Kohler 12RES Instruction Manual

Residential/Commercial Generator Sets
Models:
12RES
Similar Models (no longer available):
8.5/17/18RES
12/18TRES
Controller:
Advanced Digital Control ADC-RES
TP-6515 2/21g
Operation

WARNING: This prod ct can expose yo
to chemicals, incl ding carbon monoxide
and benzene, which are known to the State
of California to ca se cancer and birth
defects or other reprod ctive harm.
For more information go to
www.P65warnings.ca.gov
Prod ct Identification Information
Prod ct identification n mbers determine service parts.
Record the prod ct identification n mbers in the spaces
below immediately after npacking the prod cts so that
the n mbers are readily available for f t re reference.
Record field-installed kit n mbers after installing the
kits.
Generator Set Identification N mbers
Record the prod ct identification n mbers from the
generator set nameplate(s).
Model Designation
Specification N mber
Serial N mber
Accessory N mber Accessory Description
Controller Identification
Record the controller description from the generator set
operation man al, spec sheet, or sales invoice.
Controller Description
Engine Identification
Record the prod ct identification information from the
engine nameplate.
Man fact rer
Model Designation
Serial N mber

Table of Contents
TP-6515 2/21 Table of Contents
Prod ct Identification Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Preca tions and Instr ctions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introd ction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Assistance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Introd ction 13..........................................................
1.2 Generator 13............................................................
1.3 Engine 13..............................................................
1.4 Advanced Digital Control 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Accessories 14..........................................................
1.5.1 Carb retor Heater 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.2 Battery Heater Kit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Service Views for Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 OperatingArea 19.......................................................
2.2 PrestartChecklist 19.....................................................
2.3 Exercising Generator Set 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 ADC-RES Controls and Indicators 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 LEDDisplay 20..................................................
2.4.2 Controller Keypad 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Generator Set Master Switch 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 ControllerPower 22......................................................
2.5.1 StandbyMode 22................................................
2.5.2 SleepMode 22..................................................
2.6 Generator Set Operation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 Starting Generator Set 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Stopping Generator Set 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.3 Emergency Stopping (TRES Models Only) 23. . . . . . . . . . . . . . . . . . . . . . . .
2.7 Fa lts 24...............................................................
2.7.1 Sh tdowns 24...................................................
2.7.2 Warnings 24....................................................
2.7.3 Resetting Controller after a Fa lt Sh tdown 24. . . . . . . . . . . . . . . . . . . . . . .
2.8 BatteryCharger 26.......................................................
2.8.1 RES Battery Charger 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.2 TRES Battery Charger 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3 Sched led Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Sched led Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Service Sched le, 8.5/12 kW Models 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Service Sched le, 17/18 kW Models 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 L bricationSystem 32....................................................
3.2.1 Low Oil Press re Sh tdown 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 OilCheck 32....................................................
3.2.3 Engine Oil Recommendation 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 Oil Change Proced re 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.5 Oil Cooler, 17/18 kW 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 SparkPl gs 34..........................................................
3.4 AirCleanerService 34....................................................
3.4.1 Air Cleaner, 8.5/12RES 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2 Air Cleaner, 17/18RES 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 CoolingSystem 36.......................................................
3.6 Exha stSystem 36......................................................
3.7 Battery 37..............................................................

Table of Contents, contin ed
TP-6515 2/21Table of Contents
3.8 BatteryCharger 37.......................................................
3.9 Circ itProtection 38......................................................
3.9.1 Line Circ it Breaker 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9.2 F ses 38.......................................................
3.10 StorageProced re 39....................................................
3.10.1 L bricating System 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.2 F elSystem 39..................................................
3.10.3 Cylinder L brication 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.4 Exterior Preparation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10.5 Battery 39......................................................
Section 4 Tro bleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Introd ction 41..........................................................
4.2 Controller Tro bleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Generator Set Tro bleshooting 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Battery Charger Tro bleshooting 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A Abbreviations 45................................................................

