Kohler 12RES User manual

Residential/Commercial Generator Sets
Model:
12RES
Controller:
Advanced Digital Control ADC-RES
TP-6967 2/21a
Installation

WARNIN : This product can expose you
to chemicals, including carbon monoxide
and benzene, which are known to the State
o Cali ornia to cause cancer and birth
de ects or other reproductive harm.
For more in ormation go to
www.P65warnings.ca.gov
Kohler strongly recommends
that only factory-authorized
distributors or dealers install
and service the generator.
Product Identification Information
enerator Set Identification Numbers
Record the product identi ication numbers rom the
generator set nameplate(s).
Model Designation
Speci ication Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identi ication in ormation rom the
engine nameplate.
Manu acturer
Model Designation
Serial Number
Controller Identification
Record the controller description rom the generator set
operation manual, spec sheet, or sales invoice.
Controller Description

Table of Contents
TP-6967 2/21 Table o Contents 3
Product Identification Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions and Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Assistance 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Installation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Introduction 11..........................................................
1.2 Liting 11...............................................................
1.3 Generator Set Inspection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 LocationandMounting 12.................................................
1.4.1 Exhaust Requirements 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 AirRequirements 13.............................................
1.5 PowerSupply 13........................................................
1.6 FuelRequirements 13....................................................
1.6.1 FuelSupply 14..................................................
1.6.2 FuelPipeSize 14................................................
1.7 FuelConversion 15......................................................
1.7.1 Fuel Conversion, Original Fuel System 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7.2 Fuel Conversion, Revised Fuel System 17. . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 Electrical Connections 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.1 Field Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.2 Remote Start Connection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8.3 Grounding 21...................................................
1.8.4 BatteryCharger 21...............................................
1.9 Battery 21..............................................................
1.10 Accessories 23..........................................................
1.10.1 Common Fault and Auxiliary Run Relay Board 23. . . . . . . . . . . . . . . . . . . .
1.10.2 Carburetor Heater 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.11 Prestart Installation Check 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12 Controller Con iguration 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12.1 System Parameters 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.12.2 Application Code Version 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13 Voltage and Frequency Adjustments 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13.1 Voltage Adjustment 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13.2 Frequency Adjustment 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 Dimension Drawings and Wiring Diagrams 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A Abbreviations 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6967 2/214
Notes

TP-6967 2/21 5Sa ety Precautions and Instructions
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, trans er
switches, switchgear, and accessories,
can cause bodily harm and pose
li e-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware o potential dangers and act
sa ely. Read and ollow all sa ety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types o sa ety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DAN ER
DANGER indicates a hazardous
situation which, i not avoided, will
result in death or serious injury.
WARNIN
WARNING indicates a hazardous
situation which, i not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous
situation which, i not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE is used to address practices
not related to physical injury.
Sa ety decals a ixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act sa ely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables be ore
working on the generator set.
Remove the negative (- ) lead irst
when disconnecting the battery.
Reconnect the negative (- ) lead last
when reconnecting the battery.
WARNIN
Disabling the generator set.
Accidental starting can cause
severe injury or death. Be ore
working on the generator set or
equipment connected to the set,
disable the generator set as ollows:
(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 irst.
Reconnect the negative (- ) lead last
when reconnecting the battery. Follow
these precautions to prevent starting o
the generator set by an automatic
trans er switch, remote start/stop
switch, or engine start command rom a
remote computer.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNIN
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger rom
explosive umes.
WARNIN
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproo sa ety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. I battery acid splashes in
the eyes or on the skin, immediately
lush the a ected area or 15 minutes
with large quantities o clean water.
Seek immediate medical aid in the case
o eye contact. Never add acid to a
battery a ter placing the battery in
service, as this may result in hazardous
spattering o battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) o
bicarbonate o soda (baking soda) to a
container with 4 L (1 gal.) o 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 o a
chemical reaction ( oaming) has
ceased. Flush the resulting liquid with
water and dry the area.

