KOHLER 8.5RES Manuals

Manuals and User Guides for KOHLER 8.5RES. We have 7 KOHLER 8.5RES manuals available for free PDF download: Service Manual, Service, Operation And Installation Instructions Manual, Installation Manual, Operation And Installation, Operation Manual

Kohler 8.5RES Service Manual (132 pages)

Residential/Commercial Generator Sets

Brand: Kohler | Category: Portable Generator | Size: 8.7 MB

Table of Contents
3
Safety Precautions and Instructions
7
Hot Parts
10
Introduction
11
- List of Related Materials
  11
Service Assistance
12
Section 1 Specifications
13
- Introduction
  13
- Controller Specifications
  13
- Engine Features
  13
- Engine Specifications
  14
- Torque Specifications
  14
- Alternator Specifications
  15
- Service Views
  16
Section 2 Scheduled Maintenance
19
- Service Schedule
  19
- Lubrication System
  21
  - Low Oil Pressure Shutdown
    21
  - Oil Level Check
    21
  - Engine Oil Recommendation
    21
  - Oil Change Procedure
    21
  - Oil Cooler
    22
- Spark Plugs
  22
- Air Cleaner Element and Precleaner
  23
- Cooling System
  24
- Exhaust System
  24
- Battery
  24
  - Cleaning Battery
    25
  - Battery Charger
    25
- Storage Procedure
  26
  - Lubricating System
    26
  - Fuel System
    26
  - Internal Engine Components (Gas/Gasoline-Fueled Engines)
    26
  - Exterior
    26
  - Battery
    26
Section 3 Troubleshooting
27
- Introduction
  27
- Initial Checks
  27
- Troubleshooting Chart
  27
- Controller Troubleshooting
  33
Section 4 ADC 2100 and DC 2200 Controllers
35
- Introduction
  35
- Controller Display and Keypad
  36
- Sequence of Operation
  37
- Faults
  37
  - Warnings
    37
  - Shutdowns
    37
- ADC 2100 Controller Configuration and Adjustment
  40
- Continuous Power Mode Jumper
  46
- Master Switch
  48
- Relay Interface Board (RIB)
  48
- Controller Replacement
  49
Section 5 ADC-RES and DC-RET Controller
53
- Introduction
  53
- Controls and Display
  54
  - Master Switch
    54
  - LED Display
    54
  - Keypad
    55
- Sequence of Operation
  56
- Faults
  57
  - Warnings
    57
  - Shutdowns
    57
- Controller Configuration and Adjustment, ADC-RES
  59
- Voltage and Frequency Adjustments
  62
  - Voltage Adjustment
    62
  - Frequency Adjustment
    63
- Controller Relays
  66
- Optional Relay Board
  67
  - Relay Board Troubleshooting
    67
  - Relay Board Replacement Procedure
    69
- Controller Replacement
  70
Section 6 Component Testing and Adjustment
73
- Theory of Operation
  73
- Separate Excitation
  73
- Stator
  74
- Main Field (Rotor)
  77
- Slip Rings
  78
- Brushes
  78
- Voltage
  79
- Silicon Controlled Rectifier Module
  82
- Electromechanical Governor System
  84
  - Hunting/Surging
    85
    
    Governor System/Magnetic Pickup Operation Test
    85
    
    Frequency Adjustment
    88
- Mechanical Governor
  89
- Fault Shutdown Tests
  91
  - Controller Fault Shutdown Functions
    91
  - Fault Shutdown Switches
    92
- Fuel Systems
  93
  - Gas Piping
    93
  - Fuel Solenoid Valve
    93
  - Fuel Regulators
    93
  - Fuel Conversion
    94
  - Digital Spark Advance Ignition
    96
  - Fuel Metering Valve Adjustment
    96
- Starter Relay
  98
- Continuity Checks
  98
- Fuses
  98
- Disassembly
  101
Section 7 Disassembly/Reassembly
101
- Reassembly
  105
Section 8 Wiring Diagrams
109
Appendix A Abbreviations
123
Appendix B Common Hardware Application Guidelines
125
Appendix C General Torque Specifications
126
Appendix D Common Hardware Identification
127
Appendix E Common Hardware List
128

