Kohler 17RES User manual

Residential/Commercial Generator Sets
Models:
17RES/RESL/RESNT
18RES/RESL/RESNT/TRES
Controllers:
ADC-RES Advanced Digital Control
DC-RET Digital Control
TP-6519 8/17c
Service

Table of Contents
TP-6519 8/17 Table of Contents
Safety Precautions and Instructions 7.........................................................
Introduction 11...............................................................................
List of Related Materials 11......................................................
Service Assistance 12.........................................................................
Section 1 Specifications 13...................................................................
1.1 Introduction 13...........................................................
1.2 Controller Specifications 13................................................
1.3 Engine Service 13........................................................
1.4 Engine Specifications 13..................................................
1.5 Alternator Specifications 14................................................
1.6 Torque Specifications 14..................................................
1.7 Service Views 15.........................................................
Section 2 Scheduled Maintenance 17..........................................................
2.1 Service Schedule 17......................................................
2.2 Lubrication System 19....................................................
2.2.1 Low Oil Pressure Shutdown 19.....................................
2.2.2 Oil Check 19.....................................................
2.2.3 Engine Oil Recommendation 19....................................
2.2.4 Oil Change Procedure 19..........................................
2.2.5 Oil Cooler 20.....................................................
2.3 Spark Plugs 20...........................................................
2.4 Air Cleaner Service 21....................................................
2.5 Cooling System 21.......................................................
2.6 Stepper Motor Coupling 22................................................
2.7 Exhaust System 22.......................................................
2.8 Battery 22...............................................................
2.9 Battery Charger 23.......................................................
2.10 Storage Procedure 24.....................................................
2.10.1 Lubricating System 24............................................
2.10.2 Fuel System 24..................................................
2.10.3 Cylinder Lubrication 24............................................
2.10.4 Exterior Preparation 24............................................
2.10.5 Battery 24.......................................................
Section 3 Troubleshooting 25.................................................................
3.1 Introduction 25...........................................................
3.2 Initial Checks 25..........................................................
3.3 Troubleshooting Chart 25..................................................
3.4 Controller Troubleshooting 33..............................................
Section 4 Controller 35.......................................................................
4.1 Introduction 35...........................................................
4.2 Controls and Display 36...................................................
4.2.1 Master Switch 36.................................................
4.2.2 LED Display 36..................................................
4.2.3 Keypad 37.......................................................
4.3 Sequence of Operation 38.................................................
4.3.1 Starting Sequence, Master Switch Moved to RUN 38..................
4.3.2 Starting Sequence, Remote Start 38................................
4.3.3 Running Sequence 38............................................
4.3.4 Stopping Sequence, Master Switch Moved to OFF/RESET 38..........
4.3.5 Stopping Sequence, Remote Stop 38...............................
4.3.6 Standby Mode 38.................................................
4.3.7 Sleep Mode 38...................................................