TP-6967 2/216 Sa ety Precautions and Instructions
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit lames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose o a
battery in a ire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry be ore servicing the
equipment. Discharge static electricity
rom your body be ore touching
batteries by irst touching a grounded
metal sur ace away rom the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger o be ore disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation o explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery be ore
generator set installation or
maintenance. Remove all jewelry
be ore servicing the equipment. Use
tools with insulated handles. Remove
the negative (- ) lead irst when
disconnecting the battery. Reconnect
the negative (- ) lead last when
reconnecting the battery. Never
connect the negative (- ) battery cable
to the positive (+) connection terminal
o the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Risk of fire.
Can cause severe injury or death.
Do not smoke or permit lames or
sparks near uels or the uel system.
WARNIN
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit lames or
sparks near the carburetor, uel line,
uel ilter, uel pump, or other potential
sources o spilled uels or uel vapors.
Catch uels in an approved container
when removing the uel line or
carburetor.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine uels and uel
vapors are lammable and explosive.
Handle these materials care ully to
minimize the risk o ire or explosion.
Equip the compartment or nearby area
with a ully charged ire extinguisher.
Select a ire extinguisher rated ABC or
BC or electrical ires or as
recommended by the local ire code or
an authorized agency. Train all
personnel on ire extinguisher
operation and ire prevention
procedures.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproo and routinely inspected.
WARNIN
enerator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death i
inhaled or even a short time. Avoid
breathing exhaust umes when working
on or near the generator set. Never
operate the generator set inside a
building. Never operate the generator
set where exhaust gas could seep
inside or be drawn into a potentially
occupied building through windows, air
intake vents, or other openings.
Carbon monoxide detectors.
Carbon monoxide can cause severe
nausea, fainting, or death. Install
carbon monoxide detectors on each
level o any building adjacent to the
generator set. Locate the detectors to
adequately warn the building’s
occupants o the presence o carbon
monoxide. Keep the detectors
operational at all times. Periodically
test and replace the carbon monoxide
detectors according to the
manu acturer’s instructions.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death i
inhaled or even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the ollowing:
Light-headedness, dizziness
Physical atigue, weakness in
joints and muscles
Sleepiness, mental atigue,
inability to concentrate
or speak clearly, blurred vision
Stomachache, vomiting, nausea
I experiencing any o these symptoms
and carbon monoxide poisoning is
possible, seek resh air immediately
and remain active. Do not sit, lie down,
or all asleep. Alert others to the
possibility o carbon monoxide
poisoning. Seek medical attention i
the condition o a ected persons does
not improve within minutes o breathing
resh air.

TP-6967 2/21 7Sa ety Precautions and Instructions
Fuel System
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using uels.
WARNIN
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized uels are highly
explosive. Use extreme care when
handling and storing uels. Store uels
in a well-ventilated area away rom
spark-producing equipment and out o
the reach o children. Never add uel to
the tank while the engine is running
because spilled uel may ignite on
contact with hot parts or rom sparks.
Do not smoke or permit lames or
sparks to occur near sources o spilled
uel or uel vapors. Keep the uel lines
and connections tight and in good
condition. Do not replace lexible uel
lines with rigid lines. Use lexible
sections to avoid uel line breakage
caused by vibration. Do not operate the
generator set in the presence o uel
leaks, uel accumulation, or sparks.
Repair uel systems be ore resuming
generator set operation.
as fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LPG vapor or
natural gas uel system or leakage by
using a soap and water solution with
the uel system test pressurized to
6- 8 ounces per square inch
(10- 14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble ormation. A success ul
test depends on the ability o the
solution to bubble.
Hazardous Noise
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a mu ler or with a aulty
exhaust system.
CAUTION
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Moving Parts
Hazardous voltage.
Will cause severe injury or death.
This equipment must be installed and
serviced by quali ied electrical
personnel.
DAN ER
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
DAN ER
Hazardous voltage. Backfeed to
the utility system.
Can cause property damage,
severe injury, or death.
I the generator set is used or
standby power, install an automatic
trans er switch to prevent inadvertent
interconnection o standby and
normal sources o supply.
WARNIN
Welding the generator set.
Can cause severe electrical
equipment damage.
Welding on generator set will cause
serious damage to engine electronic
controls components. Disconnect all
engine electronic control connections
be ore welding.
CAUTION
rounding electrical equipment.
Hazardous voltage will cause severe
injury or death. Electrocution is
possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
trans er switch, and related equipment
and electrical circuits. Turn o the main
circuit breakers o all power sources
be ore servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk o electrocution.
Welding on the generator set. Can
cause severe electrical equipment
damage. Be ore welding on the
generator set per orm the ollowing
steps: (1) Remove the battery cables,
negative (- ) lead irst. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery-
charging alternator connections.
(5) Attach the weld ground connection
close to the weld location.

