Operation and

Installation
Residential/Commercial Generator Sets

Models:
8.5RES
12RES

Controller:
Advanced Digital Control

TP-6195 1/04
 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.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Controller Description
kits.
Generator Set Identification Numbers Engine Identification
Record the product identification information from the
Record the product identification numbers from the
engine nameplate.
generator set nameplate(s).
Manufacturer
Model Designation
Model Designation
Specification Number
Serial Number
Serial Number

Accessory Number Accessory Description

 Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside front cover

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Section 1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Advanced Digital Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3.1 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3.2 Starting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3.3 Stopping the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3.4 Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.5 Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . . 6
2.3.6 Continuous Power Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4.1 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5.1 Battery Charger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.1 Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.2 Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.3 Engine Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.4 Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Air Cleaner Element and Precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5.1 Precleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5.2 Paper Element Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.8.1 Cleaning the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.2 Checking Battery Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.3 Checking Electrolyte Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.9 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.10 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.10.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.10.2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.10.3 Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.10.4 Exterior Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.10.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

TP-6195 1/04 Table of Contents

Table of Contents, continued

Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Battery Charger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 5 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Specification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Controller Wiring Diagram Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Section 6 Installation ...................................................................... 25
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.3 Generator Set Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.5 Exhaust Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.6 Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.7 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8.1 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.8.2 Fuel Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.8.3 Fuel Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.9 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.9.1 AC Load Lead Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.9.2 Remote Start Connection (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.9.3 Continuous Power Mode Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.9.4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.9.5 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.10 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.10.1 Common Fault and Run Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.10.2 Carburetor Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.11 Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.11.1 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.11.2 Advanced Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.12 Prestart Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.13 Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Table of Contents TP-6195 1/04

 Safety Precautions and Instructions

IMPORTANT SAFETY Accidental Starting

INSTRUCTIONS. Electromechanical
WARNING
equipment, including generator sets,
transfer switches, switchgear, and WARNING
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.
aware of potential dangers and act Relays in the battery charger
safely. Read and follow all safety Accidental starting.
cause arcs or sparks.
Can cause severe injury or death.
precautions and instructions. SAVE
Locate the battery in a well-ventilated
THESE INSTRUCTIONS. Disconnect the battery cables before
area. Isolate the battery charger from
working on the generator set.
explosive fumes.
This manual has several types of safety Remove the negative (--) lead first
precautions and instructions: Danger, when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
Warning, Caution, and Notice.
when reconnecting the battery. sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
DANGER Disabling the generator set. Always wear splashproof safety
Accidental starting can cause
goggles, rubber gloves, and boots
Danger indicates the presence of a severe injury or death. Before
when servicing the battery. Do not
hazard that will cause severe working on the generator set or
open a sealed battery or mutilate the
personal injury, death, or substantial connected equipment, disable the
battery case. If battery acid splashes in
property damage. generator set as follows: (1) Move the
generator set master switch to the OFF the eyes or on the skin, immediately
position. (2) Disconnect the power to flush the affected area for 15 minutes
WARNING the battery charger. (3) Remove the with large quantities of clean water.
battery cables, negative (--) lead first. Seek immediate medical aid in the case
Reconnect the negative (--) lead last of eye contact. Never add acid to a
Warning indicates the presence of a
hazard that can cause severe when reconnecting the battery. Follow battery after placing the battery in
personal injury, death, or substantial these precautions to prevent starting of service, as this may result in hazardous
property damage. the generator set by an automatic spattering of battery acid.
transfer switch, remote start/stop
switch, or engine start command from a Battery acid cleanup. Battery acid
CAUTION remote computer. can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
Caution indicates the presence of a
hazard that will or can cause minor Battery bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
personal injury or property damage.
mix the neutralizing solution. Pour the
NOTICE WARNING neutralizing solution on the spilled
battery acid and continue to add the
Notice communicates installation,
operation, or maintenance information neutralizing solution to the spilled
that is safety related but not hazard battery acid until all evidence of a
related. chemical reaction (foaming) has
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment Sulfuric acid in batteries. water and dry the area.
in prominent places alert the operator Can cause severe injury or death.
or service technician to potential
hazards and explain how to act safely. Wear protective goggles and
The decals are shown throughout this clothing. Battery acid may cause
publication to improve operator blindness and burn skin.
recognition. Replace missing or
damaged decals.

TP-6195 1/04 Safety Precautions and Instructions I

Battery gases. Explosion can cause Engine Backfire/Flash Exhaust System
severe injury or death. Battery gases
can cause an explosion. Do not smoke Fire
or permit flames or sparks to occur near
WARNING
a battery at any time, particularly when WARNING
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals Carbon monoxide.
with tools or other metal objects. Fire. Can cause severe nausea,
Remove all jewelry before servicing the Can cause severe injury or death. fainting, or death.
equipment. Discharge static electricity
Do not smoke or permit flames or The exhaust system must be
from your body before touching
sparks near fuels or the fuel system. leakproof and routinely inspected.
batteries by first touching a grounded
metal surface away from the battery. To
Servicing the air cleaner. A sudden Generator set operation. Carbon
avoid sparks, do not disturb the battery
backfire can cause severe injury or monoxide can cause severe nausea,
charger connections while the battery
death. Do not operate the generator fainting, or death. Carbon monoxide
is charging. Always turn the battery
set with the air cleaner removed. is an odorless, colorless, tasteless,
charger off before disconnecting the
nonirritating gas that can cause death if
battery connections. Ventilate the Servicing the fuel system. A flash
inhaled for even a short time. Avoid
compartments containing batteries to fire can cause severe injury or death.
breathing exhaust fumes when working
prevent accumulation of explosive Do not smoke or permit flames or
on or near the generator set. Never
gases. sparks near the carburetor, fuel line,
operate the generator set inside a
fuel filter, fuel pump, or other potential
Battery short circuits. Explosion building. Never operate the generator
sources of spilled fuels or fuel vapors.
can cause severe injury or death. set where exhaust gas could seep
Catch fuels in an approved container
Short circuits can cause bodily injury inside or be drawn into a potentially
when removing the fuel line or
occupied building through windows, air
and/or equipment damage. carburetor.
intake vents, or other openings.
Disconnect the battery before
Combustible materials. A fire can
generator set installation or Carbon monoxide symptoms.
cause severe injury or death.
maintenance. Remove all jewelry Carbon monoxide can cause severe
Generator set engine fuels and fuel
before servicing the equipment. Use nausea, fainting, or death. Carbon
vapors are flammable and explosive.
tools with insulated handles. Remove monoxide is a poisonous gas present in
Handle these materials carefully to
the negative (--) lead first when exhaust gases. Carbon monoxide
minimize the risk of fire or explosion.
disconnecting the battery. Reconnect poisoning symptoms include but are
Equip the compartment or nearby area
the negative (--) lead last when not limited to the following:
with a fully charged fire extinguisher.
reconnecting the battery. Never D Light-headedness, dizziness
Select a fire extinguisher rated ABC or
connect the negative (--) battery cable D Physical fatigue, weakness in
BC for electrical fires or as
to the positive (+) connection terminal joints and muscles
recommended by the local fire code or
of the starter solenoid. Do not test the D Sleepiness, mental fatigue,
an authorized agency. Train all
inability to concentrate
battery condition by shorting the personnel on fire extinguisher
or speak clearly, blurred vision
terminals together. operation and fire prevention
D Stomachache, vomiting, nausea
procedures.
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.

II Safety Precautions and Instructions TP-6195 1/04

Fuel System Hazardous Noise WARNING

WARNING CAUTION

Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
Explosive fuel vapors. Hazardous noise. injury, or death.
Can cause severe injury or death. Can cause hearing loss.
If the generator set is used for
Use extreme care when handling, Never operate the generator set standby power, install an automatic
storing, and using fuels. without a muffler or with a faulty transfer switch to prevent inadvertent
exhaust system. interconnection of standby and
normal sources of supply.
The fuel system. Explosive fuel
Engine noise. Hazardous noise can
vapors can cause severe injury or
cause hearing loss. Generator sets
death. Vaporized fuels are highly
explosive. Use extreme care when
not equipped with sound enclosures CAUTION
can produce noise levels greater than
handling and storing fuels. Store fuels
105 dBA. Prolonged exposure to noise
in a well-ventilated area away from
levels greater than 85 dBA can cause
spark-producing equipment and out of
permanent hearing loss. Wear hearing
the reach of children. Never add fuel to
protection when near an operating
the tank while the engine is running
generator set. Welding the generator set.
because spilled fuel may ignite on
contact with hot parts or from sparks. Can cause severe electrical
Do not smoke or permit flames or equipment damage.
sparks to occur near sources of spilled
Hazardous Voltage/
Never weld components of the
fuel or fuel vapors. Keep the fuel lines Electrical Shock generator set without first
and connections tight and in good disconnecting the battery, controller
condition. Do not replace flexible fuel DANGER wiring harness, and engine electronic
lines with rigid lines. Use flexible control module (ECM).
sections to avoid fuel line breakage
caused by vibration. Do not operate the Grounding electrical equipment.
generator set in the presence of fuel Hazardous voltage can cause
leaks, fuel accumulation, or sparks. severe injury or death. Electrocution
Repair fuel systems before resuming Hazardous voltage.
is possible whenever electricity is
generator set operation. Will cause severe injury or death.
present. Open the main circuit
Gas fuel leaks. Explosive fuel Disconnect all power sources before breakers of all power sources before
vapors can cause severe injury or opening the enclosure. servicing the equipment. Configure the
death. Fuel leakage can cause an installation to electrically ground the
explosion. Check the LP vapor gas or generator set, transfer switch, and
natural gas fuel system for leakage by WARNING related equipment and electrical
using a soap and water solution with circuits to comply with applicable codes
the fuel system test pressurized to and standards. Never contact
6--8 ounces per square inch electrical leads or appliances when
(10--14 inches water column). Do not standing in water or on wet ground
use a soap solution containing either because these conditions increase the
Hazardous voltage. Moving rotor. risk of electrocution.
ammonia or chlorine because both
Can cause severe injury or death.
prevent bubble formation. A successful
test depends on the ability of the Operate the generator set only when
solution to bubble. all guards and electrical enclosures
are in place.