Kohler 8.5RES Service (132 pages)

Brand: Kohler | Category: Portable Generator | Size: 9 MB

Table of Contents
3
Safety Precautions and Instructions
7
Fuel System
8
Hot Parts
10
Introduction
11
- List of Related Materials
  11
Service Assistance
12
Section 1 Specifications
13
- Introduction
  13
- Controller Specifications
  13
- Engine Features
  13
- Engine Specifications
  14
- Torque Specifications
  14
- Alternator Specifications
  15
- Service Views
  16
Section 2 Scheduled Maintenance
19
- Service Schedule
  19
- Lubrication System
  21
  - Low Oil Pressure Shutdown
    21
  - Oil Level Check
    21
  - Engine Oil Recommendation
    21
  - Oil Change Procedure
    21
  - Oil Cooler
    22
- Spark Plugs
  22
- Air Cleaner Element and Precleaner
  23
- Cooling System
  24
- Exhaust System
  24
- Battery
  24
  - Cleaning Battery
    25
  - Battery Charger
    25
- Storage Procedure
  26
  - Lubricating System
    26
  - Fuel System
    26
  - Internal Engine Components (Gas/Gasoline-Fueled Engines)
    26
  - Exterior
    26
  - Battery
    26
Section 3 Troubleshooting
27
- Introduction
  27
- Initial Checks
  27
- Troubleshooting Chart
  27
- Controller Troubleshooting
  33
Section 4 ADC 2100 and DC 2200 Controllers
35
- Introduction
  35
- Controller Display and Keypad
  36
- Sequence of Operation
  37
- Faults
  37
  - Warnings
    37
  - Shutdowns
    37
- ADC 2100 Controller Configuration and Adjustment
  40
- Continuous Power Mode Jumper
  46
- Master Switch
  48
- Relay Interface Board (RIB)
  48
- Controller Replacement
  49
Section 5 ADC-RES and DC-RET Controller
53
- Introduction
  53
- Controls and Display
  54
  - Master Switch
    54
  - LED Display
    54
  - Keypad
    55
- Sequence of Operation
  56
- Faults
  57
  - Warnings
    57
  - Shutdowns
    57
- Controller Configuration and Adjustment, ADC-RES
  59
- Voltage and Frequency Adjustments
  62
  - Voltage Adjustment
    62
  - Frequency Adjustment
    63
- Controller Relays
  66
- Optional Relay Board
  67
  - Relay Board Troubleshooting
    67
  - Relay Board Replacement Procedure
    69
- Controller Replacement
  70
Section 6 Component Testing and Adjustment
73
- Theory of Operation
  73
- Separate Excitation
  73
- Stator
  74
- Main Field (Rotor)
  77
- Slip Rings
  78
- Brushes
  78
- Voltage
  79
- Silicon Controlled Rectifier Module
  82
- Electromechanical Governor System
  84
  - Governor System/Magnetic Pickup Operation Test
    85
  - Hunting/Surging
    85
  - Frequency Adjustment
    88
  - Controller Fault Shutdown Functions
    91
  - Fault Shutdown Switches
    92
  - Gas Piping
    93
  - Fuel Conversion
    94
  - Digital Spark Advance Ignition
    95
  - Fuel Metering Valve Adjustment
    96
  - Digital Spark Advance Ignition
    96
- Fuses
  98
- Disassembly
  101
Appendix A Abbreviations
123
Appendix B Common Hardware Application Guidelines
125
Appendix C General Torque Specifications
126
Appendix D Common Hardware Identification
127
Appendix E Common Hardware List
128

Kohler 8.5RES Service Manual (96 pages)