TP-6967 2/218 Sa ety Precautions and Instructions
Connecting the battery and the
battery charger. Hazardous voltage
will cause severe injury 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 quali ied
electrician install the battery(ies).
Short circuits. Hazardous
voltage/current will cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage.Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry be ore servicing the
equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a trans er switch in standby power
installations to prevent the connection
o standby and other sources o power.
Electrical back eed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
Heavy Equipment
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use li ting eyes.
Li t the generator set using li ting bars
inserted through the li ting holes on
the skid.
WARNIN
Moving Parts
Wear protective goggles and
clothing when using power tools,
hand tools, or compressed air.
Hot Parts
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNIN
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Servicing the engine heater. Hot
parts can cause minor personal
injury or property damage. Install the
heater be ore connecting it to power.
Operating the heater be ore installation
can cause burns and component
damage. Disconnect power to the
heater and allow it to cool be ore
servicing the heater or nearby parts.
Notice
NOTICE
Canadian installations only. For
standby service connect the output o
the generator set to a suitably rated
trans er switch in accordance with
Canadian Electrical Code, Part 1.

TP-6967 2/21 9
Introduction
This manual provides installation instructions or the
Model 12RES generator set.
Kohler strongly recommends that only factory-
authorized distributors or dealers install and
service the generator.
Have an authorized distributor/dealer install the
generator set outdoors according to the instructions in
this manual. The generator set installation must comply
with the National Electrical Code  (NEC) and local code
requirements. Do not install this generator set indoors.
In ormation in this publication represents data available
at the time o print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and care ully ollow all procedures
and sa ety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and ollow the
Sa ety Precautions and Instructions section at the
beginning o this manual.
The generator set is shown in Figure 1. See the
dimension drawing in Section 2 or generator set
component locations.
Figure 1 Model 12RES Generator Set
National Electrical Code is a registered trademark o the National Fire
Protection Association, Inc.
List of Related Literature
Figure 2 identi ies related literature available or the
generator sets covered in this manual. Only trained and
quali ied personnel should install or service the
generator set.
Literature Type Part Number
Speci ication Sheet, 12RES G4-248
Operation Manual, Generator Set TP-6515
Service Manual, Generator Set TP-6196
Service Manual, Engine 24 690 06
Parts Catalog TP-5868
Operation Manual, OnCueor ADC TP-6616
Figure 2 Related Literature
Startup Notification
Complete the startup and installation checklists
supplied with the startup noti ication orm. Complete
and sign the startup noti ication orm and register the
unit using the Kohler online Warranty Processing
System.

TP-6967 2/2110
Service Assistance
For pro essional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
 Consult the Yellow Pages under the heading
Generators—Electric.
 Visit the Kohler Power Systems website at
KOHLERPower.com.
 Look at the labels and decals on your Kohler product
or review the appropriate literature or documents
included with the product.
 Call toll ree in the US and Canada 1-800-544-2444.
 Outside the US and Canada, call the nearest regional
o ice.
Headquarters Europe, Middle East,Africa
(EMEA)
Kohler Power Systems Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Paci ic Regional O ice
Singapore, Republic o Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional O ice, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional O ice, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional O ice
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional O ice
Tokyo, Japan
Phone: [phone]
Fax: [phone]

TP-6967 2/21 11Section 1 Installation
Section 1 Installation
1.1 Introduction
Hazardous voltage.
Will cause severe injury or death.
This equipment must be installed and
serviced by quali ied electrical
personnel.
DAN ER
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproo and routinely inspected.
WARNIN
enerator set operation. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death i inhaled or even a short time. Avoid breathing exhaust
umes when working on or near the generator set. Never
operate the generator set inside a building. Never operate the
generator set where exhaust gas could seep inside or be
drawn into a potentially occupied building through windows, air
intake vents, or other openings.
Carbon monoxide detectors. Carbon monoxide can
cause severe nausea, fainting, or death. Install carbon
monoxide detectors on each level o any building adjacent to
the generator set. Locate the detectors to adequately warn the
building’s occupants o the presence o carbon monoxide.
Keep the detectors operational at all times. Periodically test
and replace the carbon monoxide detectors according to the
manu acturer’s instructions.
Have the generator set installed by an authorized Kohler
distributor/dealer. For all locations, ensure that the
installation complies with applicable national and local
codes. In the United States, the installation must comply
with the National Electrical Code (NEC) and all
applicable state and local codes. For Canadian
installations, re er to the Canadian Electrical Code
(CEC).
The generator set must be installed outdoors. The
exhaust systems on enclosed units are designed or
outdoor installation only.
Note: DO NOT install these generator sets inside a
building.
Note: Install carbon monoxide (CO) detector(s) on
each level o any building adjacent to a generator
set. Locate the detectors to adequately warn the
building’s occupants o the presence o carbon
monoxide.
Obtain a building permit and contact your local utility
companies to mark the locations o underground pipes
and cables.
Read and ollow the sa ety precautions in this manual
and observe the decals on the equipment. Re er to the
diagrams and drawings in this manual or dimensions
and electrical connections during the installation
procedure. Read the entire installation procedure and
obtain the accessories and tools needed be ore
beginning installation. Per orm the steps in the order
shown.
To install optional accessories, ollow the instructions
provided with each kit.
1.2 Lifting
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use li ting eyes.
Li t the generator set using li ting bars
inserted through the li ting holes on
the skid.
WARNIN
Model Weight, kg (lb.)
12RES 186 (410)
Figure 1-1 Approximate Weight
The approximate generator set weight is shown in
Figure 1-1. Use li ting bars inserted through the holes in
the skid to li t the unit. See the dimension drawings in
Section 2 or li ting hole locations.