Table of Contents, continued
TP-6519 8/17Table of Contents
4.4 Faults 39................................................................
4.4.1 Warnings 39.....................................................
4.4.2 Shutdowns 39....................................................
4.5 Controller Configuration and Adjustment, ADC-RES 41........................
4.5.1 Controller Configuration 41........................................
4.5.2 Controller Time Out 41............................................
4.5.3 Controller Application Program Version Number 41...................
4.5.4 Voltage and Frequency Adjustments 41.............................
4.6 Controller Relays 41......................................................
4.7 Optional Relay Board 42..................................................
4.8 Silicon Controlled Rectifier Module 44.......................................
4.9 Controller Replacement 45................................................
Section 5 Component Testing and Adjustment 49...............................................
5.1 Theory of Operation 49....................................................
5.2 Separate Excitation 49....................................................
5.3 Stator 51................................................................
5.4 Main Field (Rotor) 53.....................................................
5.4.1 Rotor Continuity and Resistance Tests 53............................
5.5 Slip Rings 54............................................................
5.6 Brushes 54..............................................................
5.7 Voltage Connections 55...................................................
5.7.1 Voltage Connections, Single-Phase Models 55.......................
5.7.2 Voltage Connections, 3-Phase Models 55............................
5.7.3 Voltage Regulation 55.............................................
5.8 Voltage Adjustment
(ADC-RES only) 55......................................................
5.8.1 Voltage Adjustment Procedure 56..................................
5.8.2 Volts per Hertz (Hz) Adjustments (Droop) 57.........................
5.9 Governor System 61......................................................
5.9.1 Operation 61.....................................................
5.9.2 Initial Checks and Operation Test 61................................
5.9.3 Hunting/Surging 61...............................................
5.9.4 Governor System/Magnetic Pickup Operation Test 62.................
5.9.5 Frequency Adjustment 65.........................................
5.10 Fault Shutdown Tests 66..................................................
5.10.1 Controller Fault Shutdown Functions 66.............................
5.10.2 Fault Shutdown Switches 67.......................................
5.11 Generator Set Master Switch 68............................................
5.12 Fuel Systems 68.........................................................
5.12.1 Fuel Solenoid Valve 68............................................
5.12.2 Fuel Regulators 69...............................................
5.12.3 Fuel Conversion 70...............................................
5.12.4 Digital Spark Advance Ignition (DSAI) Timing 71......................
5.13 Circuit Protection 71......................................................
5.13.1 Line Circuit Breaker 71............................................
5.13.2 Fuses 71........................................................
5.14 Starter Relay 71..........................................................
5.15 Continuity Checks 72.....................................................
Section 6 Disassembly/Reassembly 73.........................................................
6.1 Initial Steps 73...........................................................
6.2 Disassembly 74..........................................................
6.3 Reassembly 79..........................................................
Section 7 Wiring Diagrams 85.................................................................

Table of Contents, continued
TP-6519 8/17 Table of Contents
Appendix A Abbreviations 91................................................................
Appendix B Common Hardware Application Guidelines 93.....................................
Appendix C General Torque Specifications 94.................................................
Appendix D Common Hardware Identification 95..............................................
Appendix E Common Hardware List 96.......................................................

TP-6519 8/176

TP-6519 8/17 7Safety Precautions and Instructions
Safety Precautions and Instructions
IMPORTANT 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. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
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 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 cause
severe injury or death. Before
working on the generator set or
equipment 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 precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
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 from
explosive fumes.
WARNING
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 splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities 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 result in hazardous
spattering of 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.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
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. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.

TP-6519 8/178 Safety Precautions and Instructions
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
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 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 cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Generator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes 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 building
through windows, air intake vents, or
other openings.
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 if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:
DLight-headedness, dizziness
DPhysical fatigue, weakness in
joints and muscles
DSleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
DStomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Fuel System
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
WARNING

TP-6519 8/17 9Safety Precautions and Instructions
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LPG vapor or
natural gas fuel system for leakage by
using a soap and water solution with the
fuel 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 formation. A successful
test depends on the ability of the
solution to bubble.
LPG liquid withdrawal fuel leaks.
Explosive fuel vapors can cause
severe injury or death. Fuel leakage
can cause an explosion. Check the
LPG liquid withdrawal fuel system for
leakage by using a soap and water
solution with the fuel system test
pressurized to at least 90 psi
(621 kPa). Do not use a soap solution
containing either ammonia or chlorine
because both prevent bubble
formation. A successful test depends
on the ability of the solution to bubble.
Hazardous Noise
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
CAUTION
Hazardous Voltage/
Moving Parts
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
DANGER
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
WARNING
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
CAUTION
Grounding 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,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.

TP-6519 8/1710 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
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.
High voltage test. Hazardous
voltage will cause severe injury or
death. Follow the instructions of the
test equipment manufacturer when
performing high-voltage tests on the
rotor or stator. An improper test
procedure can damage equipment or
lead to generator set failure.
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 qualified
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 before servicing the
equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
Testing live electrical circuits.
Hazardous voltage or current will
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Heavy Equipment
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
WARNING
Hot Parts
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Servicing the alternator. Hot parts
can cause severe injury or death.
Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
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 before connecting it to power.
Operating the heater before installation
can cause burns 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 output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.