TP-6195 1/04 Safety Precautions and Instructions III

Welding on the generator set. Can Heavy Equipment Moving Parts
cause severe electrical equipment
damage. Before welding on the
generator set perform the following WARNING WARNING
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
Hazardous voltage. Moving rotor.
regulator circuit board connectors.
Unbalanced weight. Can cause severe injury or death.
(4) Disconnect the engine battery-
charging alternator connections. Improper lifting can cause severe Operate the generator set only when
(5) Attach the weld ground connection injury or death and equipment all guards and electrical enclosures
close to the weld location. damage. are in place.
Installing the battery charger. Do not use lifting eyes.
Hazardous voltage can cause Lift the generator set using lifting bars
severe injury or death. An inserted through the lifting holes on WARNING
ungrounded battery charger may the skid.
cause electrical shock. Connect the
battery charger enclosure to the ground
of a permanent wiring system. As an
alternative, install an equipment
Hot Parts
grounding conductor with circuit Rotating parts.
conductors and connect it to the WARNING Can cause severe injury or death.
equipment grounding terminal or the Operate the generator set only when
lead on the battery charger. Install the all guards, screens, and covers are in
battery charger as prescribed in the place.
equipment manual. Install the battery
charger in compliance with local codes Hot engine and exhaust system.
and ordinances. Can cause severe injury or death. WARNING
Connecting the battery and the Do not work on the generator set until
battery charger. Hazardous voltage it cools.
can cause severe injury or death.
Reconnect the battery correctly,
Servicing the generator. Hot parts
positive to positive and negative to
can cause severe injury or death.
negative, to avoid electrical shock and Airborne particles.
Avoid touching the generator set field
damage to the battery charger and Can cause severe injury or
or exciter armature. When shorted, the
battery(ies). Have a qualified blindness.
generator set field and exciter armature
electrician install the battery(ies).
become hot enough to cause severe Wear protective goggles and clothing
Short circuits. Hazardous burns. when using power tools, hand tools,
voltage/current can cause severe or compressed air.
Servicing the exhaust system. Hot
injury or death. Short circuits can
parts can cause severe injury or
cause bodily injury and/or equipment Tightening the hardware. Flying
death. Do not touch hot engine parts.
damage. Do not contact electrical projectiles can cause severe injury
The engine and exhaust system
connections with tools or jewelry while or death. Loose hardware can cause
components become extremely hot
making adjustments or repairs. the hardware or pulley to release from
during operation.
Remove all jewelry before servicing the the generator set engine and can cause
equipment. Servicing the engine heater. Hot personal injury. Retorque all
parts can cause minor personal crankshaft and rotor hardware after
Electrical backfeed to the utility.
injury or property damage. Install the servicing. Do not loosen the crankshaft
Hazardous backfeed voltage can
heater before connecting it to power. hardware or rotor thrubolt when making
cause severe injury or death. Install
Operating the heater before installation adjustments or servicing the generator
a transfer switch in standby power
can cause burns and component set. Rotate the crankshaft manually in
installations to prevent the connection
damage. Disconnect power to the a clockwise direction only. Turning the
of standby and other sources of power.
heater and allow it to cool before crankshaft bolt or rotor thrubolt
Electrical backfeed into a utility
servicing the heater or nearby parts. counterclockwise can loosen the
electrical system can cause severe
hardware.
injury or death to utility personnel
working on power lines.

IV Safety Precautions and Instructions TP-6195 1/04

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
pulleys when the generator set is damage by wearing an approved
running. Replace guards, screens, and grounding wrist strap when handling
covers before operating the generator electronic circuit boards or integrated
set. circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short, to
Notice ground.

NOTICE
This generator set has been
rewired from its nameplate voltage
to

246242

NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.

NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.

NOTICE
When replacing hardware, do not
substitute with inferior grade
hardware. Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.

NOTICE
Canadian installations only. For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

TP-6195 1/04 Safety Precautions and Instructions V

 Notes

VI Safety Precautions and Instructions TP-6195 1/04

 Introduction

This manual provides operation and installation EPA and California Emission
instructions for model 8.5RES and 12RES generator
sets equipped with the Kohlerr Advanced Digital
Certification
Control (ADC 2100).
An engine or generator set with the following
Information in this publication represents data available identification labels is certified to meet Small Off-Road
at the time of print. The manufacturer may provide this Engine emission standards for EPA/CARB. All model
manual for models not listed on the front cover. Kohler 8.5RES and 12RES generator sets with multi-fuel
Co. reserves the right to change this publication and the systems are emission-certified.
products represented without notice and without any
obligation or liability whatsoever.

Read this manual and carefully follow all procedures

and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

The generator set is approved for use in stationary

applications in locations served by a reliable utility
power source.

The equipment service requirements are very important

to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals. tp6195
Obtain service from an authorized service distributor/
dealer to keep equipment in top condition. Figure 1 Emissions Label, 8.5RES Engine (CH20)

Nameplate
The following illustration shows a typical generator set
nameplate. Copy the model, serial, and specification
numbers from the nameplate into the spaces provided in
the product information section on the inside front cover
of this manual. See Section 1.5, Service Views, for the
nameplate location.

tp6195

Figure 2 Emissions Label, 12 RES Engine (CH740)

TP-6195 1/04 Introduction i

 of operating hours for which the engine has been shown
to meet CARB emission requirements. The following
table provides the engine compliance period (in hours)
associated with the category descriptor found on the
certification label.

Emission Compliance Period (hours)

Moderate, Intermediate, Extended,
CARB
tp6195 125 250 500

Figure 3 Air Index Label, 8.5/12RES Refer to the certification label for engine displacement.

This engine/generator is certified to operate using The exhaust emission control system for the 8.5RES
natural gas or propane fuel. (CH20) and 12RES (CH740) is EM.
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the number

Service Assistance

For professional advice on generator power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D 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 Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa
Tokyo, Japan
(EMEA)
Phone: (813) 3440-4515
Kohler Power Systems
Fax: (813) 3440-2727
ZI Senia 122
12, rue des Hauts Flouviers Latin America
94517 Thiais Cedex Latin America Regional Office
France Lakeland, Florida, USA
Phone: (33) 1 41 735500 Phone: (863) 619-7568
Fax: (33) 1 41 735501 Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455

ii Service Assistance TP-6195 1/04

 Section 1 Specifications and Features

1.1 Specifications 1.4 Advanced Digital Control

The generator set specification sheets provide specific The generator set is equipped with the Kohlerr
generator and engine information. Refer to the spec Advanced Digital Control (ADC 2100). Controller
sheet for data not supplied in this manual. Consult the features include the following:
generator set service manual, engine operation manual,
D Compact controller
and engine service manual for additional specifications.
Obtain copies of the latest spec sheets, manuals, D Integrally mounted to the generator set
diagrams, and drawings from your local
distributor/dealer. D LED display:
D Runtime hours

1.2 Generator D Crank cycle status

D Diagnostics
The generator uses Kohler’s unique PowerBoostt
voltage regulation system, which provides instant D LED display communicates faults:
response to load changes. D Auxiliary fault
D High battery voltage
PowerBoostt ensures reliable motor starting and
D High engine temperature
consistent voltage levels. PowerBoostt utilizes a
voltage excitation system that employs a winding D Low battery voltage
independent of the main output windings to provide D Low oil pressure
excitation voltage. D Overcrank safety
D Overspeed
1.3 Engine D Overfrequency
The generator set has a four-cycle, twin cylinder, air- D Overvoltage
cooled Kohlerr engine. The engine operates on D Underfrequency
clean-burning natural gas or propane (LP) vapor. D Undervoltage
Engine features include:
D Membrane keypad for configuration and adjustment
D Efficient overhead valve design and full pressure D Password-protected user access to menus
lubrication for maximum power, torque, and reliability
D Voltage, gain, and speed adjustment
under all operating conditions.
D System configuration (system voltage, phase,
D Dependable, maintenance-free electronic ignition. and frequency settings, battery voltage, and
generator set model)
D Precision-formulated cast iron construction of parts
subjected to the most wear and tear. D Master control switch: Run/Off-Reset/Auto

D Remote two-wire start/stop capability

D Field-convertible multi-fuel systems that allow fuel
changeover from natural gas to LP vapor (and D Superior electronics protection from corrosion and
vice-versa) while maintaining CARB emission vibration
certification.
D Potted electronics
D Digital spark-advance module (DSAM) optimizes D Sealed connections
ignition timing for the selected fuel (12RES).
D Digital isochronous governor to maintain
steady-state speed at all loads
D Digital voltage regulation: ±1.5% RMS no-load to
full-load
D Automatic start for programmed cranking cycle

TP-6195 1/04 Section 1 Specifications and Features 1

1.5 Service Views

1 2 3 4 5 6 7 18 19 20

8
21

24
9

17 10
23
22

16

22

15 14 13 12 11 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. DSAM leads
7. Controller 19. Multi-fuel block
8. Generator set master switch (RUN\OFF/RESET\AUTO) 20. Gas regulator assembly
9. Nameplate 21. Fuel solenoid valve
10. Line circuit breaker 22. Air intake
11. Engine starting battery location 23. Battery charger
12. Oil drain hose 24. Relay board

Figure 1-1 Generator Set Service View

2 Section 1 Specifications and Features TP-6195 1/04

 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. In addition, some checks require switch (ATS) with an exercise option, exercise the unit in
verification after the unit starts. the presence of an operator.

Air Cleaner. Check for a clean and installed air cleaner During the exercise period apply a minimum of 35% load
element to prevent unfiltered air from entering the based on the nameplate standby rating.
engine.
The operator should perform all of the prestart checks
Air Inlets. Check for clean and unobstructed air inlets. before starting the exercise procedure. Start the
generator set according to the starting procedure in the
Battery. Check for tight battery connections. Consult controller section of this manual. While the generator
the battery manufacturer’s instructions regarding set is operating, listen for a smooth-running engine and
battery care and maintenance. visually inspect the generator set for fluid or exhaust
leaks. Check the air inlets and outlets and remove any
Exhaust System. Check for exhaust leaks and items restricting the air flow.
blockages. Check the muffler and piping condition and
check for tight exhaust system connections.
2.3 Generator Set Operation
Inspect the exhaust system components (exhaust
manifold, exhaust line, flexible exhaust, clamps, muffler, Figure 2-1 illustrates the user interface on the Advanced
and outlet pipe) for cracks, leaks, and corrosion. Digital Control (ADC 2100) generator set controller.

D Check for corroded or broken metal parts and replace 1

them as needed.
3
D Check for loose, corroded, or missing clamps and 2
hangers. Tighten or replace the exhaust clamps
and/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.

Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.

Operating Area. Check for obstructions that could

4 GM28707A-C
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the 1. LED display
generator set. 2. Select button (use for setup and adjustment only)
x:op:001:002 3. Up and down arrow buttons (use for setup and adjustment
only)
4. Generator set master switch

Figure 2-1 ADC 2100 Controller User Interface

TP-6195 1/04 Section 2 Operation 3

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.

The LED display indicates generator set status as 2.3.3 Stopping the Generator Set
shown in Figure 2-2. The display is activated by a start
The following procedures describe the actions required
or run command and remains active until the generator
to stop the generator set.
set master switch is moved to the OFF/RESET position
or power to the controller is removed. If the
factory-installed continuous power mode jumper has Local Stopping
been disconnected, the LED display turns off 48 hours
1. Run the generator set at no load for at least
after generator set shutdown. See Section 2.3.6.
2 minutes to ensure adequate engine cooldown.
The buttons on the controller keypad are used only for
2. Move the generator set master switch to the
system configuration and adjustment. The controller is OFF/RESET position. The engine stops.
factory-set and should not require configuration or
adjustment under normal operating conditions. Contact
Automatic Stopping
an authorized distributor/dealer or service technician if
adjustments are required. With the generator set master switch in the AUTO
position and an automatic transfer switch (ATS) or other
2.3.2 Starting the Generator Set automatic device connected to controller leads 3 and 4:

The following procedures describe the actions required 1. The ATS or other device disconnects the load from
to start the generator set. the generator set.

The controller attempts to start the generator set three 2. If the ATS is equipped with an engine cooldown
times (three crank cycles, 15 seconds crank and 15 time delay, the generator set continues to run for a
seconds off). If the generator set does not start in three preset engine cooldown time.
attempts, the system shuts down on an overcrank fault.
Note: There is no engine cooldown time delay on
the ADC controller.
Local Starting
3. The ATS or other device opens the connection
Move the generator set master switch to the RUN between controller leads 3 and 4. The generator
position to immediately start the generator set. set shuts down.

