Kohler 8.5RES Operation And Installation
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Kohler 8.5RES Operation And Installation

Residential/commercial generator sets
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See also: Service Manual , Service
Operation and
Installation
Residential/Commercial Generator Sets
Models:
8.5RES
12RES
Controller:
Advanced Digital Control
TP-6195 1/04

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Summary of Contents for Kohler 8.5RES

  • Page 1 Operation and Installation Residential/Commercial Generator Sets Models: 8.5RES 12RES Controller: Advanced Digital Control TP-6195 1/04...

  • 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 ..........Inside front cover Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued Section 4 Troubleshooting ..............Introduction .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting WARNING INSTRUCTIONS. Electromechanical equipment, including generator sets, WARNING transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or Explosion. maintained. To prevent accidents be Can cause severe injury or death.
  • Page 6 Battery gases. Explosion can cause Engine Backfire/Flash Exhaust System severe injury or death. Battery gases Fire can cause an explosion. Do not smoke WARNING or permit flames or sparks to occur near WARNING a battery at any time, particularly when it is charging.
  • Page 7 Fuel System Hazardous Noise WARNING CAUTION WARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. Hazardous noise. Explosive fuel vapors. Can cause hearing loss. Can cause severe injury or death. If the generator set is used for Never operate the generator set standby power, install an automatic Use extreme care when handling,...

  • Page 8: Hot Parts

    Welding on the generator set. Can Heavy Equipment Moving Parts cause severe electrical equipment damage. Before welding on the WARNING WARNING generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module (ECM) connectors.
  • Page 9 Servicing the generator set when it NOTICE is operating. Exposed moving parts Electrostatic discharge damage. can cause severe injury or death. Electrostatic discharge (ESD) Keep hands, feet, hair, clothing, and damages electronic circuit boards. test leads away from the belts and Prevent electrostatic discharge...
  • Page 10 Notes Safety Precautions and Instructions TP-6195 1/04...

  • Page 11: Introduction

    The manufacturer may provide this 8.5RES and 12RES generator sets with multi-fuel manual for models not listed on the front cover. Kohler systems are emission-certified. Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

  • Page 12: Service Assistance

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPowerSystems.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 13: Section 1 Specifications And Features

    LED display: distributor/dealer. Runtime hours 1.2 Generator Crank cycle status Diagnostics The generator uses Kohler’s unique PowerBoostt LED display communicates faults: voltage regulation system, which provides instant Auxiliary fault response to load changes. High battery voltage PowerBoostt ensures reliable motor starting and High engine temperature consistent voltage levels.

  • Page 14: Service Views

    1.5 Service Views ADV-6823-A 1. Enclosure 13. Oil drain valve 2. Muffler 14. Oil filter 3. Oil check 15. Alternator cooling air intake 4. Oil fill 16. Exhaust 5. Air cleaner 17. Spark arrestor 6. Spark plug locations (both sides) 18.

  • Page 15: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist 2.2 Exercising the Generator Set To ensure continued satisfactory operation, perform the Operate the generator set under load once each week following checks or inspections before or at each for one hour. If the generator set does not have a startup, as designated, and at the intervals specified in programmed exercise mode or an automatic transfer the service schedule.

  • Page 16: Controls And Indicators

    2.3.1 Controls and Indicators start/stop switch. (A remote start/stop switch can be connected to controller leads 3 and 4. See the wiring Figure 2-2 describes the controls and indicators located diagrams in Section 5). on the generator set controller. 2.3.3 Stopping the Generator Set The LED display indicates generator set status as shown in Figure 2-2.

  • Page 17: Fault Shutdowns

    2.3.4 Fault Shutdowns The shutdown switches on the generator set automatically reset when the problem is corrected. The The generator set shuts down automatically under the high engine temperature switch automatically resets fault conditions listed in Figure 2-3 and the controller when the generator set cools.

  • Page 18: Resetting The Controller After A Fault Shutdown

    2.3.5 Resetting the Controller after a 7. Move the generator set master switch to the AUTO position for startup by remote transfer switch or Fault Shutdown remote start/stop switch. Always identify and correct the cause of a fault Note: The controller’s LED display remains off shutdown before resetting the controller.