TP-6519 8/17 11Introduction
Introduction
This manual provides troubleshooting and repair
instructions for the generator set models listed on the
front cover. This manual may also be supplied for
similar models not listed on the front cover.
Information in this publication represents data available
at the time of 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 carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed
intervals. Maintenance work must be performed by
appropriately skilled and suitably trained maintenance
personnel familiar with generator set operation and
service.
For engine service procedures not covered in this
manual, refer to the Engine Service Manual.
6519
Figure 1-1 Model 17RES
6519
Figure 1-2 Model 17RES, Door Removed
List of Related Materials
Separate manuals contain operation, installation, and
parts information not provided in this manual. Separate
engine operation and service manuals are also
available. The following table lists the available manual
part numbers.
Document Description Part Number
Installation Manual, RES/TRES Models
(before October 2011) TP-6514
Installation Manual, RES/TRES Models
(after October 2011) TP-6792
Operation Manual, RES/TRES Models TP-6515
Installation Manual, RESL/RESNT Models TP-6516
Operation Manual, RESL/RESNT Models TP-6517
Parts Catalog TP-6518
Engine Service Manual, CH980 TP-2580

TP-6519 8/1712 Service Assistance
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please
contact your nearest Kohler distributor or dealer.
DConsult the Yellow Pages under the heading
Generators—Electric.
DVisit the Kohler Power Systems website at
KOHLERPower.com.
DLook at the labels and decals on your Kohler product
or review the appropriate literature or documents
included with the product.
DCall toll free in the US and Canada 1-800-544-2444.
DOutside the US and Canada, call the nearest regional
office.
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 Pacific Regional Office
Singapore, Republic 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-6519 8/17 13Section 1 Specifications
Section 1 Specifications
1.1 Introduction
The spec sheets for each generator set provide specific
generator and engine information. Refer to the
generator set spec sheet for ratings and other data not
supplied in this manual. Consult the generator set
installation manual, engine operation manual, and
engine service manual for additional specifications.
Consult the generator set nameplate for specific
generator set ratings.
1.2 Controller Specifications
The generator set is equipped with the Advanced Digital
Control. For a specific description of the controller, see
Section 2, Operation, in the operation manual.
Environmental Specification All Models
Operating temperature -- 2 0 _Cto70_C
Storage temperature -- 6 0 _Cto70_C
Humidity 0--95% condensing
Power requirements:
Voltage 12 VDC
Current 250 mA @ 12 VDC
1.3 Engine Service
Generator sets covered in this manual are equipped
with four-cycle, twin cylinder, air-cooled Kohler engines.
For engine service information and specifications not
covered in this manual, see the engine service manual.
See the List of Related Materials in the Introduction
section.
1.4 Engine Specifications
Engine Specification All Models
Manufacturer Kohler
Model CH980
Cycle 4
Number of cylinders 2
Compression ratio 8.8:1
Displacement, cc (cu. in.) 999 (61)
Rated power, propane fuel,
kw (HP) 21.7 (29.1)
Rated power, natural gas,
kw (HP) 18.6 (25.0)
Rpm, 60 Hz 3600
Rpm, 50 Hz 3000
Bore x stroke, mm (in.) 90 x 78.5 (3.54 x 3.1)
Valve material Steel/Stelliter
Cylinder block material Aluminum w/cast iron liners
Cylinder head material Aluminum
Piston rings 2 compression/ 1 oil
Crankshaft material Heat-treated ductile iron
Main bearings: number, type 2, parent material
Lubrication system Full pressure
Oil capacity (w/filter), L (qt.) 2.8 (3.0)
Oil pressure, kPa (psi) 172--241 (25--35)
Fuel system LP gas or natural gas
LP/natural gas minimum
supply pressure,
in. H2O (oz./in.2)
7--11 (4--6)
Battery voltage 12 VDC
Battery ground Negative
Spark plug gap, mm (in.) 0.76 (0.030)
Ignition system Capacitor discharge
Starter motor Electric, solenoid shift
Cooling system Air-cooled

