Operation

Industrial Generator Sets

Models:

10/15/20REOD/REOZD
Controller:
ADC 2100 Advanced Digital Control

TP-6392 8/05

California Proposition 65

WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

Product Identification Information

Generator Set Identification Numbers

Controller Identification

Record the product identification numbers from the

generator set nameplate(s).

Record the controller description from the generator set

operation manual, spec sheet, or sales invoice.

Model Designation
Specification Number

Controller Description

Engine Identification

Serial Number
Accessory Number

ADC 2100

Accessory Description

Record the product identification information from the

engine nameplate.
Manufacturer

Yanmar

Model Designation
Serial Number

TP-6392 8/05

Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
List of Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Maintenance and Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Alternator Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Advanced Digital Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13
13
13

Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.1
ADC 2100 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2
Local Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.3
Remote/Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.4
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.5
Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . .
2.3.6
Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.7
Controller Software Version Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1
Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15
15
15
16
16
16
17
17
17
19
19
19
19
19

Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1
Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.3
Fuel/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.4
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.1
Checking the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.2
Draining the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.3
Filling the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.4
Flushing and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8.5
Pressure Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 Belt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21
21
22
24
25
25
25
26
27
27
27
28
29
30
30
31
31
31
31
32
32
32
33

TP-6392 8/05

Table of Contents

Table of Contents, continued

3.11 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.4 Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34
34
34
34
34
34

Section 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Section 5 Reconnection/Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Four-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1
100--120-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.2
100--120/200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.3
200--240-Volt Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Twelve-Lead Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 ADC 2100 Adjustment after Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1
Configuration Mode Time Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2
Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.3
Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39
39
39
39
40
41
42
42
42
43

Section 6 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

Appendix B Operating Hour Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55

Table of Contents

TP-6392 8/05

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical
equipment,
including
generator
sets
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, or substantial
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.

TP-6392 8/05

Accidental Starting
WARNING

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.

Battery
WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.

WARNING
Disabling
the
generator set.
Accidental starting can cause
severe injury or death.
Before
working on the generator set or
connected equipment, 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.

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.
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.
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
WARNING

Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.

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.

Servicing the fuel system. A flash

fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the fuel injection system,
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 fuel system.

Using engine starting fluid.

A
sudden backfire can cause severe
injury or death. Do not use starting
fluid or similar agents to start an engine
equipped with air preheating (glow
plugs/starter element). The starter
element may cause an explosion in the
inlet manifold.

Servicing the air cleaner. A sudden

backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.

Engine Fluids and

Chemical Products

Servicing the air cleaner on a

turbocharged engine. A sudden
engine backfire or turbocharger
compressor failure can cause
severe injury or death. Do not
operate the generator set with the air
cleaner removed. Burns from hot
turbocharger components may occur.
Foreign objects sucked into the
turbocharger can cause mechanical
damage and the potential for high
velocity projectiles.

WARNING

Handling caustic engine fluids and

chemical products.
Can cause severe chemical burns,
nausea, fainting, or death.
Most chemicals such as used engine
oil, antifreeze/coolant, rustproofing
agent, inhibiting oil, degreasing
agent, spray paint, and adhesives are
hazardous to health. Read and follow
the user information found on the
packaging. Avoid inhalation and skin
contact. Use only in well-ventilated
areas and use a protective mask
when spraying. Store engine fluids
and chemical products in a locked
cabinet. Contact your local recycling
center for disposal information and
locations.