TP-6515 2/21 5Safety Preca tions and Instr ctions
Safety Preca tions and Instr ctions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical eq ipment,
incl ding generator sets, transfer
switches, switchgear, and accessories,
can ca se bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
preca tions and instr ctions. SAVE
THESE INSTRUCTIONS.
This man al has several types of safety
preca tions and instr ctions: Danger,
Warning, Ca tion, and Notice.
DANGER
DANGER indicates a hazardo s
sit ation which, if not avoided, will
res lt in death or serio s inj ry.
WARNING
WARNING indicates a hazardo s
sit ation which, if not avoided, co ld
res lt in death or serio s inj ry.
CAUTION
CAUTION indicates a hazardo s
sit ation which, if not avoided, co ld
res lt in minor or moderate inj ry.
NOTICE
NOTICE is sed to address practices
not related to physical inj ry.
Safety decals affixed to the eq ipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown thro gho t this
p blication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
Accidental starting.
Can ca se severe inj ry 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.
WARNING
Disabling the generator set.
Accidental starting can ca se
severe inj ry or death. Before
working on the generator set or
eq ipment connected to the set,
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 preca tions to prevent starting of
the generator set by an a tomatic
transfer switch, remote start/stop
switch, or engine start command from a
remote comp ter.
Battery
S lf ric acid in batteries.
Can ca se severe inj ry or death.
Wear protective goggles and
clothing. Battery acid may ca se
blindness and b rn skin.
WARNING
Explosion.
Can ca se severe inj ry or death.
Relays in the battery charger
ca se arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive f mes.
WARNING
Battery electrolyte is a dil ted
s lf ric acid. Battery acid can ca se
severe inj ry or death. Battery acid
can ca se blindness and b rn skin.
Always wear splashproof safety
goggles, r bber gloves, and boots
when servicing the battery. Do not
open a sealed battery or m tilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
fl sh the affected area for 15 min tes
with large q antities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may res lt in hazardo s
spattering of battery acid.
Battery acid clean p. Battery acid
can ca se severe inj ry or death.
Battery acid is electrically cond ctive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the ne tralizing sol tion. Po r the
ne tralizing sol tion on the spilled
battery acid and contin e to add the
ne tralizing sol tion to the spilled
battery acid ntil all evidence of a
chemical reaction (foaming) has
ceased. Fl sh the res lting liq id with
water and dry the area.

TP-6515 2/216 Safety Preca tions and Instr ctions
Battery gases. Explosion can ca se
severe inj ry or death. Battery gases
can ca se an explosion. Do not smoke
or permit flames or sparks to occ r near
a battery at any time, partic larly when
it is charging. Do not dispose of a
battery in a fire. To prevent b rns and
sparks that co ld ca se an explosion,
avoid to ching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
eq ipment. Discharge static electricity
from yo r body before to ching
batteries by first to ching a gro nded
metal s rface away from the battery. To
avoid sparks, do not dist rb the battery
charger connections while the battery
is charging. Always t rn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent acc m lation of explosive
gases.
Battery short circ its. Explosion
can ca se severe inj ry or death.
Short circ its can ca se bodily inj ry
and/or eq ipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the eq ipment. Use
tools with ins lated handles. Remove
the negative (- ) lead first when
disconnecting the battery. Reconnect
the negative (- ) lead last when
reconnecting the battery. Never
connect the negative (- ) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Risk of fire.
Can ca se severe inj ry or death.
Do not smoke or permit flames or
sparks near f els or the f el system.
WARNING
Servicing the air cleaner. A s dden
backfire can ca se severe inj ry or
death. Do not operate the generator
set with the air cleaner removed.
Servicing the f el system. A flash
fire can ca se severe inj ry or death.
Do not smoke or permit flames or
sparks near the carb retor, f el line,
f el filter, f el p mp, or other potential
so rces of spilled f els or f el vapors.
Catch f els in an approved container
when removing the f el line or
carb retor.
Comb stible materials. A fire can
ca se severe inj ry or death.
Generator set engine f els and f el
vapors are flammable and explosive.
Handle these materials caref lly to
minimize the risk of fire or explosion.
Eq ip the compartment or nearby area
with a f lly charged fire exting isher.
Select a fire exting isher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an a thorized agency. Train all
personnel on fire exting isher
operation and fire prevention
proced res.
Exha st System
Carbon monoxide.
Can ca se severe na sea,
fainting, or death.
The exha st system m st be
leakproof and ro tinely inspected.
WARNING
Generator set operation. Carbon
monoxide can ca se severe na sea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can ca se death if
inhaled for even a short time. Avoid
breathing exha st f mes when working
on or near the generator set. Never
operate the generator set inside a
b ilding. Never operate the generator
set where exha st gas co ld seep
inside or be drawn into a potentially
occ pied b ilding thro gh windows, air
intake vents, or other openings.
Carbon monoxide symptoms.
Carbon monoxide can ca se severe
na sea, fainting, or death. Carbon
monoxide is a poisono s gas present in
exha st gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can ca se death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms incl de
b t are not limited to the following:
Light-headedness, dizziness
Physical fatig e, weakness in
joints and m scles
Sleepiness, mental fatig e,
inability to concentrate
or speak clearly, bl rred vision
Stomachache, vomiting, na sea
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 min tes of breathing
fresh air.
F el System
Explosive f el vapors.
Can ca se severe inj ry or death.
Use extreme care when handling,
storing, and sing f els.
WARNING
Gas f el leaks. Explosive f el
vapors can ca se severe inj ry or
death. F el leakage can ca se an
explosion. Check the LPG vapor or
nat ral gas f el system for leakage by
sing a soap and water sol tion with
the f el system test press rized to
6- 8 o nces per sq are inch
(10- 14 inches water col mn). Do not
se a soap sol tion containing either
ammonia or chlorine beca se both
prevent b bble formation. A s ccessf l
test depends on the ability of the
sol tion to b bble.