TP-6519 8/1714 Section 1 Specifications
1.5 Alternator Specifications
Alternator Specification 17/18RES/RESL/RESNT 18TRES
Frequency Hz 50/60 50
Phase Single-Phase Three-Phase
Number of leads 412
Excitation method Static Excited
Voltage regulator type Digital
Coupling type Direct
Insulation (rotor and stator) Epoxy varnish, vacuum impregnated
Class 180 (H)
Winding material Copper
Bearing, number and type 1, Sealed Ball
Circuit protection
Controller 10 amps
Aux. winding 20 amps
Generator AC output Dependent on voltage configuration
Rotor resistance, ohms, cold 5.2 5.2
Stator resistance, ohms,* cold
Single-Phase Leads 1-2, 3-4 0.06 N/A
Three-Phase Leads 1-4, 2-5, 3-6, 7-10, 8-11, 9-12 N/A 0.10
11-44 0.13 N/A
55-66 0.60 0.19
Stator output voltage with separately excited rotor using 12-volt
battery, minimum
Leads: 1-2, 3-4 105 V N/A
Leads: 1-4, 2-5, 3-6, 7-10, 8-11, 9-12 N/A 115 V
11-44 210 V N/A
55-66 142 V 174 V
Rotor field voltage/current readings at rated output voltage, hot
No load 19 V/3.2 A 22 V/3.6 A
Full load 48 V/7.2 A 88 V/10.5 A
Brush length, new 19.05 mm (0.75 in.)
* Most ohmmeters do not give accurate readings when measuring less than 1 ohm. The stator can be considered good if a low resistance
reading (continuity) is obtained and there is no evidence of shorted windings (discoloration). Do not confuse a low resistance reading with
a reading indicating a shorted winding.
1.6 Torque Specifications
Torque Specifications Nm (ft. lb.)
Alternator overbolts 7(5)
Alternator thrubolt 53 (39)
Generator adapter screws 40 (28)
Muffler flange bolts 24 (17.7)
Oil filter 3/4to1turnafter
gasket contact
Spark plug 24.4--29.8 (18--22)

TP-6519 8/17 15Section 1 Specifications
1.7 Service Views
12 5422
17
6
3
14 27
18
21
1516
25
ADV-7341A-B
11
28 26
10
19 23
29
31
Control detail, top view
8
12
7
13
1. Muffler
2. Oil check
3. Oil fill
4. Air cleaner
5. Spark plug locations (both sides)
6. Oil filter
7. Oil cooler location
8. ADC-RES Advanced Digital Control user interface
9. DC-RET control user interface
10. Generator set master switch (RUN-OFF/RESET-AUTO)
11. Line circuit breaker
12. Fuses
13. RS-232 connector (for application program updates)
14. Engine starting battery location (battery purchased separately)
15. Oil drain hose
16. Nameplate location (on base)
17. Oil drain valve
18. Exhaust outlet
19. Relay board location (optional)
20. Carburetor heater access opening
21. LP fuel orifice location (inside hose fitting)
22. Gas regulator assembly
23. DSAI leads
24. Fuel solenoid valve
25. Fuel inlet
26. Air intake
27. Battery cables
28. Battery charger
29. Field-connection terminal block location (RES models)
30. 120 VAC receptacles for battery charger and optional
carburetor heater
31. Field connections inside junction box if optional
terminal block is not used
See control
detail 20
30
24
26
26
Fuel regulator and valve detail
21 24
22
11
10
9
12
13
ADC-RES DC-RET
Figure 1-1 Generator Set Service View

TP-6519 8/1716 Section 1 Specifications
1
GM66010
1. Emergency stop button
2. Field-connection terminal block and circuit breakers
3. Cable inlet area
4. Battery charger
2
3
ADV-7713
4
Figure 1-2 Additional Components, TRES (3-phase) Model

