions.

  • Page 21: Maintenance And Service Parts

    Optional Oil Makeup/Low Level Shutdown Kit Obtain maintenance and service parts from an authorized Kohler distributor/dealer. See Section 4.3.2 On generator sets equipped with the optional oil for fuse part numbers. makeup/low level shutdown kit, check the oil level in the oil reservoir and at the sight gauge.

  • Page 22: Gaseous Fuel System

    2. Replace the oil filter. 3.5 Gaseous Fuel System a. Remove filter rotating The gaseous fuel system uses two solenoid valves to counterclockwise with an oil filter wrench. control the fuel flow to the fuel regulator. generator-mounted regulator reduces fuel pressure as b.

  • Page 23: Air Cleaner

    3. Housing Check the exhaust gas color. If the exhaust is blue or 4. Pressure tap (1/8-27 NPT) black, contact your local authorized Kohler distributor/ Figure 3-6 Air Cleaner dealer. 1. Release the spring clips to open the housing and Visually inspect for exhaust leaks (blowby).

  • Page 24: Cooling System

    Model Coolant Capacity, L (Qt.) overheating protection. A coolant solution with more than 50% ethylene glycol can cause engine 15RES 11.5 L (3.0 qt.) or component damage. Do not use alcohol or 30RES 11.5 L (3.0 qt.)

  • Page 25: Flushing And Cleaning

    5. Add coolant to the radiator to just below the 3.9 Battery overflow tube on the filler neck. See Section 1, Service Views, for the overflow tube location. Consult battery manufacturer’s instructions regarding battery care and maintenance. 6. Replace the radiator’s pressure cap. 7.

  • Page 26: Ignition System

    Battery short circuits. Explosion can cause severe injury 3. Disconnect the generator set engine starting or death. Short circuits can cause bodily injury and/or battery, negative (--) lead first. equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before 4.
  • Page 27 8. Clean spark plugs by wiping them with a rag. File 11. Reinstall the spark plug. Do not bump the the center electrode to keep it parallel to the side electrode against the cylinder head. Rotate the electrode. spark plug clockwise until you feel resistance. Note: Do not sandblast, wire brush, scrape, or 12.

  • Page 28: Belt Check

    3.11 Belt Check 3.12 Storage Procedure Check the belt tension at the intervals specified in the Follow the procedure below when storing your service schedule. If the tension is not within generator set for a long period (3 months or more). specification, adjust as necessary using the following 1.

  • Page 29: Section 4 Troubleshooting

    If the procedures in this manual do not explain how to Troubleshooting Chart, for conditions that may indicate correct the problem, contact an authorized Kohler a blown fuse. Obtain service from an authorized Kohler distributor/dealer. Maintain a record of repairs and distributor/dealer.

  • Page 30: Generator Set Troubleshooting

    Battery connections reversed or poor. Check the connections. crank. Controller fuse (F3) blown. Replace the fuse. Contact an authorized Kohler distributor/dealer for service if fuse blows repeatedly. Relay interface board fuse (F2) blown. Engine fuses F4 or F6 blown. Generator set master switch in the OFF Move the master switch to the RUN position.

  • Page 31: Controller Troubleshooting

    RUN position. Controller fuse (F3) is blown. Replace the fuse. See Figure 4-1. If the fuse blows again, contact an authorized Kohler distributor/ dealer. Low or no battery voltage. Check connections.
  • Page 32 Notes Section 4 Troubleshooting TP-6344 4/09...

  • Page 33: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
  • Page 34 Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute μF kilogram microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...
  • Page 36 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6344 4/09c 7 Jurong Pier Road Singapore 619159 E 2004, 2006, 2008, 2009 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

This manual is also suitable for:

30res

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