TP-6515 2/21 7Safety Preca tions and Instr ctions
Hazardo s Noise
Hazardo s noise.
Can ca se hearing loss.
Never operate the generator set
witho t a m ffler or with a fa lty
exha st system.
CAUTION
Engine noise. Hazardo s noise can
ca se hearing loss. Generator sets
not eq ipped with so nd enclos res
can prod ce noise levels greater than
105 dBA. Prolonged expos re to noise
levels greater than 85 dBA can ca se
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardo s Voltage/
Moving Parts
Hazardo s voltage. Moving parts.
Will ca se severe inj ry or death.
Operate the generator set only when
all g ards and electrical enclos res
are in place.
DANGER
Hazardo s voltage. Backfeed to
the tility system.
Can ca se property damage,
severe inj ry, or death.
If the generator set is sed for
standby power, install an a tomatic
transfer switch to prevent inadvertent
interconnection of standby and
normal so rces of s pply.
WARNING
Welding the generator set.
Can ca se severe electrical
eq ipment damage.
Welding on generator set will ca se
serio s damage to engine electronic
controls components. Disconnect all
engine electronic control connections
before welding.
CAUTION
Gro nding electrical eq ipment.
Hazardo s voltage will ca se severe
inj ry or death. Electroc tion is
possible whenever electricity is
present. Ens re yo comply with all
applicable codes and standards.
Electrically gro nd the generator set,
transfer switch, and related eq ipment
and electrical circ its. T rn off the main
circ it breakers of all power so rces
before servicing the eq ipment. Never
contact electrical leads or appliances
when standing in water or on wet
gro nd beca se these conditions
increase the risk of electroc tion.
Welding on the generator set. Can
ca se severe electrical eq ipment
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 mod le
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
reg lator circ it board connectors.
(4) Disconnect the engine battery-
charging alternator connections.
(5) Attach the weld gro nd connection
close to the weld location.
Connecting the battery and the
battery charger. Hazardo s voltage
will ca se severe inj ry or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a q alified
electrician install the battery(ies).
Short circ its. Hazardo s
voltage/c rrent will ca se severe
inj ry or death. Short circ its can
ca se bodily inj ry and/or eq ipment
damage.Do not contact electrical
connections with tools or jewelry while
making adj stments or repairs.
Remove all jewelry before servicing the
eq ipment.
Electrical backfeed to the tility.
Hazardo s backfeed voltage can
ca se severe inj ry or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other so rces of power.
Electrical backfeed into a tility
electrical system can ca se severe
inj ry or death to tility personnel
working on power lines.
Wear protective goggles and
clothing when sing power tools,
hand tools, or compressed air.
Heavy Eq ipment
Unbalanced weight.
Improper lifting can ca se severe
inj ry or death and eq ipment
damage.
Do not se lifting eyes.
Lift the generator set sing lifting bars
inserted thro gh the lifting holes on
the skid.
WARNING

TP-6515 2/218 Safety Preca tions and Instr ctions
Hot Parts
Hot engine and exha st system.
Can ca se severe inj ry or death.
Do not work on the generator set ntil
it cools.
WARNING
Servicing the exha st system. Hot
parts can ca se severe inj ry or
death. Do not to ch hot engine parts.
The engine and exha st system
components become extremely hot
d ring operation.
Servicing the engine heater. Hot
parts can ca se minor personal
inj ry or property damage. Install the
heater before connecting it to power.
Operating the heater before installation
can ca se b rns and component
damage. Disconnect power to the
heater and allow it to cool before
servicing the heater or nearby parts.
Notice
NOTICE
Canadian installations only. For
standby service connect the o tp t of
the generator set to a s itably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