Auto (Automatic) Starting

Move the generator set master switch to the AUTO

position to allow startup by the ATS or the remote

Control or Indicator Item Description

LED display
p y Runtime hours Displays total generator set runtime hours while the generator set is running.
Crank indication Displays CC_1, CC_2, or CC_3 to indicate the first, second or third attempt to start the
engine. The last digit flashes during the crank cycle rest periods.
Fault codes Flashes a 2- or 3-letter fault code to indicate various fault conditions. See Section 2.3.4.
Software version See TP-6196, Generator Set Service Manual.
number
Keypad Select and arrow The keypad is used for controller setup and adjustment only. Have setup and adjustments
buttons performed only by an authorized 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.
switch switch

Figure 2-2 ADC 2100 Controls and Indicators

4 Section 2 Operation TP-6195 1/04

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. However, the fault does
displays a fault code. The generator set cannot be not clear until the controller is reset.
restarted until the fault condition is corrected and the
controller is reset. See Section 2.3.5 to reset the The controller displays a fault code but the generator set
controller after a fault shutdown. The controller resets does not shut down under the conditions shown in
automatically after a battery voltage fault condition is Figure 2-4.
corrected.

Code Fault Description Check

AF Auxiliary fault Input from a customer-supplied switch that closes when the Check the cause of the auxiliary fault.
input shutdown fault is active. The generator set shuts down and will not start
when the fault is active (input is grounded).
HE High engine Shutdown occurs if the engine coolant temperature exceeds Check for blocked air inlets and exhaust
temperature the maximum temperature for more than 5 seconds. This outlets.
shutdown protective becomes active after the engine reaches the crank
disconnect speed.
LOP Low oil pressure Shutdown occurs if a low oil pressure condition exists 7 Check for leaks in the lubrication system.
shutdown seconds after the engine has reached crank disconnect speed.
Check the oil level and add oil if the level
Note: The low oil pressure shutdown does not protect against is low.
low oil level. Check the oil level at the engine.

OC Overcrank Shutdown occurs after 3 unsuccessful starting attempts. The Check the fuel supply, spark plug, and
shutdown crank cycle is set for three starting attempts of 15 seconds battery.
cranking and 15 seconds rest.
Check for loose connections.
The generator set also shuts down after 1 crank attempt if no Contact an authorized distributor/dealer for
speed signal is sensed. Shuts down 1 second after the fault is service if problem continues.
detected.
OF Overfrequency Shutdown occurs when the governed frequency exceeds 110% Contact an authorized distributor/dealer for
shutdown of the system’s frequency setpoint for more than 1 second. service if problem continues.
This protective becomes active 30 seconds after engine start.
OS Overspeed Shutdown occurs if the engine speed exceeds 115% of the Contact an authorized distributor/dealer for
shutdown normal running speed for more than 1 second. service if problem continues.
OU Overvoltage Shutdown occurs if the voltage exceeds 120% of the voltage Contact an authorized distributor/dealer for
shutdown regulator setpoint for more than 1 second. service if problem continues.
UF Underfrequency Shutdown occurs when the governed frequency falls 1 Hz Reduce the load and restart the generator
shutdown below the system’s frequency setpoint for more than 1 second. set.
Contact an authorized distributor/dealer for
service if problem continues.
UU Undervoltage Shutdown occurs if the voltage falls below 80% of the voltage Reduce the load and restart the generator
shutdown regulator setpoint for more than 1 second. This protective set.
becomes active 30 seconds after engine start.
Contact an authorized distributor/dealer for
service if problem continues.

Figure 2-3 ADC Fault Shutdown Codes

Code Fault Description Check

HB High battery Fault code is displayed if the engine starting battery voltage rises Check the battery rating and condition.
voltage warning above 16 VDC for a 12 VDC system or above 30 VDC for a
24 VDC system for more than 10 seconds when the engine is not
Check the battery charger operation.
running. This fault condition does not inhibit engine starting.
The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 seconds.
LB Low battery Fault code is displayed if the engine starting battery voltage falls Check the battery rating and condition.
voltage warning below 8 VDC for a 12 VDC system or below 16 VDC for a 24 VDC
Check the battery charger operation.
system for more than 10 seconds when the engine is not running.
This fault condition does not inhibit engine starting. Charge or replace the battery.
The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 seconds.

Figure 2-4 ADC Fault Warning Codes

TP-6195 1/04 Section 2 Operation 5

2.3.5 Resetting the Controller after a 7. Move the generator set master switch to the AUTO
Fault Shutdown position for startup by remote transfer switch or
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. Use the
until an engine start command is received.
following procedure to reset the generator set controller
after a fault shutdown. Opening and closing a remote start/stop contact also
resets the controller.
1. Move the generator set master switch to
OFF/RESET.
2.3.6 Continuous Power Mode
2. Disconnect the generator set from the load using
the line circuit breaker or ATS. See the safety The controller is powered by the generator set engine
precautions at the beginning of this section before starting battery. A jumper on the back of the controller
proceeding. maintains power to the controller at all times.
Controllers are shipped with the jumper connected.
3. Identify and correct the cause of the fault
shutdown. See the safety precautions at the Note: The 8.5 and 12 RES generator sets are equipped
beginning of this section before proceeding. Refer with factory-installed battery chargers to prevent
to Section 4, Troubleshooting. battery discharge.
4. Start the generator set by moving the generator set Disconnecting the jumper allows the controller to power
master switch to RUN. Test operate the generator down automatically 48 hours after the generator set
set to verify that the cause of the shutdown has shuts down if the generator set master switch is in the
been corrected. AUTO position. A remote start signal (from a transfer
5. Move the generator set master switch to switch or a remote start/stop switch connected to
OFF/RESET. controller leads 3 and 4) or moving the generator set
master switch to the RUN position turns the controller
6. Reconnect the generator set to the load using the back on.
line circuit breaker or ATS.
See Section 6.9.3 for instructions to disconnect the
jumper.

6 Section 2 Operation TP-6195 1/04

2.4 Circuit Protection 2.5 Battery Charger
If the generator set circuit breaker trips or the fuses blow The generator set is equipped with a 6-amp
repeatedly, see Section 4, Troubleshooting, for possible float/equalize battery charger to maintain the engine
causes. starting battery. The charger’s power cord must be
connected to a 120 VAC power source. Figure 2-7
illustrates the battery charger.
2.4.1 Line Circuit Breaker
The battery charger uses an AGS 10 inline fuse. The
A line circuit breaker interrupts the generator output in
fuse is located in the battery lead. See Figure 2-7.
the event of a fault in the wiring between the generator
and the load. The line circuit breaker location is shown
in Figure 1-1. See Figure 2-5 for the circuit breaker 1
ratings. If the circuit breaker trips, reduce the load and
switch the breaker back to the ON position. With the INDICATOR
Red: VOLTS= 11.8--14.0
AMPS= 5.0--6.0
Red & Green: VOLTS= 14.0--14.5

breaker in the OFF position the generator set runs but Green:

CAUTION:
AMPS= 1.5--5.0
VOLTS= 13.0--13.6
AMPS= 0.1--1.5
6 AMP AUTOMATIC
BATTERY CHARGER

To reduce the risk of elect rical shock,

connect only to properly gr ounded outlet.

the generator output is disconnected from the load. INPUT: 115 VAC 50/60Hz @ 1.6A
OUTPUT: 12 VDC @ 6 Amps
MAX. BAT.: 180 Amp Hr. Max.
C R
US LISTED
BATTERY CHARGER
53AB
DATE: 2608KH
Allowable Battery Types: Lead Acid a nd Gel Cell

Circuit Breaker
Model Rating, Amps
8.5RES 40 2 4
12RES 50

Figure 2-5 Line Circuit Breakers

3

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.
1. LED indicators
Always identify and correct the cause of a blown fuse 2. Battery leads, 12 VDC
3. Fuse
before restarting the generator set. Refer to Section 4, 4. AC power cord
Troubleshooting, for conditions that may indicate a
blown fuse. Replace blown fuses with identical Figure 2-7 6-Amp Float/Equalize Battery Charger
replacement parts.

Part
Fuse Label Number Location
Auxiliary Winding F1 292937 Lead 55
Relay Interface F2 223316 Lead PF2
Board
Controller F3 358337 Lead PF1
Battery Charger — AGS 10 Battery charger DC
lead. See Section 2.5.

Figure 2-6 Fuses

TP-6195 1/04 Section 2 Operation 7

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
Green OFF BULK rate (stage 1). This charging rate is 6 amps. While the red LED is on, the voltage measured (with
the battery charger on) will be 11.8--14 volts.
If the red LED stays on for more than 24 hours, refer to Section 4.5 in this manual.
Red ON When both the green and the red LEDs are on, the battery charger is charging at an ABSORPTION rate
Green ON of between 1.5 and 5 amps (stage 2). This mode of charging gradually tops off your battery, and reduces
harmful sulfating. While both LEDs are on, the voltage measured (with the battery charger on) should be
approximately 14.0--14.5 VDC.
If both LEDs stay on longer than 24 hours, refer to Section 4.5 in this manual.
Red OFF When the green LED is on, the battery charger is charging at a FLOAT or MAINTENANCE rate of less
Green ON than 1.5 amps (stage 3). Your battery is now 90% charged and ready for use. This float charging current
will gradually decrease to as low as 0.1 amps as the battery reaches 100% charge. It will now be kept at
full charge without overcharging.
If the green LED stays on when your battery is known to be low, refer to Section 4.5 in this manual.
Figure 2-9 Battery Charger LED Indicator Functions

8 Section 2 Operation TP-6195 1/04

 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. are in place.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last Servicing the generator set when it is operating. Exposed
when reconnecting the battery. moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
Disabling the generator set. Accidental starting can guards, screens, and covers before operating the generator
cause severe injury or death. Before working on the set.
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger. 3.1 Routine Maintenance
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the Refer to the service schedule following and the runtime
battery. Follow these precautions to prevent starting of the
hours displayed on the ADC 2100 display to schedule
generator set by an automatic transfer switch, remote
routine maintenance. Have an authorized distributor/
start/stop switch, or engine start command from a remote
computer. dealer perform all generator set service. Perform
maintenance on each item in the service schedule at the
designated interval for the life of the generator set.
WARNING
Service units subject to extreme weather, long operating
hours, or dusty or dirty conditions more frequently.

3.2 Service Schedule

Hot engine and exhaust system.
Can cause severe injury or death. Perform the tasks listed in the following service
schedule at the designated intervals for the life of the
Do not work on the generator set until it
cools. generator set. For example, an item serviced every
100 hours of operation or 3 months must also be
Servicing the exhaust system. Hot parts can cause serviced after 200 hours or 6 months, 300 hours or
severe injury or death. Do not touch hot engine parts. The 9 months and so on. Rough operation, lack of power,
engine and exhaust system components become extremely and excessive oil use indicate serious generator set
hot during operation. problems. Have an authorized distributor/ dealer
perform all generator set service.