TP-6519 8/17 17Section 2 Scheduled Maintenance
Section 2 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.
WARNING
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or equipment 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 precautions to prevent
starting of the generator set by an automatic transfer switch,
remote start/stop switch, or engine start command from a
remote computer.
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
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.
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
DANGER
See the Safety Precautions and Instructions at the
beginning of this manual before attempting to service,
repair, or operate the generator set. Have an authorized
distributor/dealer perform generator set service.
Alternator Service. Under normal operating
conditions the generator set alternator does not require
scheduled service. Refer to the service schedule for
items that require maintenance.
Engine Service. Perform generator set engine service
at the intervals specified by the engine service literature.
Contact an authorized Kohlerrservice distributor/
dealer to obtain engine service literature.
All generator sets have emission-certified engines. The
carburetors on emission-certified engines are not
adjustable.
Generator Set Service. See the Safety Precautions
and Instructions at the beginning of this manual before
attempting to service, repair, or operate the generator
set. Have an authorized Kohlerrservice distributor/
dealer perform all generator service.
Routine Maintenance. Refer to the following
generator set service schedule, the engine service
schedule, and the runtime hours displayed on the
generator set controller to determine when to schedule
routine maintenance. Service the generator set more
frequently if it is subject to extreme weather, long
operating hours, or dusty or dirty conditions.
Service Schedule. Perform maintenance on each item
in the service schedule at the designated interval for the
life of the generator set.
Tools. Tools and instruments used to perform some
maintenance items are not generally available to the
generator set owner. Therefore, have service
performed by an authorized distributor/dealer.
2.1 Service Schedule
Perform the items listed in the service schedule at the
designated intervals for the life of the generator set. For
example, an item serviced every 100 hours or 3 months
must also be serviced after 200 hours or 6 months,
300 hours or 9 months, etc.

TP-6519 8/1718 Section 2 Scheduled Maintenance
System Component or Procedure
See
Section
Procedure
Visually
Inspect Check Change Clean Test
Fuel
Flexible lines and connections Q R
Main tank supply level (LP) W
Fuel piping Y
Lubrication 2.2
Oil level 2.2.2 8orE
Change oil 2.2.4 Y or 150
Replace filter 2.2.4 Y or 150
Crankcase breather hose Y or 500
Oil cooler 2.2.5 YY or 100
Cooling 2.5
Air ducts, louvers Y Y
Exhaust System 2.7
Leakage W W
Insulation, fire hazards Y
Obstructions or combustible materials near exhaust outlet W
DC Electrical System
Battery charger operation, charge rate M
Remove corrosion, clean and dry battery and rack 2.8 Y Y
Clean and tighten battery terminals and inspect boots Y Y
Tighten DC electrical connections Y
AC Electrical System
Tighten control and power wiring connections Y
Remote control system, if equipped M
Visible wear or damage Q
Wire abrasions where subject to motion 6 months 6 months
Wire-cable insulation condition 3Y or 500
Engine and Mounting
Visible wear or damage W
Air cleaner service * 2.4 150 300
Spark plugs 2.3 150 300
Replace stepper motor coupling and bushing 2.6 500 (D)
Generator
Visible wear or damage Q
Exercise generator set W
Brushes and collector ring 5.5, 5.6 Y(D) Y(D)
Measure and record resistance readings of windings with
insulation tester (Meggerr, with SCR assembly or rectifier
and load leads disconnected)
3Y (D)
General Condition of Equipment
Evidence of vibration, leakage, deterioration, unusual or
excessive noise or temperature W W W
Interior of sound enclosure Q Q
* Service more frequently under extremely dusty/dirty conditions.
Meggerris a registered trademark of Biddle Instruments.
EEachuse
W Weekly
M Monthly
Q Quarterly
Y Yearly
Number = hours of operation
D Authorized distributor/dealer only
R Replace as necessary
S/M Service Manual
Figure 2-1 Service Schedule

