Page 2 - WARNING; California Proposition 65; Product Identification Information; Generator Set Identification Numbers; Controller Identification
Engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm. WARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts.Record the product identification...
Page 4 - Table of Contents, continued
Table of Contents, continued TP-6331 5/04 Table of Contents Section 4 Troubleshooting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Introduction 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - Safety Precautions and Instructions; Accidental Starting; Battery
TP-6331 5/04 I Safety Precautions and Instructions Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanicalequipment, including generator sets,transfer switches, switchgear, andaccessories, can cause bodily harmand pose life-threatening danger whenimproperly installed, op...
Page 6 - Exhaust System
TPTPS-6331 5/04 II Safety Precautions and Instructions Battery gases. Explosion can causesevere injury or death. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of a battery in a fire. To...
Page 7 - Fuel System
TP-6331 5/04 III Safety Precautions and Instructions Fuel System Explosive fuel vapors.Can cause severe injury or death. Use extreme care when handling,storing, and using fuels. WARNING The fuel system. Explosive fuel vapors can cause severe injury ordeath. Vaporized fuels are highly explosive. Use ...
Page 8 - Heavy Equipment; Hot Parts; Moving Parts
TPTPS-6331 5/04 IV Safety Precautions and Instructions Welding on the generator set. Cancause severe electrical equipmentdamage. Before welding on the generator set perform the followingsteps: (1) Remove the battery cables,negative (--) lead first. (2) Disconnectall engine electronic control module(...
Page 9 - Notice
TP-6331 5/04 V Safety Precautions and Instructions Servicing the generator set when itis operating. Exposed moving partscan cause severe injury or death. Keep hands, feet, hair, clothing, andtest leads away from the belts andpulleys when the generator set isrunning. Replace guards, screens, andcover...
Page 10 - Notes
TPTPS-6331 5/04 VI Safety Precautions and Instructions Notes
Page 11 - Introduction; Nameplate
TP-6331 5/04 i Introduction Introduction This manual provides operation and maintenanceinstructions for model 8.5RES and 12RES generatorsets equipped with the Kohler r Advanced Digital Control (ADC 2100). This generator set is approved for use in stationaryapplications in locations served by a relia...
Page 12 - Service Assistance
TP-6331 5/04 ii Service Assistance tp6195 Figure 3 Air Index Label, 8.5/12RES This engine/generator is certified to operate usingnatural gas or propane fuel. The Emission Compliance Period referred to on theEmission Control or Air Index label indicates the number of operating hours for which the eng...
Page 13 - Section 1 Features; Advanced Digital Control
TP-6331 5/04 1 Section 1 Features Section 1 Features 1.1 Specifications The generator set specification sheets provide specificgenerator and engine information. Refer to the specsheet for data not supplied in this manual. Consult thegenerator set service manual, engine operation manual,and engine se...
Page 15 - Section 2 Operation; Prestart Checklist
TP-6331 5/04 3 Section 2 Operation Section 2 Operation 2.1 Prestart Checklist To ensure continued satisfactory operation, perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In addition, some checks requireverific...
Page 16 - Stopping Generator Set
TP-6331 5/04 4 Section 2 Operation 2.3.1 Controls and Indicators Figure 2-2 describes the controls and indicators locatedon the ADC 2100. The LED display indicates generatorset status as shown in Figure 2-2. With the factory-installed continuous power modejumper in place, the LED display is activate...
Page 18 - Continuous Power Mode
TP-6331 5/04 6 Section 2 Operation Code Fault Description Check HB High batteryvoltage warning Fault code is displayed if the engine starting battery voltage risesabove 16 VDC for a 12 VDC system or above 30 VDC for a24 VDC system for more than 10 seconds when the engine is notrunning. This fault co...
Page 19 - Battery Charger Operation
TP-6331 5/04 7 Section 2 Operation 2.6 Battery Charger The generator set is equipped with a 6-amp float/equalize battery charger to maintain the enginestarting battery. The charger’s power cord must be connected to a 120 VAC power source. Figure 2-5 illustrates the battery charger. The battery charg...
Page 21 - Section 3 Scheduled Maintenance; Routine Maintenance
TP-6331 5/04 9 Section 3 Scheduled Maintenance Section 3 Scheduled Maintenance Accidental starting.Can cause severe injury or death. Disconnect the battery cables beforeworking on the generator set. Remove the negative (--) lead firstwhen disconnecting the battery. Reconnect the negative (--) lead l...
Page 23 - Lubrication System; Low Oil Pressure Shutdown; Oil Change Procedure
TP-6331 5/04 11 Section 3 Scheduled Maintenance 3.3 Lubrication System See Section 3.2, Service Schedule, for oil change andoil filter replacement intervals. See Section 1.5, ServiceViews, for the oil drain, oil check, oil fill, and oil filterlocations. For extended operation, check the oil level ev...
Page 24 - Air Cleaner Element and; Precleaner Service
TP-6331 5/04 12 Section 3 Scheduled Maintenance b. Clean the gasket sealing surface of the oil filter adapter. c. Apply a light coat of clean oil to the rubber seal of the new oil filter. d. Install the new oil filter following the instructions provided with the filter. Note: Dispose of all waste ma...
Page 25 - Paper Element Service
TP-6331 5/04 13 Section 3 Scheduled Maintenance traces of detergent are eliminated. Squeeze outexcess water (do not wring). Allow the precleanerto 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. Reinst...
Page 28 - Circuit Protection; Storage Procedure
TP-6331 5/04 16 Section 3 Scheduled Maintenance 3.10 Circuit Protection If the generator set circuit breaker trips or the fuses blowrepeatedly, see Section 4, Troubleshooting, for possiblecauses. 3.10.1 Line Circuit Breaker A line circuit breaker interrupts the generator output inthe event of a faul...
Page 31 - Generator Set Troubleshooting
TP-6331 5/04 19 Section 4 Troubleshooting Section 4 Troubleshooting 4.1 Introduction Use the following charts to diagnose and correctcommon problems. First check for simple causes suchas a dead engine starting battery, loose connections, oran open circuit breaker. The charts include a list ofcommon ...
Page 32 - Troubleshooting
TP-6331 5/04 20 Section 4 Troubleshooting 4.3 Fault Codes The Advanced Digital Control displays fault codes to aidin troubleshooting. Fault codes, descriptions, and recommended actions are listed in Figure 2-3. Identify and correct the cause of the fault condition.Then reset the controller after a f...
Page 33 - Appendix A Abbreviations
TP-6331 5/04 Appendix A-1 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimension...