TP-6195 1/04 Section 3 Scheduled Maintenance 9

 Procedure
See Visually
System Component or Procedure Section Inspect Check Change Clean Test Frequency
Fuel
Flexible lines and connections X R Quarterly
Main tank supply level X Weekly
Fuel piping X Yearly
Lubrication 3.3
Oil level X X 8 hours or
before use
Crankcase breather* X X Yearly or 500 hours
Change oil X Yearly or 100 hours
Replace filter* X Yearly or 200 hours
Cooling 3.6
Air ducts, louvers X X Yearly
Exhaust Line 3.7
Leakage X X Weekly
Insulation, fire hazards X Yearly
Hangers and supports X Yearly
DC Electrical System 3.8
Battery charger operation, charge rate (if equipped) X Monthly
Remove corrosion, clean and dry battery and rack X X Yearly
Clean and tighten battery terminals X X Yearly
Battery electrolyte level and specific gravity[ X Yearly
AC Electrical System
Visible wear or damage X Quarterly
Wire abrasions where subject to motion X X Six Months
Tighten control and power wiring connections X Yearly
Wire-cable insulation breakdown * X 3 Years or 500 hours
Engine and Mounting
Visible wear or damage X Weekly
Air cleaner service 3.5 R Yearly or 100 hours
Spark plugs 3.4 X Yearly or 300 hours
Replace stepper motor coupling and bushing * X 500 hours
Compartment condition X X Weekly
Remote Control System
Remote control X Monthly
Run generator set X Weekly
Generator
Visible wear or damage 2.1 X Quarterly
Exercise generator set 2.2 X Weekly
Rotor and stator * X X Yearly
Measure and record resistance readings of
windings with insulation tester (Megger, with
SCR assembly or rectifier disconnected) X 3 Years
General Condition of Equipment
Evidence of vibration, leakage, excessive noise,
temperature, or deterioration X X X Weekly
Interior of sound enclosure X X Quarterly
* Contact your local distributor/dealer for parts or service. X Action
[ Not necessary for maintenance-free batteries. R Replace as necessary

Figure 3-1 Service Schedule

10 Section 3 Scheduled Maintenance TP-6195 1/04

3.3 Lubrication System 3.3.4 Oil Change Procedure

See Section 3.2, Service Schedule, for oil change and Drain the oil while it is still warm.
oil filter replacement intervals. See Section 1.5, Service
Views, for the oil drain, oil check, oil fill, and oil filter 1. Drain the oil.
locations. a. Place the generator set master switch in the
OFF position.
For extended operation, check the oil level every 8
hours. Maintain the oil level at or near, not over, the full b. Disconnect the power to the battery charger.
mark on the dipstick.
c. Disconnect the generator set engine starting
battery, negative (--) lead first.
3.3.1 Low Oil Pressure Shutdown
d. Remove the housing side panel.
The low oil pressure shutdown feature protects the
engine against internal damage if the oil pressure drops e. Remove the oil drain hose from its retaining
below 24.1 kPa ±13.8 kPa (3.5 psi ±1.5 psi) because of clip. Remove the cap from the oil drain hose
oil pump failure or other malfunction. The shutdown and lower the hose into an oil collection
feature does not protect against damage caused by container.
operating with the oil level below the safe range; it is not
a low oil level shutdown. Check the oil level regularly, f. Open the oil drain valve on the engine.
and add oil as needed.
g. Allow time for the engine oil to drain completely.

3.3.2 Oil Check h. Close the oil drain valve.

The generator set is shipped with oil. Before operating a i. Replace the cap on the oil drain hose. Replace
new generator set, check the engine oil in the the oil drain hose in its retaining clip.
crankcase. See 1.5, Service Views. Verify that the oil
level is at the F mark on the dipstick. Add oil that has a 2. Replace the oil filter.
viscosity appropriate for the climate. See Section 3.3.3,
a. Remove the oil filter by rotating it
Engine Oil Recommendation.
counterclockwise with an oil filter wrench.
Do not check the oil level when the generator set is b. Clean the gasket sealing surface of the oil filter
running. Shut down the generator set and wait several adapter.
minutes before checking the oil level.
c. Apply a light coat of clean oil to the rubber seal
3.3.3 Engine Oil Recommendation of the new oil filter.

d. Install the new oil filter following the instructions

Use API (American Petroleum Institute) Service Class
provided with the filter.
SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and
thickens less than other oils and leaves the engine Note: Dispose of all waste materials (engine
intake valves and pistons cleaner. Select the viscosity oil, fuel, filter, etc.) in an environmentally
based on the air temperature at the time of operation. safe manner.
See Figure 3-2.
3. Fill with oil.

10W-30 a. Remove the oil fill cap and fill the engine to the F
mark on the dipstick. The engine oil capacity is
1.9 L (2.0 qt.). See Section 3.3.3, Engine Oil
5W-20, 5W-30 Recommendation, for oil selection.

b. Reinstall the dipstick and the oil fill cap.

°F --20 0 20 32 40 60 80 100
°C --30 --20 --10 0 10 20 30 40 c. Check that the generator set master switch is in
Temperature Range Expected Before Next Oil Change the OFF position.

Figure 3-2 Engine Oil Selection

TP-6195 1/04 Section 3 Scheduled Maintenance 11

 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. See
allow the oil pressure to reach the operating Figure 3-5.
range.
Check for a buildup of dirt and debris around the air
g. Stop the generator set, wait 1 minute, and then cleaner system. Keep this area clean.
recheck the oil level. Add oil to bring the level
up to the F mark on the dipstick. Note: Operating the engine with loose or damaged air
cleaner components could allow unfiltered air
4. Check for leaks. into the engine causing premature wear and
failure.
a. Check for oil leaks.

b. Fix leaks and recheck the oil level. 3.5.1 Precleaner Service
c. Reinstall the housing side panel. Use the following procedure to wash and reoil the
precleaner as indicated in the service schedule. Wash
3.4 Spark Plugs and reoil the precleaner more often under extremely
dusty or dirty conditions.
Reset the spark plug gap or replace the plugs with new
plugs as necessary. 1. Place the generator set master switch in the
OFF/RESET position.
1. Clean the area around the base of the spark plug to
keep dirt and debris out of the engine. 2. Disconnect the power to the battery charger.

3. Disconnect the battery, negative (--) lead first.

2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is
4. Loosen the cover retaining knob and remove the
questionable.
cover. Remove the precleaner from the paper
element. Wash the precleaner in warm water with
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.76 mm (0.030 in.) by detergent. Rinse the precleaner thoroughly until all
traces of detergent are eliminated. Squeeze out
carefully bending the ground electrode. See
excess water (do not wring). Allow the precleaner
Figure 3-3 and Figure 3-4.
to air dry.

5. Saturate the precleaner with new engine oil.

Squeeze out all of the excess oil.

6. Reinstall the precleaner over the paper element.

7. Reinstall the air cleaner cover. Secure the cover

with the cover retaining knob.
1--514

8. Reconnect the power to the battery charger.

Figure 3-3 Checking the Spark Plug Gap
9. Reconnect the generator set engine starting
battery, negative (--) lead last.

3.5.2 Paper Element Service

Use the following procedure to replace the paper
element at the intervals specified in the service
1--511 schedule. Replace the paper element more often under
extremely dusty or dirty conditions.
Figure 3-4 Adjusting the Spark Plug Gap

12 Section 3 Scheduled Maintenance TP-6195 1/04

 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.

3. Disconnect the generator set engine starting

1
battery, negative (--) lead first.

4. Loosen the cover retaining knob and remove the

cover. 2

5. Remove the element cover nut, element cover, and 3

the paper element with precleaner.

6. Remove the precleaner from the paper element. 4

Note: Do not wash the paper element or clean it

with pressurized air, as this will damage the 5
element.

7. Replace the element if it is dirty, bent, or damaged. 6

8. Check the air cleaner base. Make sure it is secure
and not bent or damaged. Also check the element 7
cover for damage and fit. Replace all damaged air
cleaner components. Remove any loose dirt or
debris from the air cleaner base. Wipe the base 586536
carefully so that no dirt drops into the intake throat.
Check the condition of the rubber seal on the air 1. Cover knob
cleaner stud and replace the seal if necessary. 2. Air cleaner cover
3. Element cover nut
9. Reinstall the paper element, precleaner, element 4. Element cover
5. Foam precleaner
cover, element cover nut, and the air cleaner cover. 6. Air cleaner element
Secure the cover with the cover retaining knob. 7. Air cleaner base

10. Reconnect the power to the battery charger. Figure 3-5 Air Cleaner Components

11. Reconnect the generator set engine starting

battery, negative (--) lead last.
3
1
3.6 Cooling System
The engine fan draws cooling air through the openings
in the sides and end near the battery. The alternator fan
draws cooling air through openings on the side walls of
the enclosure. The cooling air mixes with the engine
exhaust and is discharged at the exhaust outlet. See 2 3
tp6195
Figure 3-6. To prevent generator set damage caused by 1. Exhaust outlet
overheating, keep the housing cooling inlets and outlets 2. Alternator air intake (both sides)
3. Engine air intake
clean and unobstructed at all times.
Figure 3-6 Cooling Air Intake and Exhaust

TP-6195 1/04 Section 3 Scheduled Maintenance 13

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
Remove all combustible materials from the exhaust battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of
location. Combustible materials include building
clean water. Seek immediate medical aid in the case of eye
materials as well as natural surroundings. Keep dry field
contact. Never add acid to a battery after placing the battery in
grass, foliage, and combustible landscaping material a
service, as this may result in hazardous spattering of battery
minimum of 0.3 m (1 ft.) from the exhaust outlet. acid.
Periodically inspect the exhaust system components Battery acid cleanup. Battery acid can cause severe
(exhaust manifold, exhaust line, flexible exhaust, injury or death. Battery acid is electrically conductive and
clamps, silencer, and outlet pipe) for cracks, leaks, and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
corrosion. soda) to a container with 4 L (1 gal.) of water and mix the
neutralizing solution. Pour the neutralizing solution on the
D Check for corroded or broken metal parts and replace spilled battery acid and continue to add the neutralizing
them as needed. solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
D Check for loose, corroded, or missing clamps and liquid with water and dry the area.
hangers. Tighten or replace clamps and/or hangers
as needed. Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke
D Check for and remove loose insulation in the exhaust or permit flames or sparks to occur near a battery at any time,
duct. particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an
D Check that the exhaust outlet is clear. explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
3.8 Battery touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the
WARNING battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury

or death. Short circuits can cause bodily injury and/or
Sulfuric acid in batteries. equipment damage. Disconnect the battery before generator
Can cause severe injury or death. set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Wear protective goggles and clothing.
Battery acid may cause blindness and Remove the negative (--) lead first when disconnecting the
burn skin. battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
Battery electrolyte is a diluted sulfuric acid. Battery acid
starter solenoid. Do not test the battery condition by shorting
can cause severe injury or death. Battery acid can cause
the terminals together.
blindness and burn skin. Always wear splashproof safety

14 Section 3 Scheduled Maintenance TP-6195 1/04

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. Do not allow the cleaning
the generator set nameplate for the engine electrical solution to enter the battery’s cells. After cleaning, flush
system voltage. Consult the generator spec sheet for the battery and cables with clean water and wipe them
battery capacity recommendations for replacement with a dry, lint-free cloth.
purposes. Wiring diagrams provide battery connection
information. See Figure 3-7 for typical battery After reconnecting the battery cables, coat the battery
connections. terminals with petroleum jelly, silicone grease, or other
nonconductive grease.
Check the electrolyte level and specific gravity of
batteries with filler caps. Maintenance-free batteries do
3.8.2 Checking Battery Electrolyte
not require electrolyte level checking or specific gravity
testing.
Level

Clean the battery and cables and tighten battery Check the battery electrolyte level before each startup.
terminals using the service schedule recommendations. Remove the filler caps and verify that the electrolyte
Clean the battery by wiping it with a damp cloth. Clean level reaches the bottoms of the filler holes; see
both battery terminals with baking soda. Keep the Figure 3-8. Refill as necessary with distilled water or
electrical connections dry and tight. clean tap water. Do not add electrolyte. Install and
tighten filler caps. After adding water to the battery in
freezing temperatures, run the generator set
1 2 20--30 minutes to mix the added water and the battery
electrolyte. Mixing the water and the electrolyte
prevents the added water from freezing and damaging
the battery.