TP-6967 2/2112 Section 1 Installation
1.3 enerator Set Inspection
Complete a thorough inspection o the generator set.
Check or the ollowing:
1. Inspect the generator set or loose or damaged
parts or wires. Repair or tighten any loose parts
be ore installation.
2. Check the engine oil. Fill, i necessary, with the
recommended viscosity and grade o oil. Use
synthetic oil, API (American Petroleum Institute)
Service Class SG or higher. See TP-6515,
Operation Manual, or additional in ormation.
1.4 Location and Mounting
Install the generator set outdoors near the incoming gas
service. The generator set location must allow easy
access or maintenance and service. The required
distance rom a structure is dependent on state or
province and local codes. See the dimension drawing in
Section 2 or the minimum clearance rom structures
and non-combustible materials.
Locate the generator set so that the hot exhaust does
not blow on plants or other combustible materials. No
plants, shrubs, or other combustible materials are
allowed within 1.2 m (4 t.) o the exhaust end o the
generator set.
Do not install the generator set where exhaust gas could
accumulate and seep inside or be drawn into a
potentially occupied building. Furnace and other similar
intakes must be at least 3 m (10 t.) rom the exhaust
end o the generator set.
Notice
DO NOT locate the generator set near patios,
decks, play areas, or animal shelters. Keep items
such as lawn urniture, toys, sports equipment,
and all combustible materials away rom the
generator set exhaust outlet.
Remind amily members, children, and visitors to
use caution near the generator set. Generator
sets connected to automatic trans er switches
start automatically during exercise periods and
power outages. Some generator set components
become hot when the generator set is running and
remain hot or a time a ter the generator set shuts
down.
The generator set is shipped on a plastic mounting pad.
Prepare a lat, level mounting area covered with a weed
barrier and gravel or a concrete pad as shown in the
generator set clearance drawing. Set the plastic
mounting pad directly on the gravel or concrete. Do not
install the mounting pad directly on grass.
See the dimension drawings in Section 2 or special
mounting instructions or high wind (150 MPH) areas.
1.4.1 Exhaust Requirements
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproo and routinely inspected.
WARNIN
enerator set operation. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death i inhaled or even a short time. Avoid breathing exhaust
umes when working on or near the generator set. Never
operate the generator set inside a building. Never operate the
generator set where exhaust gas could seep inside or be
drawn into a potentially occupied building through windows, air
intake vents, or other openings.
The exhaust system is designed or generator sets
installed outdoors. Do not install this generator set
indoors.
Figure 1-2 gives the exhaust low and temperature at
rated load. The engine exhaust mixes with the
generator set cooling air at the exhaust end o the
enclosure. Mount the generator set so that the hot
exhaust does not blow on plants or other combustible
materials. Maintain the clearances shown in the
dimension drawings in Section 2.
Exhaust System 60 Hz 50 Hz
Exhaust low at rated kW,
m
3
/min. (c m) 3.8 (135) 3.2 (113)
Exhaust gas exiting the enclosure
at rated kW, C (F) 216 (420)
Figure 1-2 Exhaust Flow and Temperature

