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Kohler 8.5RES - page 1
Residential/Commercial Generator Sets Models: 8.5RES 12RES Controller: Advanced Digital Control (ADC 2100) TP-6331 5/04 Operation ...
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Kohler 8.5RES - page 2
Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately afte ...
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Kohler 8.5RES - page 3
T able of Contents TP-6331 5/04 T able of Contents Product Identification Information Inside front cover ............................................ Safety Precautions and Instructions I ........................................................ Introduction i ............................................................................... Service As ...
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Kohler 8.5RES - page 4
T able of Contents, continued TP-6331 5/04 T able of Contents Section 4 T roubleshooting 19 ................................................................. 4.1 Introduction 19 .......................................................... 4.2 Generator Set T roubleshooting 19 .......................................... 4.3 Fault Codes 20 ............. ...
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Kohler 8.5RES - page 5
TP-6331 5/04 I Safety Precautions and Instructions Safety Precautions and Instructions IMPORT ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear , and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. T o prevent accident ...
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Kohler 8.5RES - page 6
TPTPS-6331 5/04 II Safety Precautions and Instructions Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. T o prevent burns and sparks that could cause an ...
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Kohler 8.5RES - page 7
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. W ARNING The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuels. ...
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Kohler 8.5RES - page 8
TPTPS-6331 5/04 IV Safety Precautions and Instructions Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform the following steps: (1) Remove the battery cables, negative ( - - ) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all gener ...
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Kohler 8.5RES - page 9
TP-6331 5/04 V Safety Precautions and Instructions Servicing the generator set when it is operating. Exposed 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 guards, screens, and covers before operating the generator set. Notic ...
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Kohler 8.5RES - page 10
TPTPS-6331 5/04 VI Safety Precautions and Instructions Notes ...
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Kohler 8.5RES - page 11
TP-6331 5/04 i Introduction Introduction This manual provides operation and maintenance instructions for model 8.5RES and 12RES generator sets equipped with the Kohler r Advanced Digital Control (ADC 2100). This generator set is approved for use in stationary applications in locations served by a reliable utility power source. Have the generator se ...
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Kohler 8.5RES - page 12
TP-6331 5/04 ii Service Assistance tp6195 Figure 3 Air Index Label, 8.5/12RES This engine/generator is certified to operate using natural gas or propane fuel. The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet CARB emission require ...
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Kohler 8.5RES - page 13
TP-6331 5/04 1 Section 1 Features Section 1 Features 1.1 Specifications The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications. Ob ...
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Kohler 8.5RES - page 14
TP-6331 5/04 2 Section 1 Features 1.5 Generator Set Components 12 3 6 57 1 9 13 14 4 11 21 16 18 12 9 20 ADV- 6823 -A 1. Enclosure 2. Muffler 3. Oil check 4. Oil fill 5. Air cleaner 6. Spark plug locations (both sides) 7. ADC 2100 8. Generator set master switch (RUNOFF/RESETAUTO) 9. Nameplate 10. Line circuit breaker 1 1. Engine starting battery ...
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Kohler 8.5RES - page 15
TP-6331 5/04 3 Section 2 Operation Section 2 Operation 2.1 Prestart Checklist T o ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. Air Cleaner . Ch ...
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Kohler 8.5RES - page 16
TP-6331 5/04 4 Section 2 Operation 2.3.1 Controls and Indicators Figure 2-2 describes the controls and indicators located on the ADC 2100. The LED display indicates generator set status as shown in Figure 2-2. With the factory-installed continuous power mode jumper in place, the LED display is activated when the generator set master switch is moved ...
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Kohler 8.5RES - page 17
TP-6331 5/04 5 Section 2 Operation 2.4 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2-3 and the controller displays a fault code. The generator set cannot be restarted until the fault condition is corrected and the controller is reset. See Section 2.4.1 to reset the controller after a fault ...
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Kohler 8.5RES - page 18
TP-6331 5/04 6 Section 2 Operation Code Fault Description Check HB High battery voltage warning Fault code is displayed if the engine starting battery voltage rises 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 running. This fault condition does not inhibit engine starting. The ...
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Kohler 8.5RES - page 19
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 engine starting battery . The charger ’s power cord must be connected to a 120 V AC power source. Figure 2-5 illustrates the battery charger . The battery charger uses an AGS 10 inline fuse. The fuse is ...
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Kohler 8.5RES - page 20
TP-6331 5/04 8 Section 2 Operation Notes ...
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Kohler 8.5RES - page 21
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 before working on the generator set. Remove the negative ( - - ) lead first when disconnecting the battery . Reconnect the negative ( - - ) lead last when reconnecting the battery . W AR ...
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Kohler 8.5RES - page 22
TP-6331 5/04 10 Section 3 Scheduled Maintenance 3.2 Service Schedule Procedure System Component or Procedure See Section Visually Inspect Check Change Clean T est Frequency Fuel Flexible lines and connections X R Quarterly Main tank supply level X Weekly Fuel piping X Y early Lubrication 3.3 Oil level X X 8 hours or before use Crankcase breather ho ...
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Kohler 8.5RES - page 23
TP-6331 5/04 11 Section 3 Scheduled Maintenance 3.3 Lubrication System See Section 3.2, Service Schedule, for oil change and oil filter replacement intervals. See Section 1.5, Service Views, for the oil drain, oil check, oil fill, and oil filter locations. For extended operation, check the oil level every 8 hours. Maintain the oil level at or near ...
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Kohler 8.5RES - page 24
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 materials (engine oil, fuel, filter , etc.) in an ...
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Kohler 8.5RES - page 25
TP-6331 5/04 13 Section 3 Scheduled Maintenance traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner 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 wi ...
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Kohler 8.5RES - page 26
TP-6331 5/04 14 Section 3 Scheduled Maintenance 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 Figure 3 ...
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Kohler 8.5RES - page 27
TP-6331 5/04 15 Section 3 Scheduled Maintenance Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the n ...
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Kohler 8.5RES - page 28
TP-6331 5/04 16 Section 3 Scheduled Maintenance 3.10 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly , see Section 4, Troubleshooting, for possible causes. 3.10.1 Line Circuit Breaker A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the ...
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Kohler 8.5RES - page 29
TP-6331 5/04 17 Section 3 Scheduled Maintenance 3.1 1.3 Cylinder Lubrication 1. Remove the spark plugs. 2. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the plugs. 3. T oggle the generator set master switch to crank the engine two or three revolution ...
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Kohler 8.5RES - page 30
TP-6331 5/04 18 Section 3 Scheduled Maintenance Notes ...
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Kohler 8.5RES - page 31
TP-6331 5/04 19 Section 4 Troubleshooting Section 4 T roubleshooting 4.1 Introduction Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery , loose connections, or an open circuit breaker . The charts include a list of common problems, possible causes of the problem, a ...
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Kohler 8.5RES - page 32
TP-6331 5/04 20 Section 4 Troubleshooting 4.3 Fault Codes The Advanced Digital Control displays fault codes to aid in 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 fault shutdown. See Section 2.4.1. 4.4 T roublesh ...
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Kohler 8.5RES - page 33
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 dimensional drawing AHWT anticipatory high water temperatur ...
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Kohler 8.5RES - page 34
TP-6331 5/04 A-2 Appendix ISO International Organization for Standardization J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 10 bytes) kg kilogram kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k Ω kilo-ohm kPa kil ...
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Kohler 8.5RES - page 35
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Kohler 8.5RES - page 36
E 2004 by Kohler Co. All rights reserved. TP-6331 5/04 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 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455 ...
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