EZ-273000-J

1. To positive (+) terminal on starter solenoid. 1

2. To ground (--) terminal on or near starter motor.

Figure 3-7 12-Volt Engine Electrical System Single 2

Starter Motor, Typical Battery Connection

3.8.1 Cleaning the Battery

To prevent dirt and grime buildup, occasionally wipe the
battery with a damp cloth.
5810321

To prevent corrosion, maintain tight, dry electrical 1. Filler caps

connections at the battery terminals. To remove 2. Electrolyte level
corrosion from battery terminals, disconnect the cables
Figure 3-8 Checking Electrolyte Level

TP-6195 1/04 Section 3 Scheduled Maintenance 15

3.8.3 Checking Electrolyte Specific
°C °F Correction
Gravity 71.1 160 + .032

+ .030
Use a battery hydrometer to check the specific gravity of 65.6 150 + .028
Example 1:
the electrolyte in each battery cell. Use the + .026
hydrometer’s test instructions, if available, or Figure 3-9 60.0 140 + .024 Temperature below 26.7°C (80°F)
for bead-type testers. + .022 Hydrometer Reading 1.250
54.4 130 + .020
Number of Battery + .018
Electrolyte Temperature
Beads Floating Condition --6.7°C (20°F)
48.9 120 + .016

5 Overcharged + .014 Subtract .024 Specific Gravity

43.3 110 + .012 Corrected Specific Gravity is 1.226
4 Full Charge
+ .010
3 Adequate Charge 37.8 100 + .008
1, 2 Low Charge + .006 Example 2:
0 Battery Dead 32.2 90 + .004
Temperature above 26.7°C (80°F)
+ .002
Figure 3-9 Electrolyte Testing Chart 26.7 80 0 Hydrometer Reading 1.235
-- .002
Temperature affects specific gravity; correct the Electrolyte Temperature
21.1 70 -- .004
indicated hydrometer readings for temperature. If the 37.8°C (100°F)
--. 006
hydrometer does not have a correction table, use 15.6 60 -- .008 Add .008 Specific Gravity
Figure 3-10. A fully charged battery should have a -- .010 Corrected Specific Gravity is
specific gravity of 1.260 with the electrolyte at 26.7_C 10 50 -- .012
1.243
(80_F). Charge the battery if the specific gravity from -- .014
cell to cell varies by more than 0.01. Charge the battery 4.4 40 -- .016
if the specific gravity is less than 1.215 with the -- .018
electrolyte at 26.7_C (80_F). -- 1.1 30 -- .020

-- .022

-- 6.7 20 -- .024

-- .026

-- 12.2 10 -- .028

The temperature correction amounts to about .004 (4 points) of

specific gravity for each 5.5°C (10°F) change in electrolyte
temperature. 5810322

Figure 3-10 Specific Gravity Temperature Correction

16 Section 3 Scheduled Maintenance TP-6195 1/04

3.9 Battery Charger 2. Stop the generator set.

The generator set is equipped with a 6-amp 3. While the engine is still warm, drain the engine
lubrication oil from the engine crankcase.
float/equalize battery charger to maintain the engine
starting battery. The charger’s DC leads are 4. Refill the engine crankcase with oil. See Section
factory-wired. Figure 3-11 illustrates the battery 3.3.3 for oil recommendations.
charger.
5. Run the generator set for a few minutes to
1 distribute the clean oil.
2 2
6. Stop the generator set.
INDICATOR
Red: VOLTS= 11.8--14.0
AMPS= 5.0--6.0
Red & Green: VOLTS= 14.0--14.5
AMPS= 1.5--5.0
6 AMP AUTOMATIC
Green: VOLTS= 13.0--13.6
AMPS= 0.1--1.5 BATTERY CHARGER

CAUTION:
To reduce the risk of elect rical shock,
connect only to properly gr ounded outlet.
INPUT: 115 VAC 50/60Hz @ 1.6A
OUTPUT: 12 VDC @ 6 Amps
C R
US LISTED
3.10.2 Fuel System
MAX. BAT.: 180 Amp Hr. Max. BATTERY CHARGER
53AB
DATE: 2608KH
Allowable Battery Types: Lead Acid a nd Gel Cell

1. Start the generator set.

3 2. With the generator set running, shut off the gas
5
supply.

3. Run the generator set until the engine stops.

4
4. Place the generator set master switch in the
OFF/RESET position.

3.10.3 Cylinder Lubrication

1. LED indicators 4. Fuse

1. Remove the spark plugs.
2. Mounting flanges 5. AC power cord 2. Pour one tablespoon of engine oil into each spark
3. Battery leads, 12 VDC
plug hole. Install the spark plugs and ground the
Figure 3-11 6-Amp Float/Equalize Battery Charger spark plug leads. Do not connect the leads to the
plugs.
Periodically tighten all connections. No other
maintenance on the battery charger is required. 3. Toggle the generator set master switch to crank the
engine two or three revolutions to lubricate the
cylinders.
3.10 Storage Procedure
Perform the following storage procedure before 3.10.4 Exterior Preparation
removing the generator set from service for three
months or longer. Follow the engine manufacturer’s 1. Clean the exterior surface of the generator set.
recommendations for storage, if available.
2. Seal all openings in the engine with nonabsorbent
Note: Run the generator set monthly whenever adhesive tape.
possible.
3. Mask all areas to be used for electrical contact.

3.10.1 Lubricating System 4. Spread a light film of oil over unpainted metallic
surfaces to prevent rust and corrosion.
1. Operate the generator set until it reaches operating
temperature, or about 15 minutes.

TP-6195 1/04 Section 3 Scheduled Maintenance 17

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
OFF/RESET position. 5. Connect the battery to a float/equalize battery
charger, or charge the battery monthly using a
2. Disconnect the battery, negative (--) lead first. trickle charger. Follow the battery charger
manufacturer’s recommendations.

18 Section 3 Scheduled Maintenance TP-6195 1/04

 Section 4 Troubleshooting

4.1 Introduction dealer. Maintain a record of repairs and adjustments

performed on the equipment. Use the record to help
Use the following charts to diagnose and correct describe the problem and repairs or adjustments made
common problems. First check for simple causes such to the equipment.
as a dead engine starting battery, loose connections, or
an open circuit breaker. The charts include a list of 4.2 Generator Set Troubleshooting
common problems, possible causes of the problem, and
recommended corrective actions. Figure 4-1 contains generator set troubleshooting,
diagnostic, and repair information. Check for loose
If the procedures in this manual do not explain how to connections before replacing parts.
correct the problem, contact an authorized distributor/

Problem Possible Cause Corrective Action

The generator set Battery weak or dead Check power to the battery charger.
does not crank. Recharge or replace the battery.
Battery charger fuse blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Battery connections reversed or poor Check the connections.
Controller fuse (F3) blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Relay interface board fuse (F2) blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.
Generator set master switch in the OFF position Move the master switch to the RUN position.
The generator
g set Air cleaner clogged Clean and/or replace the air cleaner.
cranks
k but
b does
d not
Battery weak or dead Check power to the battery charger.
start, starts hard, lacks
Recharge or replace the battery.
power or operates
power,
y
erratically. Battery connection poor Clean and tighten the battery connections.
Spark plug wire connection loose Check the spark plug wires.
Low oil pressure shutdown Check the oil level.
Fuel pressure insufficient Check the fuel supply and valves.
Engine malfunction Contact the distributor/dealer.
No AC output.
p AC circuit breaker in the OFF position Place the circuit breaker in the ON position.
AC circuit breaker tripping because of overload Reduce the load on the generator set.
AC circuit breaker tripping because of short circuit Contact an authorized distributor/dealer for service.
Low output or Generator set overloaded Reduce the load.
excessive drop in
voltage.
Generator set stops
p Low oil pressure shutdown Check the oil level.
suddenly.
dd l
Out of fuel Check fuel supply.
Overcrank shutdown Reset the controller. If the overcrank fault occurs again,
contact the distributor/dealer.
Controller fuse (F3) blown Replace the fuse. If the fuse blows again, contact the
distributor/dealer.
Overspeed shutdown Reset the controller. If the overspeed fault occurs again,
contact the distributor/dealer.
Generator set master switch in the OFF/RESET Move the switch to the correct position (RUN or AUTO).
position
Remote stop command received from a remote switch Check the remote switch position.
or ATS
Engine malfunction Contact the distributor/dealer.
Auxiliary winding fuse (F1) blown Replace the fuse. Contact an authorized distributor/dealer
for service if fuse blows repeatedly.

Figure 4-1 General Troubleshooting Chart

TP-6195 1/04 Section 4 Troubleshooting 19

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.
Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Section 2.3.5.

4.4 Controller Troubleshooting

Figure 4-2 contains troubleshooting, diagnostic, and
repair information for the Advanced Digital Control.

Problem Possible Cause Corrective Action

Controller LED display No power to the controller:
is off Continuous power mode jumper is disconnected Controller display will automatically activate when a remote
and the generator set has not run for 48 hours or start command is received or the generator set master
longer. switch is moved to the RUN position. Connect the jumper
to maintain continuous power to the controller, if desired.
See Sections 2.3.6 and 6.9.3.
Controller fuse (F3) is blown. Replace the fuse. If the fuse blows again, contact the
distributor/dealer.
Low or no battery voltage. Check connections.
Check generator set battery and battery charger. See
Figure 4-1.
Generator set master switch is in the OFF/RESET Move generator set master switch to the AUTO or RUN
position. position.
Generator set master switch in AUTO but no start No action required (see Section 2.3.1). Controller display
command has been received since last controller will activate when a remote start command is received or
reset. the generator set master switch is moved to the RUN
position. Use the remote switch to start generator set and
activate the controller display, if desired.

Figure 4-2 Controller Troubleshooting Chart

Problem Cause Solution

Red LED stays
y One or more defective or damaged cells. Load test the battery and replace, if necessary
on for
f more th
than Battery charger has reduced its output voltage below Remove the source of the overload or short. Disconnect the
24 hours
the normal level due to a DC overload or a DC short. battery charger’s black (NEGATIVE) ring terminal from the
battery. Reapply AC power and the green LED only should now
light.
Onboard DC systems are drawing more current than Turn off all DC equipment while charging.
the battery charger can replace.
Red and green Onboard DC systems are drawing between 1.5 and Turn off all DC equipment while charging.
LEDs stayy on for 5 amps.
more th
than
One or more defective or damaged cells. Load test the battery and replace, if necessary
24 hours
Extremely low AC voltage at the battery charger. Apply a higher AC voltage source or reduce the length of the
extension cord.
Green LED staysy Open DC output fuse. Replace AGS-10 fuse.
on when
h theth
Faulty or contaminated terminal connections. Clean and tighten or repair all terminal connections.
battery is known
to be low One or more defective or damaged cells. Load test the battery and replace, if necessary.
Neither of the No AC power available at the battery charger. Connect AC power or reset the AC breaker on the main panel.
LEDs turn on
when the AC Component failure. Replace battery charger.
power is applied

Figure 4-3 Battery Charger Troubleshooting

20 Section 4 Troubleshooting TP-6195 1/04

 Section 5 Wiring Diagrams

5.1 Specification Numbers 5.2 Controller Wiring Diagram

Reference
At the time of print, this manual applied to the model
numbers and specification (spec) numbers in Figure 5-2 lists the wiring diagram numbers and
Figure 5-1. On occasion the manufacturer may provide locations.
this manual with units that are not listed below, such as
when similar new specs are created prior to the updated Drawing
reprint or in other cases when the manual is a suitable Wiring Diagram Description Number Page
substitute for a manual under development. Schematic Diagram
Sheet 1 ADV-6835A 22
Model No. Spec. No. Sheet 2 ADV-6835B 23
8.5RES GM29253-GA1 Point-to-Point Wiring Diagram GM29358 24
12RES GM29253-GA2
Figure 5-2 Controller Wiring Diagrams
Figure 5-1 Generator Set Specification Numbers