TP-6515 2/21 9Introd ction
Introd ction
This man al provides operation and maintenance
instr ctions for residential/commercial generator sets
eq ipped with ADC-RES controls. The generator set
models covered by this man al are listed on the front
cover.
This generator set is approved for se in stationary
applications in locations served by a reliable tility
power so rce. Have the generator set installed by an
a thorized distrib tor/dealer or service technician.
Refer to TP-6514, Installation Man al, for installation
instr ctions.
Information in this p blication represents data available
at the time of print. Kohler Co. reserves the right to
change this p blication and the prod cts represented
witho t notice and witho t any obligation or liability
whatsoever.
Read this man al and caref lly follow all proced res
and safety preca tions to ens re proper eq ipment
operation and to avoid bodily inj ry. Read and follow the
Safety Preca tions and Instr ctions section at the
beginning of this man al. Keep this man al with the
eq ipment for f t re reference.
The eq ipment service req irements are very important
to safe and efficient operation. Inspect the parts often
and perform req ired service at the prescribed intervals.
Obtain service from an a thorized service distrib tor/
dealer to keep eq ipment in top condition.
List of Related Literat re
Fig re 1 identifies literat re available for the generator
sets covered in this man al and related accessories.
Only trained and q alified personnel sho ld install or
service the generator set.
Generator Set Literat re Part N mber
Specification Sheet, 8.5RES G4- 97
Specification Sheet, 12RES G4- 248
Specification Sheet, 17RES G4- 120
Specification Sheet, 18RES G4- 133
Installation Man al, Generator Set,
8.5/18RES, 12/18TRES TP-6792
Installation Man al, Generator Set ,
12RES TP- 6967
Service Man al, Generator
Set,8.5/12RES TP-6196
Service Man al, Generator Set,
17/18RES, 18TRES TP- 6519
Accessory Literat re
Operation Man al, SiteTechSoftware TP- 6701
Installation Instr ctions,
Load Shed Kit TT- 1609
Installation Instr ctions,
Programmable Interface Mod le (PIM) TT- 1584
Installation Instr ctions, PowerSync
A tomatic Paralleling Mod le (APM) TT-1596
Installation Instr ctions,
Battery Heater Kit TT- 1634
Installation Instr ctions,
Carb rettor Heater Kit TT- 1297
Fig re 1 Related Literat re

TP-6515 2/2110 Introd ction
Nameplate
The following ill stration shows a typical generator set
nameplate. Copy the model, serial, and specification
n mbers from the nameplate into the spaces provided in
the prod ct information section on the inside front cover
of this man al. See Section 1.6 for the nameplate
location.
Emission Information
The KohlerModel CH640 engine sed on the model
8.5RES generator set, CH740 engine sed on the
12RES generator set, and CH980 engine sed on the
17/18RES generator set are certified to operate sing
nat ral gas or propane f el.
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the n mber
of operating ho rs for which the engine has been shown
to meet CARB or EPA emission req irements. The
following table provides the engine compliance period
(in ho rs) associated with the category descriptor, which
may be fo nd on the certification label.
Emission Compliance Period
EPA Category C
250 ho rs
Category B
500 ho rs
Category A
1000 ho rs
CARB Moderate
125 ho rs
Intermediate
250 ho rs
Extended
500 ho rs
Fig re 2 Emission Compliance Period
Refer to the certification label for engine displacement.
The exha st emission control system for the CH640,
CH740, and CH980 engines is EM for U.S. EPA,
California, and E rope.
The engine sed in the Model 17/18RES generator set
is certified for emergency standby se only.