TP-6967 2/21 13Section 1 Installation
1.4.2 Air Requirements
The generator set requires correct air low or cooling
and combustion. The inlet and outlet openings in the
sound enclosure provide the cooling and combustion
air. Figure 1-3 shows the locations o the cooling air
intake and exhaust vents. Inspect the air inlet and outlet
openings inside and outside the housing to ensure that
the air low is not blocked.
tp6195
2
1. Exhaust outlet
2. Alternator air intake (both sides)
3. Engine air intake
3
1
3
Figure 1-3 Cooling Air Intake and Exhaust, Typical
Air Requirements, m
3
/min. (cfm)
Model Hz
Cooling
Air
Combustion
Air
Total
Inlet Air
12RES 60 26.9 (950) 1.1 (39.2) 28.0 (990)
50 22.4 (790) 0.9 (32.6) 23.4 (825)
Figure 1-4 Air Requirements
1.5 Power Supply
Power must be supplied rom a source that is GFCI
protected to the generator set location or the battery
charger and the optional accessories shown in
Figure 1-5.
Connect power rom a circuit on the essential loads
panel to the utility power connection points on the
terminal block. The circuit must be backed up by the
generator set. See Section 1.8 and the wiring diagrams
in Section 2 or connection details. See Figure 1-5 or
the power requirements or the battery charger and
accessories.
Equipment
Power Requirement, Max.
Watts Amps Volts
Battery charger (standard) 192 1.6
120
Carburetor heater (optional) 37 0.33
Battery heater (optional) 110 0.92
Figure 1-5 Power Requirements
1.6 Fuel Requirements
The generator set operates using natural gas or LPG
uel. The generator set is EPA-certi ied or both natural
gas and LPG uels.
The uel system installation must comply with applicable
national, state, and local codes.
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using uels.
WARNIN
as fuel leaks. Explosive fuel vapors can cause severe
injury or death. Fuel leakage can cause an explosion. Check
the LPG vapor or natural gas uel system or leakage by using
a soap and water solution with the uel system test pressurized
to 6- 8 ounces per square inch (10- 14 inches water column).
Do not use a soap solution containing either ammonia or
chlorine because both prevent bubble ormation. A success ul
test depends on the ability o the solution to bubble.

TP-6967 2/2114 Section 1 Installation
The fuel system. Explosive fuel vapors can cause severe
injury or death. Vaporized uels are highly explosive. Use
extreme care when handling and storing uels. Store uels in a
well-ventilated area away rom spark-producing equipment
and out o the reach o children. Never add uel to the tank
while the engine is running because spilled uel may ignite on
contact with hot parts or rom sparks. Do not smoke or permit
lames or sparks to occur near sources o spilled uel or uel
vapors. Keep the uel lines and connections tight and in good
condition. Do not replace lexible uel lines with rigid lines. Use
lexible sections to avoid uel line breakage caused by
vibration. Do not operate the generator set in the presence o
uel leaks, uel accumulation, or sparks. Repair uel systems
be ore resuming generator set operation.
1.6.1 Fuel Supply
Because o variable climates and geographical
considerations, contact the local uel supplier or uel
system planning and installation. Figure 1-6 lists the
recommended uel ratings and other uel supply
in ormation or natural gas and LPG uels.
Fuel Type Natural as LP
Fuel supply inlet 1/2 NPT 1/2 NPT
Fuel supply pressure,
kPa (in. H
2
O)
0.9- 2.7
(3.5- 11)
1.7- 2.7
(7- 11)
Fuel low rate, Btu/hr. 193000 203000
Nominal Fuel Rating,
Btu/ t.
3
1000 2500
Figure 1-6 Fuel Supply
Veri y that the output pressure rom the primary gas
utility (or LPG tank) pressure regulator meets the
speci ications in Figure 1-6 and that the utility gas meter
low rate is su icient to supply the generator set at rated
load plus all other gas-consuming appliances. See
Figure 1-7 or uel consumption. Contact the uel
supplier or low rate in ormation or a gas meter
upgrade.
The dimension drawings in Section 2 show the location
o the uel inlet connection. Use lexible sections to
prevent uel line breakage caused by vibration. Hold the
uel pipe coupling with a wrench when tightening the uel
connections. Protect all uel lines rom machinery or
equipment contact, adverse weather conditions, and
environmental damage.
Fuel Consumption,
at % load, m
3
/hr. (cfh) 60 Hz 50 Hz
Natural Gas, m
3
/hr. (c h)
100% 5.4 (193) 4.8 (173)
75% 4.7 (163) 4.2 (148)
50% 3.5 (124) 3.1 (108)
25% 2.6 (93) 2.4 (84)
LPG, m
3
/hr. (c h)
100% 2.3 (81) 2.1 (74)
75% 2.1 (75) 1.9 (68)
50% 1.8 (60) 1.5 (53)
25% 1.2 (45) 1.1 (40)
LPG conversion actors:
8.58 t.
3
= 1 lb.
0.535 m
3
= 1 kg
36.39 t.
3
= 1 gal.
Nominal uel rating:
Natural gas: 37 MJ/m
3
(1000 Btu/ t.
3
)
LPG: 93 MJ/m
3
(2500 Btu/ t.
3
)
Figure 1-7 Fuel Consumption
1.6.2 Fuel Pipe Size
Ensure that the natural gas pipe size and length meet
the speci ications in Figure 1-8. Measure the pipe
length rom the primary gas pressure regulator to the
pipe connection on the generator set uel inlet. Add
2.4 m (8 t.) to the measured length or each 90 degree
elbow. Compare the total pipe length with the chart in
Figure 1-8 to ind the required pipe size.
Contact the local LPG provider or LPG installation
in ormation.
Minimum as Pipe Size Recommendation, in. NPT
Pipe Length,
m (ft.)
Natural as
(193,000 Btu/hr.)
LP
(203,000 Btu/hr.)
8 m (25 t.) 3/4 3/4
15 m (50 t.) 1 3/4
30 m (100 t.) 1 1
46 m (150 t.) 1 1/4 1
61 m (200 t.) 1 1/4 1
Figure 1-8 Fuel Pipe Size