TP-6392 8/05

WARNING

Exhaust System
WARNING

Flammable engine solvents and

cleaners.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near flammable engine
solvents and cleaners. Read and
follow the user information found on
the packaging. Use only in wellventilated areas. Never use gasoline
or low flash-point solvents as
cleaning agents.
Leaking or accumulated engine
fluids. A fire can cause severe injury
or death. Clean up engine fluids
including fuel, oil, grease, and coolant.
Determine the source of engine leaks
and correct before starting the
generator set. Keep the generator set
area clean and remove combustible
materials.
Used engine oil. Contact with used
engine oil may cause severe skin
irritation. Repeated and prolonged
skin exposure may have other
health risks. Used engine oil is a
suspected carcinogen. Avoid contact
with skin. Thoroughly wash your hands
and nails with soap and water shortly
after handling used engine oil. Wash or
dispose of clothing or rags containing
used engine oil. Dispose of used
engine oil in a responsible manner.
Contact your local recycling center for
disposal information and locations.
Fire-damaged or burned O-rings
may cause the formation of
hydrofluoric acid.
Contact with
hydrofluoric acid may cause severe
skin irritation and chemical burns.
O-rings and other fluoroelastomer
seals exposed to fire or temperatures
above 316_C (600_F) (i.e., during
welding) may decompose forming
hydrofluoric acid. Avoid inhalation or
skin contact. Do not incinerate O-rings.
Dispose of O-ring waste material in a
responsible manner.

TP-6392 8/05

Carbon monoxide.
Can cause severe
fainting, or death.

nausea,

The exhaust system must be

leakproof and routinely inspected.
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 unless the exhaust gas is
piped safely outside. Never operate
the generator set where exhaust gas
could accumulate and seep back inside
a potentially occupied building.
Carbon
monoxide
symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide
poisoning symptoms include but are
not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, 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.

Copper tubing exhaust systems.

Carbon monoxide can cause severe
nausea, fainting, or death. Do not
use copper tubing in diesel exhaust
systems. Sulfur in diesel exhaust
causes rapid deterioration of copper
tubing exhaust systems, resulting in
exhaust leakage.

Fuel System
WARNING

Explosive fuel vapors.

Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.

WARNING

Avoid high pressure fluids.

Can cause severe injury or death.
Do not work on high pressure fuel or
hydraulic systems without protective
gloves. Avoid the hazard by relieving
pressure before disconnecting fuel
injection pressure lines. Search for
leaks using a piece of cardboard.
Always protect hands and body from
high pressure fluids. If an accident
occurs, seek medical attention
immediately. Any fluid injected in the
skin tissues must be surgically
removed within a few hours or
gangrene may result.

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.
Fuel tanks. Explosive fuel vapors
can cause severe injury or death.
Gasoline and other volatile fuels stored
in day tanks or subbase fuel tanks can
cause an explosion. Store only diesel
fuel in tanks.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.

Hazardous Voltage/
Electrical Shock
WARNING

Hazardous voltage. Moving rotor.

Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.

WARNING

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.

CAUTION

Hazardous Noise
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.

Grounding electrical equipment.

Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present.
Open the main circuit
breakers of all power sources before
servicing the equipment. Configure the
installation to electrically ground the
generator set, transfer switch, and
related equipment and electrical
circuits to comply with applicable codes
and standards.
Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
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 batterycharging
alternator
connections.
(5) Attach the weld ground connection
close to the weld location.
Installing the battery charger.
Hazardous voltage can cause
severe injury or death.
An
ungrounded battery charger may
cause electrical shock. Connect the
battery charger enclosure to the ground
of a permanent wiring system. As an
alternative, install an equipment
grounding conductor with circuit
conductors and connect it to the
equipment grounding terminal or the
lead on the battery charger. Install the
battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.

Never weld components of the

generator
set
without
first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).

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.

TP-6392 8/05

Connecting the battery and the

battery charger. Hazardous voltage
can 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).
Servicing the day tank. Hazardous
voltage can cause severe injury or
death. Service the day tank electrical
control module (ECM) as prescribed in
the equipment manual. Disconnect the
power to the day tank before servicing.
Press the day tank ECM OFF
pushbutton to disconnect the power.
Notice that line voltage is still present
within the ECM when the POWER ON
light is lit. Ensure that the generator set
and day tank are electrically grounded.
Do not operate the day tank when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
Short
circuits.
Hazardous
voltage/current can 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.
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
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.