Residential/Commercial Generator Sets

Brand: Kohler | Category: Controller | Size: 6.56 MB

Table of Contents
3
Introduction
9
- List of Related Materials
  9
Service Assistance
10
Section 1 Specifications
11
- Introduction
  11
- Generator Set Ratings
  11
- Controller Specifications
  11
- Engine Features
  11
- Engine Specifications
  12
- Alternator Specifications
  13
- Torque Specifications
  13
- Service View
  14
Section 2 Scheduled Maintenance
15
- Service Schedule
  15
- Lubrication System
  17
  - Low Oil Pressure Shutdown
    17
  - Oil Level Check
    17
  - Engine Oil Recommendation
    17
  - Oil Change Procedure
    18
- Spark Plugs
  19
- Air Cleaner Element and Precleaner
  19
- Cooling System
  21
- Exhaust System
  21
- Battery
  21
  - Cleaning the Battery
    22
  - Battery Charger
    22
- Storage Procedure
  22
  - Lubricating System
    22
  - Fuel System
    22
  - Internal Engine Components (Gas/Gasoline-Fueled Engines)
    23
  - Exterior
    23
  - Battery
    23
Section 3 Troubleshooting
25
- Introduction
  25
- Inital Checks
  25
- Troubleshooting Chart
  25
Section 4 Controller
31
- Introduction
  31
- Controller Display and Keypad
  32
- Sequence of Operation
  33
- Faults
  34
  - Warnings
    34
  - Shutdowns
    34
- Controller Configuration and Adjustment
  36
- Continuous Power Mode Jumper
  42
- Master Switch
  43
- Relay Interface Board (RIB)
  44
- Silicon Controlled Rectifier (SCR) Module
  45
- Controller Replacement
  46
Section 5 Component Testing and Adjustment
49
- Theory of Operation, 1-Phase Generator Sets
  49
- Separate Excitation
  49
- Stator
  51
- Main Field (Rotor)
  52
  - Rotor Continuity and Resistance Tests
    52
- Slip Rings
  54
- Brushes
  54
- Voltage
  55
  - Voltage Regulation
    55
  - Voltage Adjustment
    55
  - Voltage Connections
    56
- Governor System
  57
  - Operation
    57
  - Initial Checks and Operation Test
    57
  - Hunting/Surging
    57
  - Governor System/Magnetic Pickup Operation Test
    58
  - Frequency Adjustment
    60
- Fault Shutdown Tests
  61
  - Controller Fault Shutdown Functions
    62
  - Fault Shutdown Switches
    63
- Fuel Systems
  64
  - Gas Piping
    64
  - Fuel Solenoid Valve
    64
  - Fuel Regulators
    64
  - Fuel Conversion
    65
  - Digital Spark Advance Module (DSAM)
    67
  - Fuel Metering Valve Adjustment
    67
- Fuses
  69
- Continuity Checks
  69
Section 6 Disassembly/Reassembly
71
- Disassembly
  71
- Reassembly
  75
Section 7 Wiring Diagrams
81
- Specification Numbers
  81
- Controller Wiring Diagram Reference
  81
Appendix A Abbreviations
85
Appendix B Common Hardware Application Guidelines
87
Appendix C General Torque Specifications
88
Appendix D Common Hardware Identification
89
Appendix E Common Hardware List
90

KOHLER 8.5RES Operation And Installation Instructions Manual (56 pages)