TP-6519 8/17 19Section 2 Scheduled Maintenance
2.2 Lubrication System
See Section 2.1, Service Schedule, for oil change and
oil filter replacement intervals. See Section 1.7, Service
View, for the oil drain, oil check, oil fill, and oil filter
locations.
2.2.1 Low Oil Pressure Shutdown
The low oil pressure (LOP) shutdown feature protects
the engine against internal damage if the oil pressure
drops below a minimum pressure because of oil pump
failure or other malfunction.
Note: The LOP shutdown feature does not protect
against damage caused by operating when the
oil level is low; it is not a low oil level shutdown.
Check the oil level regularly, and add oil as
needed.
2.2.2 Oil Check
The generator set is shipped with oil. Before operating
the generator set, check the engine oil in the crankcase.
See Figure 2-2 for the dipstick location.
Maintain the oil level at or near, not over, the full mark on
the dipstick. Add 5W-30 synthetic oil when the oil level is
low. See Section 2.2.3, Engine Oil Recommendation.
Check the oil level before each use. For extended
operation, check the oil level every 8 hours. Do not
check the oil level when the generator set is running.
Shut down the generator set and wait several minutes
before checking the oil.
6515
Figure 2-2 Oil Check
2.2.3 Engine Oil Recommendation
Use 5W-30 API (American Petroleum Institute) Service
Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes
and thickens less than other oils and leaves the engine
intake valves and pistons cleaner.
2.2.4 Oil Change Procedure
Note: Dispose of all waste materials (engine oil, fuel,
filter, etc.) in an environmentally safe manner.
Drain the oil while it is still warm.
1. Drain the oil.
a. Place the generator set master switch in the
OFF position.
b. Disconnect the power to the battery charger.
c. Disconnect the generator set engine starting
battery, negative (--) lead first.
d. Remove the housing side panel.
e. Clean the area around the dipstick and oil fill
cap.
f. Remove the oil drain hose from its retaining
clip. Remove the cap from the oil drain hose
and lower the hose into an oil collection
container.
g. Open the oil drain valve on the engine.
h. Remove the dipstick and oil fill cap. Allow time
for the engine oil to drain completely.
i. Close the oil drain valve. Replace the cap on
the oil drain hose. Replace the oil drain hose in
its retaining clip.
j. Replace the dipstick.
2. Replace the oil filter.
a. Clean the area around the oil filter. Remove the
oil filter by rotating it counterclockwise with an
oil filter wrench.
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.

TP-6519 8/1720 Section 2 Scheduled Maintenance
3. Fill with oil.
a. Fill the engine to the F mark on the dipstick.
The engine oil capacity is approximately 2.8 L
(3.0 qt.). See Section 2.2.3, Engine Oil
Recommendation, for oil selection.
b. Reinstall the dipstick and the oil fill cap.
c. Check that the generator set master switch is in
the OFF position.
d. Reconnect the generator set engine starting
battery, negative (--) lead last.
e. Reconnect the power to the battery charger.
f. Start and run the generator set for a minute to
allow the oil pressure to reach operating range.
g. Stop the generator set, wait 1 minute, and then
recheck the oil level. Add oil to bring the level
up to the F mark on the dipstick.
4. Check for leaks.
a. Check for oil leaks.
b. Fix leaks and recheck the oil level.
c. Reinstall the housing side panel.
2.2.5 Oil Cooler
Inspect and clean the oil cooler at the intervals indicated
in the service schedule. The oil cooler must be kept free
of debris.
See Figure 2-3 for the oil cooler location. The oil cooler
is located under the No. 2 cylinder shroud. Remove the
top mounting screw and loosen the two side screws,
then lift off the cylinder shroud.
1
62 590 01
1. Oil cooler
Figure 2-3 Oil Cooler Location
Clean the outside of the oil cooler fins with a brush or
with compressed air.
2.3 Spark Plugs
Reset the spark plug gap or replace the plugs with new
plugs as necessary.
1. Clean the area around the base of the spark plug to
keep dirt and debris out of the engine.
2. Remove the spark plug and check its condition.
Replace the spark plug if it is worn or if its reuse is
questionable.
3. Check the spark plug gap using a wire feeler
gauge. Adjust the gap to 0.76 mm (0.030 in.) by
carefully bending the ground electrode. See
Figure 2-4 and Figure 2-5.
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 24.4--29.8 Nm
(18--22 ft. lb.)
1--514
Figure 2-4 Checking the Spark Plug Gap
1--511
Figure 2-5 Adjusting the Spark Plug Gap