TP-6515 2/21 11Service Assistance
Service Assistance
For professional advice on generator set power
req irements and conscientio s service, please contact
yo r nearest Kohler distrib tor or dealer.
 Visit the Kohler Co. website at KOHLERPower.com.
 Look at the labels and decals on yo r Kohler prod ct
or review the appropriate literat re or doc ments
incl ded with the prod ct.
 Call toll free in the US and Canada 1-800-544-2444.
 O tside the US and Canada, call the nearest regional
office.
Headq arters E rope, Middle East,Africa
(EMEA)
Kohler EMEA Headq arters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Rep blic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

TP-6515 2/2112 Service Assistance
Notes

TP-6515 2/21 13Section 1 Specifications
Section 1 Specifications
1.1 Introd ction
The generator set specification sheets provide specific
generator and engine information. Refer to the spec
sheet for data not s pplied in this man al. Cons lt the
generator set service man al, engine operation man al,
and engine service man al for additional specifications.
Obtain copies of the latest spec sheets, man als,
diagrams, and drawings from yo r local distrib tor/
dealer.
1.2 Generator
The generator ses Kohler’s niq e PowerBoost
voltage reg lation system, which provides instant
response to load changes.
PowerBoostens res reliable motor starting and
consistent voltage levels. PowerBoosttilizes a
voltage excitation system that employs a winding
independent of the main o tp t windings to provide
excitation voltage.
1.3 Engine
The generator set has a fo r-cycle, twin cylinder, air-
cooled Kohlerengine. The engine operates on clean-
b rning nat ral gas or propane (LP) vapor. Engine
feat res incl de:
 Efficient overhead valve design and f ll press re
l brication for maxim m power, torq e, and reliability
nder all operating conditions.
 Dependable, maintenance-free electronic ignition.
 Precision-form lated cast iron constr ction of parts
s bjected to the most wear and tear.
 Field-convertible m lti-f el systems that allow f el
changeover from nat ral gas to LP vapor (and vice-
versa) while maintaining CARB emission
certification.
 Digital spark advance optimizes ignition timing for the
selected f el. (12 - 18 kW models)
1.4 Advanced Digital Control
The generator set is eq ipped with the Kohler
ADC-RES Advanced Digital Control. Controller
feat res incl de the following:
 Compact controller
 Integrally mo nted to the generator set
 LED display:
 Engine r ntime, ho rs
 AC voltage
 Freq ency (Hz)
 Battery voltage
 Crank cycle stat s
 Set p information
 Application software version
 LED display comm nicates fa lts:
 High battery voltage
 High engine temperat re
 Low battery voltage
 Low oil press re
 Overcrank safety
 Overfreq ency
 Overspeed
 Overvoltage
 Underfreq ency
 Undervoltage
 Membrane keypad for config ration and adj stment
 Password-protected ser access to men s
 Voltage, gain, and speed adj stment
 System config ration (system voltage/freq ency
settings and generator set model)
 Remote two-wire start/stop capability
 Digital isochrono s governor to maintain steady-
state speed at all loads
 Digital voltage reg lation: ±1.5% RMS no-load to
f ll-load
 A tomatic start for programmed cranking cycle
 Master control switch mo nted on the j nction box:
R n/Off-Reset/A to
 Upgradeable application software

TP-6515 2/2114 Section 1 Specifications
1.5 Accessories
The following optional accessories are offered for the
generator sets.
1.5.1 Carb retor Heater
An optional carb retor heater is recommended for
improved cold starting in locations where the ambient
temperat re drops below 0C (32F). The carb retor
heater prevents condensation and carb retor icing. The
heater req ires a contin o s so rce of AC power.
Install the heater between the engine air cleaner and the
carb retor. Pl g the carb retor heater into a 120 VAC
receptacle. Verify that AC power is connected to the
generator set as described in the generator set
Installation Man al. The circ it m st be backed p by
the generator set to provide power at all times.
See the generator set Installation man al for more
information.
Voltage 120 VAC
Thermostat ON 4±3C (40 ±5F)
Thermostat OFF 16 ±3C (60 ±5F)
Fig re 3 Heater Specifications
2
GM19462
1. 120 VAC pl g
2. Thermostat
1
Fig re 4 Carb retor Heater
1.5.2 Battery Heater Kit
The battery heater kit contains a heating wrap to help
warm the battery in cold climates. See Fig re 5. The
battery heater is eq ipped with a thermostat that t rns
the heater on at 16- 18C (60- 65F) and off at 27C
(80F). Battery heaters are recommended for regions
where the temperat re reg larly falls below 0C (32F).
Note: Battery heaters are compatible with all
Kohler-s pplied lead-acid batteries.* For other
battery types, check the battery man fact rer’s
instr ctions for any restrictions regarding the se
of battery heaters.
The battery heater req ires a so rce of AC power. Verify
that AC power is connected to the generator set as
described in the generator set Installation Man al. The
circ it m st be backed p by the generator set to provide
power at all times.
1. Battery heater wrap
2. Retaining strap or cable ties (incl ded)
3. Power cord
1
2
3
Fig re 5 Battery Heater (typical)