TP-6967 2/21 15Section 1 Installation
1.7 Fuel Conversion
The multi- uel system allows conversion rom natural
gas to LPG (or vice-versa) in the ield while maintaining
emissions-standard compliance. A Kohler authorized
distributor/dealer can convert the uel system.
A revised uel system was implemented in February,
2021. The uel system can be identi ied by comparing
the regulator and solenoid valve with the illustrations in
the ollowing sections.
The original uel system uses uel ori ice ittings to
control the uel low or natural gas (NG) or LPG uels.
The original system uses a uel regulator and a separate
uel solenoid valve. See Section 1.7.1 or illustrations
and instructions to convert the uel on generator sets
with the original design.
The revised uel system uses a uel regulator with a uel
selector valve and an integrated uel solenoid valve.
See Section 1.7.2 or illustrations and instructions to
convert the uel on generator sets with the revised uel
system.
Rating Change
Converting the uel will change the generator set rating.
See the generator set speci ication sheet or ratings with
natural gas and LP. Order a new nameplate with the
updated rating and uel in ormation rom a Kohler
authorized distributor/dealer, i necessary. Provide the
ollowing in ormation rom the original nameplate:
Model Number kVA
Spec Number Amps
Serial Number Volts
Fuel (original and new) Hz
kW
Attach the new nameplate over the old one. Do NOT
cover the UL listing in ormation on the old nameplate.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables be ore
working on the generator set.
Remove the negative (- ) lead irst
when disconnecting the battery.
Reconnect the negative (- ) lead last
when reconnecting the battery.
WARNIN
Disabling the generator set. Accidental starting can
cause severe injury or death. Be ore working on the
generator set or equipment connected to the set, disable the
generator set as ollows: (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 irst. Reconnect the negative (- ) lead last when
reconnecting the battery. Follow these precautions to prevent
starting o the generator set by an automatic trans er switch,
remote start/stop switch, or engine start command rom a
remote computer.
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using uels.
WARNIN
1.7.1 Fuel Conversion, Original Fuel
System
For natural gas and LPG uel, ori ice ittings are used in
the uel line. See Figure 1-9. The natural gas ori ice
itting is silver in color and stamped NG. The LPG itting
is gold in color and stamped LPG. The ittings are
threaded. A straight-blade screwdriver is required to
remove and replace the ittings.
N LP
Figure 1-9 NG and LPG Fuel Ori ice Fittings
The unit is typically shipped set up or natural gas, with
the LPG itting tied to the uel regulator. To convert to
LPG, remove the NG itting and install the LPG itting as
described below. See Figure 1-10 or the uel system
component locations.