TP-6195 1/04 Section 5 Wiring Diagrams 21

 -

Figure 5-3 8.5/12RES Schematic Diagram, Single Phase, Sheet 1, ADV-6835A-A

22 Section 5 Diagrams and Drawings TP-6195 1/04

 ADC 2100 CONTROLLER RELAY INTERFACE BOARD

Figure 5-4

TP-6195 1/04
P1 CONNECTIONS P13 CONNECTIONS
P1--1 STARTER RELAY OUT P13--1 RUN RELAY COMMON 3 1
24 1 ADC2100 RIB
P1--2 SPARE OUTPUT P13--2 COMMON FAULT COMMON
P1--3 COMMON FAULT P13--3 COMMON FAULT NC 3 2 1 P7
P1--4 GOVERNOR 1B P13--4 RUN RELAY NO
P1--5 GOVERNOR 1A P13--5 RUN RELAY NC 6 P13 4
P1--6 GOVERNOR 2A P13--6 COMMON FAULT NO 3 1
P14
P1--7 GOVERNOR 2B
P1--8 COOLANT TEMP SENSOR HIGH
P1--9 COOLANT TEMP SENSOR LOW
P1--10 EXTERNAL CAN H
P1--11 EXTERNAL CAN L P14 CONNECTIONS
P1
P1--12 AUX SHUTDOWN P14--1 FUEL/AUX RUN RELAY CONTROL 9 7
P1--13 FUEL RELAY OUT P14--2 COMMON FAULT RELAY CONTROL T1FN
P1--14 TACH OUT P14--3 STARTER RELAY CONTROL
P1--15 OIL PRESSURE SWITCH P14--4 IGNITION NEGATIVE T2 FP
P1--16 GROUND P14--5 FLASH RELAY CONTROL
P1--17 VR SENSOR LOW P14--6 VBAT
P1--18 GROUND P14--7 FUEL (70A) J16
P1--19 PRESSURE SENSOR GROUND P14--8 GROUND
RED BLK
P1--20 GROUND P14--9 STARTER (71A) 4 1
35 12
P1--21 GROUND FL
P1--22 GROUND 5 2
5 6 3
P1--23 GROUND 9
4 YEL ORG
P1--24 VBAT + 8 P5
3
7 OFF/RESET
P1--25 REMOTE START/STOP 1 2
6
P1--26 REMOTE START/STOP 2 1
RUN AUTO
P1--27 GROUND J15
P1--28 COOLANT LEVEL/LOSS HIGH BLU
AUTO 1
P1--29 VR SENSOR HIGH VBAT 2
P1--30 PRESSURE SENSOR SOURCE RUN VIO
P1--31 PRESSURE SENSOR SIGNAL 3
P1--32 GROUND GRY
P1--33 VBAT ON
P1--34 GROUND
P1--35 RS232 TXD

P5 CONNECTIONS
P5--1 N/C
P5--2 RS232 RXD
P5--3 RS232 TXD
P5--4 N/C
P5--5 GROUND
P5--6 N/C
P5--7 N/C
P5--8 N/C

8.5/12RES Schematic Diagram, Single Phase, Sheet 2, ADV-6835B

P5--9 N/C

P7 CONNECTIONS
P7--1 N/C
P7--2 CONTINUOUS POWER MODE SELECT
P7--3 GROUND

J16 CONNECTIONS
P16--1 FIELD DRIVE PLUS (G)
P16--2 FLASH RELAY OUT
P16--3 AUX WINDING INPUT (55)
P16--4 FIELD DRIVE MINUS (F+)
P16--5 N/C
P16--6 AUX WINDING INPUT (66)

J15 CONNECTIONS
J15--1 AC INPUT (V7/11)
J15--2 AC INPUT (V8)
J15--3 AC INPUT (V9/44)

Section 5 Diagrams and Drawings

23
-
Figure 5-5 8.5/12RES Point-to-Point Wiring Diagram, Single Phase, GM29358-B

24 Section 5 Diagrams and Drawings TP-6195 1/04

 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. Do not install this generator set indoors. Figure 6-1. Do not install the generator set where
The generator set installation must comply with state exhaust gas could accumulate and seep inside or be
and local code requirements. drawn into a potentially occupied building. Mount the
generator set so that the hot exhaust does not blow on
Use the specifications provided here only in the initial plants or other combustible materials.
planning. Use the generator set and transfer switch
spec sheets, dimension drawings, and wiring diagrams See Figure 6-1 for the generator set dimensions and
for installation. Contact an authorized service fuel and electric inlet locations. The drawing
distributor/dealer for the most current information. dimensions are shown in millimeters, with inches in
brackets.
6.2 Weight The generator set is shipped on a plastic mounting pad.
Prepare a flat, level mounting area covered with gravel
WARNING or compacted soil. Set the plastic mounting pad directly
on the gravel or compacted soil. Do not install the
mounting pad directly on the grass.

6.5 Exhaust Requirements

Unbalanced weight.
Improper lifting can cause severe WARNING
injury or death and equipment
damage.

Do not use lifting eyes.

Lift the generator set using lifting bars
inserted through the lifting holes on Carbon monoxide.
the skid. Can cause severe nausea,
fainting, or death.

The generator set weighs approximately 186 kg The exhaust system must be
leakproof and routinely inspected.
(410 lb.). Use lifting bars inserted through the holes in
the skid to lift the unit. See Figure 6-1 for lifting hole
Generator set operation. Carbon monoxide can cause
locations.
severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
6.3 Generator Set Inspection death if inhaled for even a short time. Avoid breathing exhaust
fumes when working on or near the generator set. Never
Complete a thorough inspection of the generator set. operate the generator set inside a building. Never operate the
Check for the following: generator set where exhaust gas could seep inside or be
drawn into a potentially occupied building through windows, air
1. Inspect the generator set for loose or damaged intake vents, or other openings.
parts or wires. Repair or tighten any loose parts
before installation. The exhaust system is complete for generator sets
installed outdoors. Do not install this generator set
2. Check the engine oil. Fill, if necessary, with the indoors.
recommended make and grade of oil. See
Section 3.3.3 for engine oil recommendations.

TP-6195 1/04 Section 6 Installation 25

 Note: Dimensions in [ ] are in inch equivalents.

Figure 6-1 Generator Set Mounting Details and Dimensions, ADV-6823-B

26 Section 6 Installation TP-6195 1/04

Figure 6-2 gives the exhaust flow and temperature at 6.7 Power Supply
rated load. Mount the generator set so that the hot
exhaust does not blow on plants or other combustible Utility power must be supplied to the generator set
materials. location. Provide a 110- or 120-volt outlet connected to
Exhaust System 60 Hz 50 Hz the utility power supply for the battery charger
(standard) and carburetor heater (optional). Figure 6-5
Exhaust flow at rated kW, m3/min. (cfm)
lists the battery charger power requirements.
8.5RES 3.3 (115) 2.7 (96)
12RES 3.8 (135) 3.2 (113) Input Requirement
Exhaust temperature at rated kW, dry Rated AC voltage 90--135 VAC, 50/60 Hz
exhaust, _C (_F) 816 (1500) Current draw 1.6 amp at full output

Figure 6-2 Exhaust Flow and Temperature Figure 6-5 Battery Charger Power Requirements

6.6 Air Requirements 6.8 Fuel System

The generator set requires correct air flow for cooling The generator set operates using natural gas or LP
and combustion. The inlet and outlet openings in the vapor fuel. The multi-fuel system allows conversion
sound enclosure provide the cooling and combustion from natural gas to LP vapor (or vice-versa) in the field
air. Figure 6-3 shows the locations of the cooling air while maintaining emissions-standard compliance. A
intake and exhaust vents. Inspect the air inlet and outlet trained technician or authorized distributor/dealer can
openings inside and outside the housing to ensure that convert the fuel system. Generator sets with multi-fuel
the air flow is not blocked. systems are CARB- and EPA-certified for both natural
gas and LP vapor fuels.

3 6.8.1 Fuel Supply

1
Comply with local, state, and federal codes regarding
the correct storage of fuel. Because of variable climates
and geographical considerations, contact an authorized
service distributor/dealer for fuel system planning and
installation.

2 3 Figure 6-1 shows the location of the fuel inlet

tp6195
1. Exhaust outlet connection. Bring the fuel supply lines through the rear
2. Alternator air intake (both sides)
access opening. Use flexible sections to prevent fuel
3. Engine air intake
line breakage caused by vibration. Remove the housing
Figure 6-3 Cooling Air Intake and Exhaust end panel and hold the fuel solenoid valve with a wrench
when tightening the fuel connections. Protect all fuel
8.5RES 12RES
Cooling Air lines from machinery or equipment contact, adverse
Requirements 60 Hz 50 Hz 60 Hz 50 Hz weather conditions, and environmental damage.
Cooling air,
m3/min. (cfm) 26.9 (950) 22.4 (790) 26.9 (950) 22.4 (790) Verify that the output pressure from the primary gas
Total inlet air utility (or LP tank) pressure regulator is 1.7--2.7 kPa
requirement,
m3/min. (cfm) 27.8 (980) 23.2 (820) 28.0 (990) 23.4 (825) (7--11 in. water column) and that the utility gas meter
Combustion air,
flow rate is sufficient to supply the generator set plus all
m3/min. (cfm) 0.94 (33.4) 0.8 (28.0) 1.1 (39.2) 0.9 (32.6) other gas-consuming appliances. Figure 6-8 shows the
Figure 6-4 Cooling Air Requirements flow rate required for the generator set. Figure 6-6 lists

TP-6195 1/04 Section 6 Installation 27

the recommended fuel ratings for natural gas and LP 6.8.2 Fuel Pipe Size
vapor fuels. Contact the natural gas utility for flow rate
information or a gas meter upgrade. Ensure that the natural gas pipe size and length meet
the specifications in Figure 6-9. Measure the pipe
Fuel System
length from the primary gas pressure regulator to the
Fuel types Natural Gas or LP Vapor
pipe connection on the generator set fuel inlet. Add
Fuel supply inlet 1/2 NPT 2.4 m (8 ft.) to the measured length for each 90 degree
Fuel supply pressure, kPa (in. H2O) 1.7--2.7 (7-11) elbow. Compare the pipe size and length with the chart
Nominal Fuel Rating Btu/ft3 MJ/m3 in Figure 6-9. If the piping is longer than the maximum
Natural gas 1000 37 length shown for that size, replace it with the specified
LP vapor 2500 93 size before proceeding.
Figure 6-6 Fuel Supply Contact the local LP provider for LP installation
Fuel information.
8.5RES 12RES
Consumption
Consumption,
Maximum Pipe Length m (ft.)
m3/hr. (cfh) 60 Hz 50 Hz 60 Hz 50 Hz
Pipe Size 8.5RES 12RES
Natural Gas at % load
3/4 in. NPT 18.3 (60) 9.2 (30)
100% 3.7 (132) 3.3 (118) 5.9 (209) 4.9 (175)
1 in. NPT 61 (200) 30 (100)
75% 3.2 (113) 2.9 (101) 4.8 (168) 4.0 (141)
1 1/4 in. NPT 91.5 (300) 68.6 (225)
50% 2.6 (93) 2.3 (83) 3.6 (127) 3.0 (106)
Figure 6-9 Maximum Natural Gas Pipe Length
25% 2.2 (77) 1.9 (69) 2.4 (85) 2.0 (71)
LP Vapor at % load
100% 2.0 (72) 1.7 (61) 3.1 (108) 2.5 (89) 6.8.3 Fuel Conversion
75% 1.3 (45) 1.1 (38) 2.5 (87) 2.0 (72)
50% 1.0 (36) 0.9 (31) 1.9 (65) 1.5 (53)
WARNING
25% 0.8 (29) 0.7 (25) 1.2 (44) 1.0 (36)
LP vapor conversion factors:
8.58 ft3 = 1 lb.
36.39 ft3 = 1 gal.