  • Page 19: Circuit Protection

    2608KH Allowable Battery Types: Lead Acid a nd Gel Cell Circuit Breaker Model Rating, Amps 8.5RES 12RES Figure 2-5 Line Circuit Breakers 2.4.2 Fuses The engine harness contains two 10-amp and one 20-amp inline fuses. See Figure 2-6. Another 10-amp fuse protects the battery charger.

  • Page 20: Battery Charger Operation

    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 Figure 2-9 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...

  • Page 21: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance WARNING WARNING Hazardous voltage. Moving rotor. Accidental starting. Can 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 on the generator set.
  • Page 22 Procedure Visually Check Change Clean Test Inspect System Component or Procedure Frequency Section Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level 8 hours or before use Crankcase breather* Yearly or 500 hours Change oil Yearly or 100 hours Replace filter*...

  • Page 23: Lubrication System

    3.3 Lubrication System 3.3.4 Oil Change Procedure Drain the oil while it is still warm. See Section 3.2, Service Schedule, for oil change and oil filter replacement intervals. See Section 1.5, Service 1. Drain the oil. Views, for the oil drain, oil check, oil fill, and oil filter locations.

  • Page 24: Spark Plugs

    d. Reconnect the generator set engine starting 3.5 Air Cleaner Element and battery, negative (--) lead last. Precleaner e. Reconnect the power to the battery charger. The engine has a replaceable high-density paper air f. Start and run the generator set for a minute to cleaner element with an oiled foam precleaner.

  • Page 25: Cooling System

    1. Place the generator set master switch in the Note: Do not block the generator set cooling air inlets or OFF/RESET position. mount other equipment above them. Overheating and severe generator damage may 2. Disconnect the power to the battery charger. occur.

  • Page 26: Exhaust System

    3.7 Exhaust System 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 Remove all combustible materials from the exhaust flush the affected area for 15 minutes with large quantities of location.

  • Page 27: Cleaning The Battery

    Refer to this section for general battery information and from the battery and scrub the terminals with a wire maintenance. All generator set models use a negative brush. Clean the battery and cables with a solution of ground with a12-volt engine electrical system. Consult baking soda and water.

  • Page 28: Checking Electrolyte Specific Gravity

    3.8.3 Checking Electrolyte Specific ° ° Correction Gravity 71.1 + .032 + .030 Use a battery hydrometer to check the specific gravity of 65.6 + .028 Example 1: the electrolyte in each battery cell. Use the + .026 ° ° hydrometer’s test instructions, if available, or Figure 3-9 Temperature below 26.7 C (80...

  • Page 29: Battery Charger

    3.9 Battery Charger 2. Stop the generator set. 3. While the engine is still warm, drain the engine The generator set is equipped with a 6-amp lubrication oil from the engine crankcase. float/equalize battery charger to maintain the engine starting battery. The charger’s DC leads are 4.

  • Page 30: Battery

    3.10.5 Battery 3. Clean the battery. Refer to Section 3.8.1 for the cleaning procedure. Perform battery storage last. 4. Place the battery in a warm, dry location. 1. Place the generator set master switch in the 5. Connect the battery to a float/equalize battery OFF/RESET position.

  • Page 31: Section 4 Troubleshooting

    Section 4 Troubleshooting 4.1 Introduction 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 Use the following charts to diagnose and correct to the equipment. common problems.

  • Page 32: Fault Codes

    4.3 Fault Codes 4.5 Battery Charger Troubleshooting The Advanced Digital Control displays fault codes to aid in troubleshooting. Fault codes, descriptions, and Use the battery charger’s LED indicators and the table in recommended actions are listed in Figure 2-3. Figure 4-3 to troubleshoot battery charger operation problems.

  • Page 33: Section 5 Wiring Diagrams

    Page substitute for a manual under development. Schematic Diagram Sheet 1 ADV-6835A Model No. Spec. No. Sheet 2 ADV-6835B 8.5RES GM29253-GA1 Point-to-Point Wiring Diagram GM29358 12RES GM29253-GA2 Figure 5-2 Controller Wiring Diagrams Figure 5-1 Generator Set Specification Numbers TP-6195 1/04...
  • Page 34 Figure 5-3 8.5/12RES Schematic Diagram, Single Phase, Sheet 1, ADV-6835A-A Section 5 Diagrams and Drawings TP-6195 1/04...
  • Page 35 Figure 5-4 8.5/12RES Schematic Diagram, Single Phase, Sheet 2, ADV-6835B TP-6195 1/04 Section 5 Diagrams and Drawings...
  • Page 36 Figure 5-5 8.5/12RES Point-to-Point Wiring Diagram, Single Phase, GM29358-B Section 5 Diagrams and Drawings TP-6195 1/04...