TP-6515 2/21 15Section 1 Specifications
1.6 Service Views for Maintenance
ADV-7466-
1. M ffler
2. Oil check
3. Oil fill
4. Air cleaner
5. F ses
6. RS-232 connector (for application program pdates)
7. Controller ser interface (see Fig re 2-1)
8. Generator set master switch (RUN-OFF/RESET-AUTO)
9. Line circ it breaker (single-phase models)*
10. Field-connection terminal block location (single-phase models)*
11. Spark pl g locations (both sides)
12. Oil drain hose
13. Oil drain valve
14. Oil filter
15. Exha st
16. Eq ipment gro nd
17. Relay board location (optional)
18. Battery charger (single-phase models)
19. DSAI lead location (12 kW models)
20. F el block
21. Gas reg lator assembly
22. F el solenoid valve
23. F el inlet
24. Air intake
25. Engine starting battery location (battery p rchased separately)
1 2 3 4
14 13
25
9
816
18 21
22
23
24
15
11
10
19 2017
12
5 6 7
24
* See Fig re 1-4 for additional components for 3-phase models.
See Fig re 2-9 for 3-phase battery charger locations.
Fig re 1-1 Generator Set Components, 8.5kW

TP-6515 2/2116 Section 1 Specifications
ADV-9747-
1. M ffler
2. Oil check
3. Oil fill
4. Air cleaner
5. F ses
6. RS-232 connector (for application program pdates)
7. Controller ser interface (see Fig re 2-1)
8. Generator set master switch (RUN-OFF/RESET-AUTO)
9. Line circ it breaker
10. Field-connection terminal block location
11. Spark pl g locations (both sides)
12. Oil drain hose
13. Oil drain valve
14. Oil filter
15. Exha st
16. Eq ipment gro nd
17. Relay board location (optional)
18. Battery charger
19. DSAI lead location
20. F el block
21. Gas reg lator assembly
22. F el solenoid valve
23. Nameplate location
24. F el inlet
25. Air intake
26. Engine starting battery location (battery p rchased separately)
1 2 3 4
14 13
25
9
8
16
18
21
22
23
24
15
11
10
19 20
17
12
567
26
- A-- B-
- B-
0.006 A
- C-
+
25
Fig re 1-2 Generator Set Components, 12kW

TP-6515 2/21 17Section 1 Specifications
1 2 54 21
16
6
3
13 26
17
20
1415
24
ADV-7341A-B
10
27 25
9
18 22
28
Control detail, top view 8
11
7
12
1. M ffler
2. Oil check
3. Oil fill
4. Air cleaner
5. Spark pl g locations (both sides)
6. Oil filter
7. Oil cooler location
8. ADC-RES Advanced Digital Control ser interface
9. Generator set master switch (RUN-OFF/RESET-AUTO)
10. Line circ it breaker (single-phase models )*
11. F ses
12. RS-232 connector (for application program pdates)
13. Engine starting battery location (battery p rchased separately)
14. Oil drain hose
15. Nameplate location (on base)
16. Oil drain valve
17. Exha st o tlet
18. Relay board location (optional)
19. Carb retor heater access opening
20. LP f el orifice location (inside hose fitting)
21. Gas reg lator assembly
22. DSAI leads
23. F el solenoid valve
24. F el inlet
25. Air intake
26. Battery cables
27. Battery charger (single-phase models)
28. Field-connection terminal block location (single-phase models)*
29. 120 VAC receptacles for battery charger and optional
carb retor heater (single-phase models)
See control
detail 19
29
23
25
25
* See Fig re 1-4 for additional components for 3-phase models.
See Fig re 2-9 for 3-phase battery charger locations.
Fig re 1-3 Generator Set Components, 17/18 kW

TP-6515 2/2118 Section 1 Specifications
1
GM66010
1. Emergency stop switch
2. Field-connection terminal block and circ it breakers
3. Cable inlet area
2
3
Fig re 1-4 Additional Components, TRES (3-phase)
Models