TP-6392 8/05

Heavy Equipment

WARNING

WARNING
Hot engine oil.
Can cause severe injury or death.
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.

Hot Parts
WARNING

Hot coolant and steam.

Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

Avoid skin contact with hot oil. Do not

start or operate the generator set with
the engine oil filler cap removed, as
hot oil can spray out. Ensure that the
lubrication system is not under
pressure when servicing. Do not
work on the generator set until it
cools.
Checking the coolant level. Hot
coolant can cause severe injury or
death. Allow the engine to cool.
Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure cap with a thick cloth and then
slowly turn the cap counterclockwise to
the first stop. Remove the cap after
pressure has been completely
released and the engine has cooled.
Check the coolant level at the tank if the
generator set has a coolant recovery
tank.
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.

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.
Do not work on the generator set until
it cools.

Moving Parts
WARNING

Hazardous voltage. Moving rotor.

Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.

WARNING

Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.

WARNING

Airborne particles.
Can cause severe
blindness.

Tightening the hardware. Flying

projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator set engine and can cause
personal injury.
Retorque all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotor thrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise can loosen the
hardware.
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.

Notice

NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from
an
authorized
service
distributor/dealer.

NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.

NOTICE
When replacing hardware, do not
substitute with inferior grade
hardware.
Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.

NOTICE

NOTICE

This generator set has been

rewired from its nameplate voltage
to

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.

246242

injury

or

Wear protective goggles and clothing

when using power tools, hand tools,
or compressed air.

10

TP-6392 8/05

Introduction
This manual provides operation instructions for Model
10/15/20REOD/REOZD generator sets.
Refer to the engine operation manual for generator set
engine scheduled maintenance information.
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.
Obtain service from an authorized service
distributor/dealer to keep equipment in top condition.

List of Related Literature

Figure 1 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.
Literature Type

TP-6393

Operation Manual (Generator)

TP-6392

Operation Manual (Engine)

TP-6412

Parts Catalog*

TP-6395

Service Manual (Engine)

Figure 2 identifies maintenance and service parts for

your generator set.
Obtain a complete list of
maintenance and service parts from your authorized
generator distributor/dealer.
Part Description

Part Number

Air Cleaner Element for:

10REOD/REOZD
15REOD/REOZD

GM42265

Air Cleaner Element for:

20REOD/REOZD

GM42266

Belt

GM42428

Fuel Filter Element

GM32359

Fuel/Water Separator Element

225259

Fuse, Auxiliary Winding (F1):

20 amp for 12 lead generator sets

GM39266

10 amp for 4 lead generator sets

223316

Fuse, Relay Interface Board (F2) 10 amp

223316

Fuse, Controller (F3) 10 amp

223316

Oil Filter

252834

Spray Paint (Black)

221292

Figure 2

Maintenance and Service Parts

x:in:001:004

Part Number

Installation Manual

Service Manual (Generator)

Maintenance and Service Parts

TBD
TP-6293

* One manual combines Generator and Engine information.

Figure 1

Generator Set Literature

x:in:001:005

TP-6392 8/05

Introduction 11

Service Assistance
For professional advice on generator power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading

GeneratorsElectric
D Visit

the Kohler Power Systems website at

KohlerPowerSystems.com

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents

included with the product
D Call toll free in the US and Canada 1-800-544-2444
D Outside the US and Canada, call the nearest regional

office
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems
ZI Senia 122
12, rue des Hauts Flouviers
94517 Thiais Cedex
France
Phone: (33) 1 41 735500
Fax: (33) 1 41 735501

China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131

Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

12 Introduction

TP-6392 8/05

Section 1 Features
1.1 Specifications
The spec sheets for each generator set provide specific
alternator and engine information. The controller spec
sheet provides specifications particular to the controller.
Refer to the respective spec sheet for data not supplied
in this manual. Consult the generator set service
manual, generator set installation manual, engine
operation manual, and engine service manual for
additional specifications.