TP-6967 2/2116 Section 1 Installation
Procedure to Convert from N to LP
1. Place the generator set master switch in the
OFF/RESET position.
2. Disconnect the utility power to the generator.
3. Disconnect the generator set engine starting
battery, negative (- ) lead irst.
4. Turn o and disconnect the uel supply.
5. Remove the hose clamp and uel hose rom the
hose itting. See Figure 1-10.
6. Use a straight-blade screwdriver to remove the NG
ori ice rom the hose itting. See Figure 1-11.
7. Insert the LPG ori ice into the hose itting. Use a
straight-blade screwdriver to tighten the itting until
it is snug.
8. Slide the hose onto the hose itting and secure it
with the clamp.
9. Disconnect ignition timing leads 65 and N5 or
LPG. The ignition timing leads are located near the
uel solenoid valve. See Figure 1-10.
Note: Do not disconnect the leads to the uel
solenoid valve.
3
1. LPG itting tied to regulator or shipping
2. Fuel hose and clamp
3. Ignition timing lead location (leads not shown)
2
Ignition Timing Lead Connection
1
Figure 1-10 Fuel System, As Shipped
10. Connect and turn on the new uel supply.
11. Reconnect the generator set engine starting
battery leads, negative (- ) lead last.
12. Reconnect the utility power to the generator.
13. Start the generator set by moving the master
switch to the RUN position.
14. Check or leaks using a gas leak detector.
15. Run the generator set and check the operation.
16. Move the generator set master switch to the
OFF/RESET position to shut down the generator
set.

TP-6967 2/21 17Section 1 Installation
Conversion from LP to Natural as
To convert rom LPG to natural gas, repeat the steps
above, removing the LPG uel ori ice and installing the
NG itting. Connect ignition timing leads 65 and N5
together or natural gas.
1. Fuel ori ice itting
2. Hose itting
3. Ori ice tied to regulator or shipping
1
GM29253
2
3
Figure 1-11 Fuel Ori ice Fitting Installation
1.7.2 Fuel Conversion, Revised Fuel
System
The revised uel system uses a knob that controls a
valve on the regulator to select the uel type. See
Figure 1-12 and Figure 1-13.
1
GM114161
1. Fuel selector
2. Fuel inlet
3. Integral uel solenoid valve
4. Place a wrench here to hold this coupling when connecting
the uel line.
2
34
Figure 1-12 Revised Fuel System
1
2
GM110973- CMP
1. Fuel selector
2. Pressure port
Figure 1-13 Fuel Selection (NG Position Shown)

TP-6967 2/2118 Section 1 Installation
Fuel Selection, Revised Fuel System
1. Place the generator set master switch in the
OFF/RESET position.
2. Disconnect the utility power to the generator.
3. Disconnect the generator set engine starting
battery, negative (- ) lead irst.
4. Turn o and disconnect the uel supply.
5. To change the uel selection:
a. For natural gas (NG), turn the selection knob all
the way clockwise. The knob lines up with the
UP arrow on the regulator body as shown in
Figure 1-14.
Img_0899
Figure 1-14 Knob Position, NG
b. For LPG, turn the selection knob
counterclockwise as ar as it will go,
approximately ¼turn. See Figure 1-15.
Img_0900
Figure 1-15 Knob Position, LPG
6. The ignition timing leads 65 and N, located near the
regulator. See Figure 1-16.
a. For natural gas (NG), connect lead 65 to lead N.
b. For LPG, disconnect lead 65 rom lead N.
7. Connect and turn on the uel supply (Ensure that
the uel supply matches the uel setting).
8. Reconnect the generator set engine starting
battery leads, negative (- ) lead last.
9. Reconnect the utility power to the generator.
10. Change the uel type setting on the RDC2
controller in the Genset System menu. See the
Operation Manual or instructions to change
settings on the controller.
11. Start the generator set by moving the master
switch to the RUN position.
12. Check or leaks using a gas leak detector.
13. Run the generator set and check the operation.
14. Move the generator set master switch to the
OFF/RESET position to shut down the generator
set.
Figure 1-16 Ignition Timing Leads
A pressure port is provided on the uel regulator. See
Figure 1-13. Follow these steps to check the uel
pressure at the regulator, i necessary.
1. Remove the plug rom the uel pressure port.
2. Connect a manometer capable o measuring low
pressures (3- 11 inches water column) to the
pressure port.
3. When inished, replace the plug in the pressure
port and check or leaks.