Residential/Commercial Generator Sets, Controller: Advanced Digital Control

Brand: KOHLER | Category: Inverter | Size: 2.96 MB

Product Identification
2
- Information
  2
- Table of Contents
  3
Safety Precautions and Instructions
5
Introduction
11
Service Assistance
12
Section I Specifications and Features
13
- Specifications
  13
- Generator
  13
- Engine
  13
- Advanced Digital Control
  13
- Service Views
  14
Section 2 Operation
15
- Prestart Checklist
  15
- Exercising the Generator Set
  15
- Generator Set Operation
  15
  - Controls and Indicators
    16
  - Starting the Generator Set
    16
  - Stopping the Generator Set
    16
  - Fault Shutdowns
    17
  - ADC Fault Shutdown Codes
    17
  - Resetting the Controller after a Fault Shutdown
    18
  - Continuous Power Mode
    18
- Circuit Protection
  19
  - Line Circuit Breaker
    19
  - Fuses
    19
- Battery Charger
  19
  - Battery Charger Operation
    20
Section 3 Scheduled
21
- Maintenance
  21
- Routine Maintenance
  21
- Service Schedule
  21
- Lubrication System
  23
  - Low Oil Pressure Shutdown
    23
  - Oil Check
    23
  - Engine Oil Recommendation
    23
  - Oil Change Procedure
    23
- Spark Plugs
  24
- Air Cleaner Element and Precleaner
  24
  - Precleaner Service
    24
  - Paper Element Service
    24
- Cooling System
  25
- Exhaust System
  26
- Battery
  26
- Battery Charger
  29
- 3.10 Storage Procedure
  29
  - Lubricating System
    29
  - Fuel System
    29
  - Cylinder Lubrication
    29
  - Exterior Preparation
    29
  - Battery
    30
Section 4 Troubleshooting
31
- Introduction
  31
- Generator Set Troubleshooting
  31
- Fault Codes
  32
- Controller Troubleshooting
  32
- Battery Charger Troubleshooting
  32
Section 5 Wiring Diagrams
33
- Specification Numbers
  33
- Controller Wiring Diagram Reference
  33
Section 6 Installation
37
- General
  37
- Weight
  37
- Generator Set Inspection
  37
- Mounting
  37
- Exhaust Requirements
  37
- Air Requirements
  39
- Power Supply
  39
- Fuel System
  39
  - Fuel Supply
    39
  - Fuel Pipe Size
    40
  - Fuel Conversion
    40
- Electrical Connections
  43
  - AC Load Lead Connections
    43
  - Remote Start Connection (Optional)
    44
  - Continuous Power Mode Jumper
    44
  - Battery
    45
  - Battery Charger
    46
- 6.10 Accessories
  47
  - Common Fault and Run Relay Board
    47
  - Carburetor Heater
    48
- Controller Configuration
  49
  - System Configuration
    49
  - Advanced Configuration Mode
    49
- Prestart Installation Check
  49
- Warranty Registration
  49
Appendix A Abbreviations
51

Kohler 8.5RES Operation And Installation (56 pages)

Residential/Commercial Generator Sets

Brand: Kohler | Category: Portable Generator | Size: 3.01 MB

Product Identification Information
2
Table of Contents
3
Safety Precautions and Instructions
5
Hot Parts
8
Introduction
11
Service Assistance
12
Section 1 Specifications and Features
13
- Specifications
  13
- Generator
  13
- Engine
  13
- Advanced Digital Control
  13
- Service Views
  14
Section 2 Operation
15
- Prestart Checklist
  15
- Exercising the Generator Set
  15
- Generator Set Operation
  15
  - Controls and Indicators
    16
  - Starting the Generator Set
    16
  - Stopping the Generator Set
    16
  - Fault Shutdowns
    17
  - Resetting the Controller after a Fault Shutdown
    18
  - Continuous Power Mode
    18
- Circuit Protection
  19
  - Line Circuit Breaker
    19
  - Fuses
    19
- Battery Charger
  19
  - Battery Charger Operation
    20
Section 3 Scheduled Maintenance
21
- Routine Maintenance
  21
- Service Schedule
  21
- Lubrication System
  23
  - Low Oil Pressure Shutdown
    23
  - Oil Check
    23
  - Engine Oil Recommendation
    23
  - Oil Change Procedure
    23
- Spark Plugs
  24
- Air Cleaner Element and Precleaner
  24
  - Precleaner Service
    24
  - Paper Element Service
    24
- Cooling System
  25
- Exhaust System
  26
- Battery
  26
- Battery Charger
  29
- Storage Procedure
  29
  - Lubricating System
    29
  - Fuel System
    29
  - Cylinder Lubrication
    29
  - Exterior Preparation
    29
  - Battery
    30
Section 4 Troubleshooting
31
- Introduction
  31
- Generator Set Troubleshooting
  31
- Fault Codes
  32
- Controller Troubleshooting
  32
- Battery Charger Troubleshooting
  32
Section 5 Wiring Diagrams
33
- Specification Numbers
  33
- Controller Wiring Diagram Reference
  33
Section 6 Installation
37
- General
  37
- Weight
  37
- Generator Set Inspection
  37
- Mounting
  37
- Exhaust Requirements
  37
- Air Requirements
  39
- Power Supply
  39
- Fuel System
  39
  - Fuel Supply
    39
  - Fuel Pipe Size
    40
  - Fuel Conversion
    40
- Electrical Connections
  43
  - AC Load Lead Connections
    43
  - Remote Start Connection (Optional)
    44
  - Continuous Power Mode Jumper
    44
  - Battery
    45
  - Battery Charger
    46
- Accessories
  47
  - Common Fault and Run Relay Board
    47
  - Carburetor Heater
    48
- Controller Configuration
  49
  - System Configuration
    49
  - Advanced Configuration Mode
    49
- Prestart Installation Check
  49
- Warranty Registration
  49
Appendix A Abbreviations
51