Figure 6-7 Fuel Consumption Accidental starting.

Can cause severe injury or death.
Gas Flow Rate
Generator Set Model Btu/hr. MJ/hr. Disconnect the battery cables before
8.5RES 132,000 139 working on the generator set.
12RES 202,000 213
Remove the negative (--) lead first
when disconnecting the battery.
Figure 6-8 Natural Gas Flow Rate Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.

28 Section 6 Installation TP-6195 1/04

 WARNING 1 2

Explosive fuel vapors.

Can cause severe injury or death.
Use extreme care when handling, 3
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.
1. DSAM connector location GM29253

Two fuel connections on the fuel block allow field- 2. Fuel block
3. Fuel inlet, 1/2 in. NPT female
conversion between natural gas and LP vapor. The fuel
metering valves are factory-set and sealed to comply Figure 6-10 Fuel System Locations, Air Inlet Side
with applicable emission standards and to provide the
best possible hot and cold starting. 1
2
Note: Do not adjust the factory-sealed fuel-metering 5
adjustments on the fuel block. Changing the 4
fuel-metering adjustments may violate federal or
state laws.

Use the following procedure to convert from natural gas

to LP vapor, moving the fuel connection from the natural
gas to the LP port, plugging the natural gas port, and
connecting the DSAM leads. See Figure 6-10 for the
fuel system component locations. 3

Fuel Conversion Procedure

1. Place the generator set master switch in the OFF

position.
tp6195

2. Disconnect the power to the battery charger. 1. Fuel block

2. Fuel metering valves—factory-sealed, do not adjust
3. Fuel inlet, 1/2 in. NPT
3. Disconnect the generator set engine starting 4. Hose fitting
battery, negative (--) lead first. 5. Plug

4. Turn off the fuel supply. Figure 6-11 Fuel Block Connections, Natural Gas
System Shown
5. Remove the hose clamp and fuel hose from the
hose fitting in the fuel block. See Figure 6-11.

6. Remove the hose fitting from the natural gas outlet

port in the fuel block. See Figure 6-11.

TP-6195 1/04 Section 6 Installation 29

 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
into the natural gas outlet port. To convert from LP vapor to natural gas, follow the same
fuel conversion procedure, moving the hose fitting to the
8. Clean the hose fitting with a dry cloth or brush, natural gas port and plugging the LP port. For the
apply fresh pipe sealant to the threads, and install 12RES model, disconnect the DSAM leads for LP vapor.
the fitting into the LP port. See Figure 6-12.

Note: Do not adjust the fuel metering valves.

9. Slide the hose onto the hose fitting and secure it

with the clamp.

10. For the 12RES only: Connect the digital

spark-advance module (DSAM) leads together for
natural gas. (Disconnect the leads for LP.) See
Figure 6-12.

11. Connect and turn on the new fuel supply.

12. Check that the generator set master switch is in the

OFF position.

13. Reconnect the generator set engine starting tp6195

battery leads, negative (--) lead last. 1

14. Reconnect power to the battery charger. 1. DSAM leads: connect for natural gas, disconnect for LP.

15. Start the generator set by moving the generator set Figure 6-12 Digital Spark Advance Module (DSAM)
master switch to the RUN position. Leads (located in generator set air intake
area)
16. Check for leaks using a gas leak detector.

30 Section 6 Installation TP-6195 1/04

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.

2. Connect the L0 white leads from the ATS and the

main panel to the neutral terminal.
Hazardous voltage. 3. Connect the green lead to the equipment ground
Backfeed to the utility system can
terminal (labeled GRD).
cause property damage, severe
injury, or death.
Verify that the electrical installation complies with the
If the generator set is used for National Electrical Code (NEC) and all applicable local
standby power, install an automatic and state codes.
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply. 1
2
Grounding electrical equipment. Hazardous voltage can 3
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical Bottom of Junction Box
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of
electrocution.
1
Electrical backfeed to the utility. Hazardous backfeed
voltage can cause severe injury or death. Install a transfer
switch in standby power installations to prevent the connection
of standby and other sources of power. Electrical backfeed
into a utility electrical system can cause severe injury or death
to utility personnel working on power lines.
2,
NOTICE 3
Canadian installations only. For standby service connect
the output of the generator set to a suitably rated transfer
switch in accordance with Canadian Electrical Code, Part 1.

Have an authorized distributor/dealer or a licensed

electrician make the following load connections. Verify
that the electrical installation complies with the National GM29253A-F
1. Line circuit breaker
Electrical Code (NEC) and all applicable local and state 2. Ground terminal (GRD)
codes. 3. Neutral terminal (L0)

Connect the AC output leads in the controller Figure 6-13 Field-Installed Wiring Connections
compartment to the AC circuit breaker. Route AC leads
through flexible conduit directly to the AC circuit breaker
box. See Figure 6-1 for the recommended electrical
inlet location. Verify that the leads and conduit do not
interfere with the operation of the generator set or
obstruct the service areas.

TP-6195 1/04 Section 6 Installation 31

6.9.2 Remote Start Connection 4. Locate the P7 connector near the top of the
(optional) controller. See Figure 6-14. Remove the jumper
from pins 1 and 2 of the P7 connector. If the P7
Connect leads 3 and 4 from the ADC 2100 controller to connector has three pins, connect the jumper
the automatic transfer switch’s engine start terminals or across pins 2 and 3 for storage.
to an optional remote start/stop switch.
5. Replace the controller’s back cover and secure the
cover screws.
6.9.3 Continuous Power Mode Jumper 6. Reconnect the three pink connectors to the
generator set master switch.
A jumper on connector P7 on the back of the controller
causes the controller to remain powered at all times. 7. Reconnect the J15 and J16 connectors.
See the wiring diagram and schematic drawing in
Section 5. Controllers are shipped from the factory with 8. Reconnect the generator set engine starting
the jumper connected. Disconnecting the jumper allows battery, negative (--) lead last.
the controller to power down 48 hours after the
generator set shuts down. See Section 2.3.6. 9. Reconnect power to the battery charger.

Note: For most applications, it is not necessary to 10. Place the generator set master switch in the AUTO
disconnect the continuous power mode jumper. position.

Use the following procedure to disconnect the jumper, if

2
desired.
1
Procedure to disconnect the continuous power
mode jumper (optional).

1. Prevent the generator set from starting.

a. Move the generator set master switch to the

OFF/RESET position.

b. Disconnect power to the battery charger.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

2. Remove the controller from the generator set

housing.

a. Disconnect the engine wiring harness

connector P1 plug (35-pin) from the controller.
Disconnect the J15 and J16 connectors. See
Figure 6-14.
5 4 3
b. Remove the controller from the generator set tp6195
housing in order to access the back of the 1. Engine wiring harness connector plug (P1)
controller. 2. Continuous power mode jumper location (P7)
3. J15 connector
4. J16 connector
3. Remove the controller’s back cover to access the
5. Generator set master switch connectors
jumper.
Figure 6-14 Advanced Digital Control Connections
a. Note the labels on the three leads connected to
the generator set master switch for
reconnection later. Disconnect the leads at the
pink connectors. See Figure 6-14.

b. Remove the cover screws and remove the

controller’s back cover. See Figure 6-14.

32 Section 6 Installation TP-6195 1/04

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. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.
Sulfuric acid in batteries.
Battery gases. Explosion can cause severe injury or
Can cause severe injury or death.
death. Battery gases can cause an explosion. Do not smoke
Wear protective goggles and or permit flames or sparks to occur near a battery at any time,
clothing. Battery acid may cause particularly when it is charging. Do not dispose of a battery in a
blindness and burn skin. fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
WARNING touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.
Explosion.
Can cause severe injury or death. Battery short circuits. Explosion can cause severe injury
Relays in the battery charger or death. Short circuits can cause bodily injury and/or
cause arcs or sparks. equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
Locate the battery in a well-ventilated
area. Isolate the battery charger from servicing the equipment. Use tools with insulated handles.
explosive fumes. Remove the negative (--) lead first when disconnecting the
battery. Reconnect the negative (--) lead last when
Battery electrolyte is a diluted sulfuric acid. Battery acid reconnecting the battery. Never connect the negative (--)
can cause severe injury or death. Battery acid can cause battery cable to the positive (+) connection terminal of the
blindness and burn skin. Always wear splashproof safety starter solenoid. Do not test the battery condition by shorting
goggles, rubber gloves, and boots when servicing the battery. the terminals together.
Do not open a sealed battery or mutilate the battery case. If
Connecting the battery and the battery charger.
battery acid splashes in the eyes or on the skin, immediately
Hazardous voltage can cause severe injury or death.
flush the affected area for 15 minutes with large quantities of
Reconnect the battery correctly, positive to positive and
clean water. Seek immediate medical aid in the case of eye negative to negative, to avoid electrical shock and damage to
contact. Never add acid to a battery after placing the battery in the battery charger and battery(ies). Have a qualified
service, as this may result in hazardous spattering of battery electrician install the battery(ies).
acid.

TP-6195 1/04 Section 6 Installation 33

Use a 12-volt battery with a minimum rating of 675 cold 6. Connect the positive (+) lead to the engine starting
cranking amps at 0_F. The generator set uses a battery.
negative ground with a 12-volt engine electrical system.
See Figure 6-15 for battery connections. Make sure 7. Connect the negative (--) lead to the engine starting
that the battery is correctly connected and the terminals battery.
are tight.
Refer to Section 3.8 for battery maintenance
Note: The generator set will not start and circuit board instructions.
damage may occur if the battery is connected in
reverse. 6.9.5 Battery Charger
Figure 6-16 shows the location of the engine starting The generator set requires an external battery charger
battery. Standard battery cables provide easy to keep the starting battery fully charged. A 6-amp
connection to the battery. Use the following procedure battery charger is factory-installed in the battery
to install and connect the battery. compartment. The battery charger’s DC leads are
factory-connected.
Battery Installation Procedure
Plug the battery charger’s power cord into a 120 VAC
1. Ensure that the starting battery is fully charged outlet on the load side of the system. Refer to Section
before placing the battery in service. 2.5 for battery charger operation information.

2. Clean the battery posts and/or adapters if

necessary.

3. Install the battery post adapters, if needed.

4. Place the battery in the housing.

5. Verify that the controller master switch is in the OFF

position.
1
1 2

GM29253

EZ-273000-J
1. Engine starting battery location
1. To positive (+) terminal on starter solenoid.
2. To ground (--) terminal on or near starter motor. Figure 6-16 Battery Location, Air Intake End

Figure 6-15 12-Volt Engine Electrical System Single

Starter Motor Typical Battery Connection

34 Section 6 Installation TP-6195 1/04

6.10 Accessories
Have accessories installed by an authorized 1
distributor/dealer or a licensed electrician. Follow the 2
installation instructions provided with each kit. Use
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. Verify that
the electrical installation complies with the National
Electrical Code (NEC) and all applicable local and state
codes. See Section 5, Wiring Diagrams, for more
information regarding generator set electrical
connections.