TP-6515 2/21 19Section 2 Operation
Section 2 Operation
2.1 Operating Area
Hazardo s voltage. Moving parts.
Will ca se severe inj ry or death.
Operate the generator set only when
all g ards and electrical enclos res
are in place.
DANGER
Carbon monoxide.
Can ca se severe na sea,
fainting, or death.
The exha st system m st be
leakproof and ro tinely inspected.
WARNING
Generator set operation. Carbon monoxide can ca se
severe na sea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can ca se
death if inhaled for even a short time. Avoid breathing exha st
f mes when working on or near the generator set. Never
operate the generator set inside a b ilding. Never operate the
generator set where exha st gas co ld seep inside or be
drawn into a potentially occ pied b ilding thro gh windows, air
intake vents, or other openings.
Carbon monoxide symptoms. Carbon monoxide can
ca se severe na sea, fainting, or death. Carbon monoxide
is a poisono s gas present in exha st gases. Carbon
monoxide is an odorless, colorless, tasteless, nonirritating gas
that can ca se death if inhaled for even a short time. Carbon
monoxide poisoning symptoms incl de b t are not limited to
the following:
Light-headedness, dizziness
Physical fatig e, weakness in
joints and m scles
Sleepiness, mental fatig e,
inability to concentrate
or speak clearly, bl rred vision
Stomachache, vomiting, na sea
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 min tes of breathing fresh air.
Carbon monoxide detectors. Carbon monoxide can
ca se severe na sea, fainting, or death. Install carbon
monoxide detectors on each level of any b ilding adjacent to
the generator set. Locate the detectors to adeq ately warn the
b ilding’s occ pants of the presence of carbon monoxide.
Keep the detectors operational at all times. Periodically test
and replace the carbon monoxide detectors according to the
man fact rer’s instr ctions.
Hot s rfaces.
CAUTION
Remind family members, children, and visitors to se
ca tion near the generator set. Generator sets
connected to a tomatic transfer switches will start
a tomatically d ring exercise periods and power
o tages. Some generator components become hot
when the generator is r nning and remain hot for a time
after the generator set sh ts down.
2.2 Prestart Checklist
To ens re contin ed satisfactory operation, perform the
following checks or inspections before or at each
start p, as designated, and at the intervals specified in
the service sched le. In addition, some checks req ire
verification after the nit starts.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent nfiltered air from entering the
engine.
Air Inlets. Check for clean and nobstr cted air inlets.
Battery. Check for tight battery connections. Cons lt
the battery man fact rer’s instr ctions regarding
battery care and maintenance.
Exha st System. Check for exha st leaks and
blockages. Check the m ffler condition and check for
tight exha st system connections.
Inspect the exha st system components for cracks,
leaks, and corrosion.
 Check for corroded or broken metal parts and replace
them as needed.
 Check that the exha st o tlet is nobstr cted.

TP-6515 2/2120 Section 2 Operation
Oil Level. Maintain the oil level at or near, not over, the
f ll mark on the dipstick.
Operating Area. Check for obstr ctions that co ld
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.
2.3 Exercising Generator Set
Operate the generator set witho t load once each week
for 20 min tes. If the generator set is not connected to
an a tomatic transfer switch (ATS) with an exercise
option, exercise the nit in the presence of an operator.
The operator sho ld perform all of the prestart checks
before starting the exercise proced re. Start the
generator set according to the starting proced re in the
controller section of this man al. While the generator
set is operating, listen for a smooth-r nning engine and
vis ally inspect the generator set for fl id or exha st
leaks. Check the air inlets and o tlets and remove any
items restricting the air flow.
2.4 ADC-RES Controls and
Indicators
Fig re 2-1 ill strates the ADC-RES ser interface and
other items on the generator set j nction box.
Fig re 2-2 describes the ADC-RES controls and
indicators.
1. LED display
2. Up and down arrow b ttons
3. Generator set master switch
4. Line circ it breaker (single-phase models)
5. F ses
6. RS-232 connector (for application program pgrade)
7. Select b tton ( se for set p and adj stment only)
1
7
3
2
4
5
6
Fig re 2-1 ADC-RES Controls
2.4.1 LED Display
The LED display is activated by a start or RUN
command as follows:
 Move the master switch to RUN.
 With the master switch in AUTO, send a remote start
command (close the remote start contact across
leads 3 and 4).
The LED display indicates generator set stat s as
shown in Fig re 2-2. When the generator set is r nning,
engine r ntime ho rs are shown nless the arrow
b ttons are sed to step thro gh the other displays as
described in Section 2.4.2.
When the master switch is in AUTO, the display may
t rn off 48 ho rs after generator set sh tdown. See
Section 2.5, Controller Power.