Kohler 12RESM1 Manual
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Kohler 12RESM1 Manual

Residential/commercial generator sets
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Operation
Residential/Commercial Generator Sets
Models:
12RESM1
12RESL
Controller:
DC 2200 Digital Control
TP-6398 4/07b

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Summary of Contents for Kohler 12RESM1

  • Page 1 Operation Residential/Commercial Generator Sets Models: 12RESM1 12RESL Controller: DC 2200 Digital Control TP-6398 4/07b...

  • 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 Table of Contents, continued Section 4 Troubleshooting ..............Introduction .

  • 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 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 The fuel system. Explosive fuel Hazardous Voltage/ Grounding electrical equipment. vapors can cause severe injury or Hazardous voltage cause Moving Parts death. Vaporized fuels are highly severe injury or death. Electrocution explosive. Use extreme care when is possible whenever electricity is handling and storing fuels.
  • Page 8 Electrical backfeed to the utility. Hot Parts Notice Hazardous backfeed voltage can cause severe injury or death. Install NOTICE WARNING a transfer switch in standby power installations to prevent the connection of standby and other sources of power. This generator set has been Electrical backfeed into...

  • Page 9: Introduction

    Refer to TP-6397, Installation Manual, for installation instructions. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented 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 Features

    LED display: 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 High engine temperature response to load changes. Low battery voltage PowerBoostt ensures reliable motor starting and Low oil pressure consistent voltage levels.

  • Page 12: Generator Set Components

    1.5 Generator Set Components ADV-7023-A 1. Enclosure 16. Oil drain valve 2. Silencer 17. Oil filter 3. Oil check 18. Alternator cooling air intake 4. Oil fill 19. Exhaust outlet 5. Air cleaner 20. Spark arrestor 6. Spark plug locations (both sides) 21.

  • Page 13: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist 2.2 Generator Set Operation To ensure continued satisfactory operation, perform the 2.2.1 Controls and Indicators following checks or inspections before or at each startup, as designated, and at the intervals specified in Figure 2-1 illustrates the front panel of the Digital the service schedule.

  • Page 14: Starting Generator Set

    2.2.2 Starting Generator Set Automatic Stopping With the generator set master switch in the AUTO The following procedures describe the actions required position and an (ATS) or other automatic device to start the generator set. connected to controller leads 3 and 4: The controller attempts to start the generator set three 1.

  • Page 15: Faults

    2.4 Faults The shutdown switches on the generator set automatically reset when the problem is corrected. The high engine temperature switch automatically resets The DC 2200 controller displays the fault warning and when the generator set cools. However, the fault does shutdown codes shown in Figure 2-3.

  • Page 16: Resetting Controller After Fault Shutdown

    2.4.3 Resetting Controller After Fault 2.5 Battery Charger Shutdown The generator set is equipped with a 6-amp Always identify and correct the cause of a fault float/equalize battery charger to maintain the engine shutdown before resetting the controller. Use the starting battery.
  • Page 17 Figure 2-5 illustrates the three-stage charging method. Red and green LEDs indicate charger operation. The chart in Figure 2-6 describes the LED indicator operation during each stage of the charging process. Figure 2-5 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 BULK rate Green OFF (stage 1).
  • Page 18 Notes Section 2 Operation TP-6398 4/07...

  • Page 19: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance Servicing the exhaust system. Hot parts can cause WARNING severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the...

  • Page 20: Service Schedule

    3.2 Service Schedule 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 use Crankcase breather hose Yearly or 500 hours Change oil Yearly or 100 hours...

  • Page 21: 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 22: 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 23: Paper Element Service

    3. Disconnect the battery, negative (--) lead first. 9. Reinstall the paper element, precleaner, element cover, element cover nut, and the air cleaner cover. 4. Loosen the cover retaining knob and remove the Secure the cover with the cover retaining knob. cover.

  • Page 24: Battery

    Check for loose, corroded, or missing clamps and Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or hangers. Tighten or replace clamps and/or hangers equipment damage. Disconnect the battery before generator as needed. set installation or maintenance.

  • Page 25: Battery Charger

    3.9 Battery Charger Model Circuit Breaker Rating, Amps 12RESM1/RESL The generator set is equipped with a 6-amp Figure 3-8 Line Circuit Breakers float/equalize battery charger to maintain the engine starting battery. The charger’s DC leads are factory- wired. Figure 3-7 illustrates the battery charger.

  • Page 26: Fuel System

    4. Refill the engine crankcase with oil. See Section 3.11.4 Exterior Preparation 3.3.3 for oil recommendations. 1. Clean the exterior surface of the generator set. 5. Run the generator set for a few minutes to distribute the clean oil. 2. Seal all openings in the engine with nonabsorbent adhesive tape.

  • Page 27: Section 4 Troubleshooting

    Section 4 Troubleshooting 4.1 Introduction 4.2 Fault Codes Use the following charts to diagnose and correct The Digital Control displays fault codes to aid in common problems. First check for simple causes such troubleshooting. Fault codes, descriptions, and as a dead engine starting battery, loose connections, or recommended actions are listed in Figure 2-3.

  • Page 28: Generator Set Troubleshooting

    4.3 Generator Set Troubleshooting Figure 4-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Battery weak or dead Check power to the battery charger. The generator set Recharge or replace the battery. does not crank.

  • Page 29: Battery Charger Troubleshooting

    4.4 Battery Charger Troubleshooting Use the battery charger’s LED indicators and the table in Figure 4-2 to troubleshoot battery charger operation problems. Problem Cause Solution Red LED stays on for One or more defective or damaged cells. Load test the battery and replace, if necessary more than 24 hours.
  • Page 30 Notes Section 4 Troubleshooting TP-6398 4/07...

  • Page 31: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per hour engineering special, engineered special ABDC after bottom dead center cubic feet per minute electrostatic discharge alternating current center of gravity est.
  • Page 32 (2 bytes) μF microfarad remote terminal unit KBus Kohler communication protocol N, norm. normal (power source) room temperature vulcanization kilogram not available, not applicable read/write kg/cm kilograms per square nat. gas natural gas...
  • Page 33 Notes TP-6398 4/07...
  • Page 34 Notes TP-6398 4/07...
  • 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-6398 4/07b 7 Jurong Pier Road Singapore 619159 E 2006, 2007, 2008 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...

This manual is also suitable for:

12resl

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