TP-6967 2/21 19Section 1 Installation
1.8 Electrical Connections
Hazardous voltage. Backfeed to
the utility system.
Can cause property damage,
severe injury, or death.
I the generator set is used or
standby power, install an automatic
trans er switch to prevent inadvertent
interconnection o standby and
normal sources o supply.
WARNIN
rounding electrical equipment. Hazardous voltage will
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, trans er switch, and related equipment and
electrical circuits. Turn o the main circuit breakers o all
power sources be ore servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk o
electrocution.
Electrical backfeed to the utility. Hazardous backfeed
voltage can cause severe injury or death. Install a trans er
switch in standby power installations to prevent the connection
o standby and other sources o power. Electrical back eed
into a utility electrical system can cause severe injury or death
to utility personnel working on power lines.
NOTICE
Canadian installations only. For standby service connect
the output o the generator set to a suitably rated trans er
switch in accordance with Canadian Electrical Code, Part 1.
Have a Kohler authorized distributor/dealer or a
licensed electrician make the ollowing electrical
connections. The electrical installation must comply
with the National Electrical Code (NEC) and all
applicable local codes. Canadian installations must
comply with the Canadian Electrical Code (CEC) and
applicable local codes.
Ground the generator set according to applicable
codes. See Section 1.8.3.
For customer-supplied wiring, select the wire
temperature rating in Figure 1-17 based upon the
ollowing criteria:
 Select row 1, 2, 3, or 4 i the circuit rating is
110 amperes or less or requires #1 AWG (42.4 mm
2
)
or smaller conductors.
 Select row 3 or 4 i the circuit rating is greater than
110 amperes or requires #1 AWG (42.4 mm
2
) or
larger conductors.
Row Temp. Rating Copper (Cu) Only Cu/Aluminum (Al) Combinations Al Only
160C (140F)
or
75C (167F)
Use No. * AWG, 60C wire or
use No. * AWG, 75C wire
Use 60C wire, either No. * AWG Cu, or No. *
AWG Al or use 75C wire, either No. * AWG
Cu or No. * AWG Al
Use 60C wire, No. * AWG or
use 75C wire, No. * AWG
260C (140F) Use No. * AWG, 60C wire Use 60C wire, either No. * AWG Cu or No. *
AWG Al
Use 60C wire, No. * AWG
375C (167F) Use No. *AWG, 75C wire Use 75C wire, either No. *AWG Cu or No. *
AWG Al
Use 75C wire, No.*AWG
490C (194F) Use No. *AWG, 90C wire Use 90C wire, either No. *AWG Cu or No. *
AWG Al
Use 90C wire, No.*AWG
* The wire size or 60C (140F) wire is not required to be included in the marking. I included, the wire size is based on ampacities or the
wire given in Table 310-16 o the National Electrical Code, in ANSI/NFPA 70, and on 115% o the maximum current that the circuit carries
under rated conditions. The National Electrical Codeis a registered trademark o the National Fire Protection Association, Inc.
Use the larger o the ollowing conductors: the same size conductor as that used or the temperature test or one selected using the
guidelines in the preceding ootnote.
Figure 1-17 Terminal Markings or Various Temperature Ratings and Conductors

TP-6967 2/2120 Section 1 Installation
1.8.1 Field Connections
The generator set is equipped with a ield-connection
terminal block located below the uel inlet. Leads have
been actory-installed rom the junction box to the
terminal block or easy ield wiring. Re er to the decal
near the terminal block or connections. Also see
Section 2, Wiring Diagrams.
Re er to the decal below the terminal block and the
trans er switch speci ications or the cable size range or
each connection. Route leads through lexible conduit.
Use separate conduit or AC wiring and low-voltage
engine start leads. Ensure that the leads and conduit do
not inter ere with the operation o the generator set or
obstruct the service areas.
Field Connections to the Terminal Block
1. Remove the cover rom the electrical connection
access area. See Figure 1-18.
2. Drill holes or conduit ittings:
a. See Figure 1-18 or the electrical inlet location.
Remove the cover rom the electrical inlet area.
b. Drill holes in the cover or the conduit ittings
and replace the cover. Use separate conduit
or AC wiring and low-voltage engine start
leads.
c. Feed the cables through the openings.
ADV-8024
Figure 1-18 Electrical Connection Area
3. See Figure 1-19. Connect the leads rom the
trans er switch emergency source lugs to the L1
and L2 connections on the generator set terminal
block.
4. Connect the neutral (L0) and ground (GRD) leads
rom the ATS and the main panel to the
corresponding connection points on the terminal
block. See Section 1.8.3, Grounding.
5. Connect 120 VAC utility power to the terminals
marked Utility Power. Power to this circuit must be
backed-up by the generator set. See Section 1.5
or more in ormation about the utility power
requirement.
6. Connect the engine start leads rom the automatic
trans er switch or remote start switch to terminals 3
and 4 on the terminal block. See Section 1.8.2.
7. Replace the cover over the electrical connection
access area. See Figure 1-18.
GM58022
GM54820
Note: Sample decal shown. See the decal on the generator
set or wire gauge.
Figure 1-19 Field-Connection Terminal Block, typical