6.10.1 Common Fault and Run Relay

Board GM30414

1. Relay board
The optional relay board provides two additional relays 2. Relay board harness
to control customer-provided equipment:
Figure 6-17 Common Fault and Run Relay Board
D Common fault relay
Harness
Lead Connector
D Auxiliary run relay Number Pin Number Connection
88 6 Common fault normally open
The optional relay board replaces the standard relay
89 2 Common fault common
board. The relay board location is shown in Figure 6-17.
90 3 Common fault normally closed
Connect customer equipment to the relay board
91 4 Run relay normally open
harness. Figure 6-18 lists the customer connections.
92 1 Run relay common
The common fault relay is energized on a fault. The 93 5 Run relay normally closed
auxiliary run relay is energized when the generator set is
running. Connect to each relay’s normally open or
normally closed contacts depending on the application.

Figure 6-18 Common Fault and Run Relay Board

Harness Connections

TP-6195 1/04 Section 6 Installation 35

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 1 2
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).

The heater requires a continuous source of 120 VAC

power. The heater power cord and thermostat are
located in the generator set housing air intake
area/battery compartment. See Figure 6-16. Plug the
carburetor heater into an outlet that supplies continuous
120 VAC power.

The heater thermostat is installed in the cord.

Figure 6-20 shows the location of the thermostat on the
power cord. tp6195
1. Carburetor heater (air cleaner removed to show heater)
Note: Do not place the heater thermostat inside the 2. Carburetor heater power cord
generator set engine compartment. The
thermostat must be exposed to the ambient air. Figure 6-19 Carburetor Heater
The thermostat will shut off power to the heater
when the ambient temperature reaches
approximately 60_F (16_C).

1 2 3

GM19463
1. Thermostat
2. Connector
3. Heater

Figure 6-20 Carburetor Heater with Thermostat

36 Section 6 Installation TP-6195 1/04

6.11 Controller Configuration 6.12 Prestart Installation Check
Review the entire installation section. Inspect all wiring
6.11.1 System Configuration and connections to verify that the generator set is ready
The system configuration is factory-set and should not for operation. Check that there are no obstructions to
normally require changes in the field. However, the the air inlet and outlet. Check all items in the Prestart
controller’s configuration modes allow setting of the Checklist. See Section 2.1.
system voltage/frequency and adjustment of the output
voltage and frequency after reconnection. Have 6.13 Warranty Registration
reconnection and the related adjustments performed by
an authorized distributor/dealer or service technician. Complete the startup procedure and installation
checklists supplied with the startup notification form.
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
to:
not be changed in the field.
Kohler Power Systems
Generator Warranty Administrator
6.11.2 Advanced Configuration Mode M.S. 072
The controller’s advanced configuration mode allows a Kohler, Wisconsin 53044
technician to set the data input type for different
senders, change the battery voltage to 12 or 24 VDC if
the battery voltage is changed in the field, and change
the controller communications setting for field-installed
meters. Have these adjustments performed by an
authorized distributor/dealer or service technician.

TP-6195 1/04 Section 6 Installation 37

 Notes

38 Section 6 Installation TP-6195 1/04

 Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.
A, amp ampere cfh cubic feet per hour est. estimated
ABDC after bottom dead center cfm cubic feet per minute E-Stop emergency stop
AC alternating current CG center of gravity etc. et cetera (and so forth)
A/D analog to digital CID cubic inch displacement exh. exhaust
ADC analog to digital converter CL centerline ext. external
adj. adjust, adjustment cm centimeter F Fahrenheit, female
ADV advertising dimensional CMOS complementary metal oxide fglass. fiberglass
drawing substrate (semiconductor) FHM flat head machine (screw)
AHWT anticipatory high water cogen. cogeneration fl. oz. fluid ounce
temperature com communications (port) flex. flexible
AISI American Iron and Steel coml commercial freq. frequency
Institute Coml/Rec Commercial/Recreational
ALOP anticipatory low oil pressure FS full scale
conn. connection ft. foot, feet
alt. alternator cont. continued
Al aluminum ft. lbs. foot pounds (torque)
CPVC chlorinated polyvinyl chloride ft./min. feet per minute
ANSI American National Standards crit. critical
Institute g gram
(formerly American Standards CRT cathode ray tube ga. gauge (meters, wire size)
Association, ASA) CSA Canadian Standards gal. gallon
AO anticipatory only Association gen. generator
API American Petroleum Institute CT current transformer genset generator set
approx. approximate, approximately Cu copper GFI ground fault interrupter
AR as required, as requested cu. in. cubic inch
cw. clockwise GND, ground
AS as supplied, as stated, as
suggested CWC city water-cooled gov. governor
ASE American Society of Engineers cyl. cylinder gph gallons per hour
ASME American Society of D/A digital to analog gpm gallons per minute
Mechanical Engineers DAC digital to analog converter gr. grade, gross
assy. assembly dB decibel GRD equipment ground
ASTM American Society for Testing dBA decibel (A weighted) gr. wt. gross weight
Materials DC direct current HxWxD height by width by depth
ATDC after top dead center DCR direct current resistance HC hex cap
ATS automatic transfer switch deg., ° degree HCHT high cylinder head temperature
auto. automatic dept. department HD heavy duty
aux. auxiliary dia. diameter HET high exhaust temperature,
A/V audiovisual high engine temperature
DI/EO dual inlet/end outlet
avg. average hex hexagon
DIN Deutsches Institut fur Normung
AVR automatic voltage regulator e. V. Hg mercury (element)
AWG American Wire Gauge (also Deutsche Industrie HH hex head
AWM appliance wiring material Normenausschuss) HHC hex head cap
bat. battery DIP dual inline package HP horsepower
BBDC before bottom dead center DPDT double-pole, double-throw hr. hour
BC battery charger, battery DPST double-pole, single-throw HS heat shrink
charging DS disconnect switch hsg. housing
BCA battery charging alternator DSAM digital spark-advance module HVAC heating, ventilation, and air
BCI Battery Council International DVR digital voltage regulator conditioning
BDC before dead center E, emer. emergency (power source) HWT high water temperature
BHP brake horsepower EDI electronic data interchange Hz hertz (cycles per second)
blk. black (paint color), block EFR emergency frequency relay IC integrated circuit
(engine) e.g. for example (exempli gratia) ID inside diameter, identification
blk. htr. block heater EG electronic governor IEC International Electrotechnical
BMEP brake mean effective pressure EGSA Electrical Generating Systems Commission
bps bits per second Association IEEE Institute of Electrical and
br. brass EIA Electronic Industries Electronics Engineers
BTDC before top dead center Association IMS improved motor starting
Btu British thermal unit EI/EO end inlet/end outlet in. inch
Btu/min. British thermal units per minute EMI electromagnetic interference in. H2O inches of water
C Celsius, centigrade emiss. emission in. Hg inches of mercury
cal. calorie eng. engine in. lbs. inch pounds
CARB California Air Resources Board EPA Environmental Protection Inc. incorporated
CB circuit breaker Agency ind. industrial
cc cubic centimeter EPS emergency power system int. internal
CCA cold cranking amps ER emergency relay int./ext. internal/external
ccw. counterclockwise ES engineering special, I/O input/output
engineered special IP iron pipe
CEC Canadian Electrical Code ESD electrostatic discharge
cert. certificate, certification, certified

TP-6195 1/04 Appendix A-1

ISO International Organization for MS military standard RH round head
Standardization m/sec. meters per second RHM round head machine (screw)
J joule MTBF mean time between failure rly. relay
JIS Japanese Industry Standard MTBO mean time between overhauls rms root mean square
k kilo (1000) mtg. mounting rnd. round
K kelvin MW megawatt ROM read only memory
kA kiloampere mW milliwatt rot. rotate, rotating
KB kilobyte (210 bytes) µF microfarad rpm revolutions per minute
kg kilogram N, norm. normal (power source) RS right side
kg/cm2 kilograms per square NA not available, not applicable RTV room temperature vulcanization
centimeter nat. gas natural gas SAE Society of Automotive
kgm kilogram-meter NBS National Bureau of Standards Engineers
kg/m3 kilograms per cubic meter NC normally closed scfm standard cubic feet per minute
kHz kilohertz NEC National Electrical Code SCR silicon controlled rectifier
kJ kilojoule NEMA National Electrical s, sec. second
km kilometer Manufacturers Association SI Systeme international d’unites,
kOhm, kΩ kilo-ohm NFPA National Fire Protection International System of Units
kPa kilopascal Association SI/EO side in/end out
kph kilometers per hour Nm newton meter sil. silencer
kV kilovolt NO normally open SN serial number
kVA kilovolt ampere no., nos. number, numbers SPDT single--pole, double--throw
kVAR kilovolt ampere reactive NPS National Pipe, Straight SPST single--pole, single--throw
kW kilowatt NPSC National Pipe, Straight-coupling spec, specs
kWh kilowatt-hour NPT National Standard taper pipe specification(s)
kWm kilowatt mechanical thread per general use sq. square
L liter NPTF National Pipe, Taper-Fine sq. cm square centimeter
LAN local area network NR not required, normal relay sq. in. square inch
L x W x H length by width by height ns nanosecond SS stainless steel
lb. pound, pounds OC overcrank std. standard
lbm/ft3 pounds mass per cubic feet OD outside diameter stl. steel
LCB line circuit breaker OEM original equipment tach. tachometer
LCD liquid crystal display manufacturer TD time delay
ld. shd. load shed OF overfrequency TDC top dead center
LED light emitting diode opt. option, optional TDEC time delay engine cooldown
Lph liters per hour OS oversize, overspeed TDEN time delay emergency to
Lpm liters per minute OSHA Occupational Safety and Health normal
Administration TDES time delay engine start
LOP low oil pressure OV overvoltage
LP liquefied petroleum TDNE time delay normal to
oz. ounce emergency
LPG liquefied petroleum gas p., pp. page, pages TDOE time delay off to emergency
LS left side PC personal computer TDON time delay off to normal
Lwa sound power level, A weighted PCB printed circuit board temp. temperature
LWL low water level pF picofarad term. terminal
LWT low water temperature
PF power factor TIF telephone influence factor
m meter, milli (1/1000)
ph., ∅ phase TIR total indicator reading
M mega (106 when used with SI
units), male PHC Phillips head crimptite (screw) tol. tolerance
m3 cubic meter PHH Phillips hex head (screw) turbo. turbocharger
m3/min. cubic meters per minute PHM pan head machine (screw) typ. typical (same in multiple
PLC programmable logic control locations)
mA milliampere
PMG permanent-magnet generator UF underfrequency
man. manual
pot potentiometer, potential UHF ultrahigh frequency
max. maximum
ppm parts per million UL Underwriter’s Laboratories, Inc.
MB megabyte (220 bytes)
PROM programmable read-only UNC unified coarse thread (was NC)
MCM one thousand circular mils
memory UNF unified fine thread (was NF)
MCCB molded-case circuit breaker psi pounds per square inch univ. universal
meggar megohmmeter pt. pint US undersize, underspeed
MHz megahertz PTC positive temperature coefficient UV ultraviolet, undervoltage
mi. mile PTO power takeoff V volt
mil one one-thousandth of an inch PVC polyvinyl chloride VAC volts alternating current
min. minimum, minute qt. quart, quarts VAR voltampere reactive
misc. miscellaneous qty. quantity VDC volts direct current
MJ megajoule
R replacement (emergency) VFD vacuum fluorescent display
mJ millijoule power source VGA video graphics adapter
mm millimeter rad. radiator, radius VHF very high frequency
mOhm, mΩ RAM random access memory
milliohm W watt
RDO relay driver output WCR withstand and closing rating
MOhm, MΩ ref. reference
megohm w/ with
MOV metal oxide varistor rem. remote w/o without
MPa megapascal Res/Coml Residential/Commercial wt. weight
mpg miles per gallon RFI radio frequency interference xfmr transformer
mph miles per hour

A-2 Appendix TP-6195 1/04

 KOHLER CO. Kohler, Wisconsin 53044
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