Kohler 8.5RES Operation Manual (36 pages)

Advanced Digital Control ADC-RES

Brand: Kohler | Category: Inverter | Size: 1.62 MB

Product Identification Information
2
Table of Contents
3
Safety Precautions and Instructions
5
Emission Compliance
9
Introduction
9
Service Assistance
10
Section 1 Features
11
- Specifications
  11
- Generator
  11
- Engine
  11
- Advanced Digital Control
  11
- Generator Set Components
  12
Section 2 Operation
13
- Prestart Checklist
  13
- Exercising Generator Set
  13
- ADC-RES Controls and Indicators
  13
  - LED Display
    13
  - Controller Keypad
    14
  - Generator Set Master Switch
    14
- Controller Power
  15
  - Standby Mode
    15
  - Sleep Mode
    15
- Generator Set Operation
  15
  - Starting Generator Set
    15
  - Stopping Generator Set
    15
- Faults
  16
  - Shutdowns
    16
  - Warnings
    16
  - Resetting Controller after a Fault Shutdown
    16
- Battery Charger
  18
  - Battery Charger Operation
    18
Section 3 Scheduled Maintenance
19
- Routine Maintenance
  19
- Service Schedule
  20
- Lubrication System
  21
  - Low Oil Pressure Shutdown
    21
  - Oil Check
    21
  - Engine Oil Recommendation
    21
  - Oil Change Procedure
    21
  - Oil Cooler
    22
- Spark Plugs
  22
- Air Cleaner Service
  23
- Cooling System
  23
- Exhaust System
  24
- Battery
  24
- Battery Charger
  25
- Circuit Protection
  25
  - Line Circuit Breaker
    25
  - Fuses
    25
- Storage Procedure
  26
  - Lubricating System
    26
  - Fuel System
    26
  - Cylinder Lubrication
    26
  - Exterior Preparation
    26
  - Battery
    26
Section 4 Troubleshooting
27
- Introduction
  27
- Controller Troubleshooting
  27
- Generator Set Troubleshooting
  28
- Battery Charger Troubleshooting
  29
Appendix A Abbreviations
31

Kohler 8.5RES Installation Manual (56 pages)

Residential/Commercial Generator Sets

Brand: Kohler | Category: Portable Generator | Size: 6.9 MB

Product Identification Information
2
Table of Contents
3
Safety Precautions and Instructions
5
- Exhaust System
  6
- Hot Parts
  8
Introduction
9
Service Assistance
12
Section 1 Installation
13
- General
  13
- Lifting
  13
- Generator Set Inspection
  13
- Location and Mounting
  13
  - Exhaust Requirements
    21
  - Air Requirements
    21
- Power Supply
  22
- Fuel Requirements
  22
  - Fuel Supply
    22
  - Fuel Pipe Size
    24
- Fuel Conversion
  24
  - Fuel Conversion, 8.5/12 Kw
    25
  - Fuel Conversion, 17/18 Kw
    26
- Electrical Connections
  28
  - AC Connections
    28
  - Remote Start Connection
    30
  - Grounding
    30
  - Battery Charger
    30
- Battery
  31
- Accessories
  32
  - Common Fault and Auxiliary Run Relay Board
    32
  - Carburetor Heater
    33
- Prestart Installation Check
  35
- Startup Notification
  35
- Controller Configuration
  35
  - System Parameters
    35
  - Application Code Version
    36
- Voltage and Frequency Adjustments
  38
  - Voltage Adjustment
    38
  - Frequency Adjustment
    39
Section 2 Wiring Diagrams
43
Appendix A Abbreviations
53

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