  • Page 37: Section 6 Installation

    Section 6 Installation 6.1 General 6.4 Mounting Have an authorized distributor/dealer install the Install the generator set outdoors. Maintain a minimum generator set outdoors according to the instructions in clearance of 0.9 m (3 ft.) from any building as shown in this section.
  • Page 38 Figure 6-1 Generator Set Mounting Details and Dimensions, ADV-6823-B Section 6 Installation TP-6195 1/04...

  • Page 39: Air Requirements

    Exhaust System 60 Hz 50 Hz (standard) and carburetor heater (optional). Figure 6-5 Exhaust flow at rated kW, m /min. (cfm) lists the battery charger power requirements. 8.5RES 3.3 (115) 2.7 (96) Input Requirement 12RES 3.8 (135) 3.2 (113)

  • Page 40: Fuel Pipe Size

    1000 Natural gas size before proceeding. 2500 LP vapor Figure 6-6 Fuel Supply Contact the local LP provider for LP installation information. Fuel 8.5RES 12RES Consumption Consumption, Maximum Pipe Length m (ft.) 60 Hz 50 Hz 60 Hz 50 Hz /hr.
  • Page 41 WARNING 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. A trained technician or authorized distributor/dealer can convert the fuel system.
  • Page 42 7. Remove the plug from the LP port in the fuel block. 17. Move the generator set master switch to the AUTO See Figure 6-11. Clean the plug with a dry cloth or position. brush, apply fresh pipe sealant, and install the plug To convert from LP vapor to natural gas, follow the same into the natural gas outlet port.

  • Page 43: Electrical Connections

    6.9 Electrical Connections See Figure 6-13 and Section 5, Wiring Diagrams, for the generator set electrical connections. Make the following AC connections: 6.9.1 AC Load Lead Connections 1. Connect the output leads going to the transfer WARNING switch (L1/L2 black leads) to the AC circuit breaker load side.

  • Page 44: Remote Start Connection (Optional)

    6.9.2 Remote Start Connection 4. Locate the P7 connector near the top of the controller. See Figure 6-14. Remove the jumper (optional) from pins 1 and 2 of the P7 connector. If the P7 connector has three pins, connect the jumper Connect leads 3 and 4 from the ADC 2100 controller to across pins 2 and 3 for storage.

  • Page 45: Battery

    6.9.4 Battery 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 WARNING soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution.

  • Page 46: Battery Charger

    Use a 12-volt battery with a minimum rating of 675 cold 6. Connect the positive (+) lead to the engine starting battery. cranking amps at 0_F. The generator set uses a negative ground with a 12-volt engine electrical system. 7. Connect the negative (--) lead to the engine starting See Figure 6-15 for battery connections.

  • Page 47: Accessories

    6.10 Accessories Have accessories installed authorized distributor/dealer or a licensed electrician. Follow the installation instructions provided with each kit. 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.

  • Page 48: Carburetor Heater

    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).

  • Page 49: Controller Configuration

    The unit configuration and engine type are factory-set Return the form to the distributor/dealer or mail it directly for each type of generator set and engine, and should not be changed in the field. Kohler Power Systems Generator Warranty Administrator 6.11.2 Advanced Configuration Mode M.S. 072 Kohler, Wisconsin 53044 The controller’s advanced configuration mode allows a...
  • Page 50 Notes Section 6 Installation TP-6195 1/04...

  • Page 51: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per hour est. estimated ABDC after bottom dead center cubic feet per minute E-Stop emergency stop alternating current center of gravity etc.
  • Page 52 International Organization for military standard round head Standardization m/sec. meters per second round head machine (screw) joule MTBF mean time between failure rly. relay Japanese Industry Standard MTBO mean time between overhauls root mean square kilo (1000) mtg. mounting rnd. round kelvin megawatt...
  • Page 56 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 TP-6195 1/04 7 Jurong Pier Road Singapore 619159 E 2004 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

This manual is also suitable for:

12res

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