1.2 Alternator Features

The Model REOD alternator is equipped with Kohlers
PowerBoostt voltage regulation system which
provides instant response to load changes.

D LED display communicates faults:

D High battery voltage
D High engine temperature
D Low battery voltage
D Low oil pressure
D Overcrank safety
D Overspeed
D Overfrequency
D Overvoltage
D Underfrequency

PowerBoostt is a unique system that ensures reliable

motor starting and consistent voltage levels.
PowerBoostt utilizes a voltage excitation system that
employs a winding independent of the main output
windings to provide excitation voltage.

D Undervoltage
D Membrane keypad for configuration and adjustment:
D Password-protected user access to menus
D System configuration

1.3 Advanced Digital Control

The generator set is equipped with the Kohlerr
Advanced Digital Control (ADC 2100). Controller
features include the following:
D Compact controller

D Voltage adjustment
D Master control switch: Run/Off-Reset/Auto
D Remote two-wire start/stop capability
D Superior electronics protection from corrosion and

D Integrally mounted to the generator set

vibration:

D LED display:

D Potted electronics

D Runtime hours
D Crank cycle status
D Diagnostics

TP-6392 8/05

D Sealed connections
D Digital voltage regulation: 1.5% RMS no-load to

full-load
D Automatic start for programmed cranking cycle

Section 1 Features

13

Notes

14

Section 1 Features

TP-6392 8/05

Section 2 Operation
2.1 Prestart Checklist
To ensure continued satisfactory operation perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.
Air Cleaner. Check for a clean air cleaner element to
prevent unfiltered air from entering the engine.
Air Inlets. Check for clean and unobstructed air inlets.
Air Shrouding. Check for securely installed and
positioned air shrouding.
Battery. Check for tight battery connections. Consult
the battery manufacturers instructions regarding
battery care and maintenance.
Coolant Level. Check the coolant level according to
the cooling system maintenance information.
Note: Block heater damage. The block heater will fail
if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
the system before energizing the block heater.

Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
Operating Area. Check for obstructions that could
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.

2.2 Exercising the Generator Set

Operate the generator set without load once each week
for 20 minutes. If the generator set does not have a
programmed exercise mode or an automatic transfer
switch (ATS) with an exercise option, exercise the unit in
the presence of an operator.
The operator should perform all of the prestart checks
before starting the exercise procedure. Start the
generator set according to the starting procedure in
Section 2.3.2 of this manual. While the generator set is
operating, listen for a smooth-running engine and
visually inspect the generator set for fluid or exhaust
leaks. Check the air inlets and outlets and remove any
items restricting the air flow.

Drive Belt(s). Check the belt condition and tension of

the water pump and battery charging alternator belt(s).
Exhaust System. Check for exhaust leaks and
blockages. Check the muffler and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components for cracks and
corrosion (exhaust manifold, exhaust line, exhaust
clamps, and muffler).
D Check for corroded or broken metal parts and replace

them as needed.
D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace the exhaust clamps

and/or hangers as needed.
D Check that the exhaust outlet is unobstructed.
D Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components.

Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.

TP-6392 8/05

Section 2 Operation

15

2.3 Generator Set Operation

Figure 2-1 illustrates the user interface on the Advanced
Digital Control (ADC 2100) generator set controller.
1

switch is moved to the RUN or AUTO position and

remains active until the master switch is moved to the
OFF/RESET position or power to the controller is
removed. The LED display turns off 48 hours after
generator set shutdown. See Section 2.3.6.
The buttons on the controller keypad are used only for
system configuration and adjustment. The system
configuration is factory-set and should not require
changes under normal operating conditions. Contact an
authorized distributor/dealer or service technician if
adjustments are required.

3
2

2.3.2

Local Operation

Local Starting
Move the generator set master switch to the RUN
position to start the generator set.

4
1.
2.
3.
4.

GM28707A-C

LED display
Select button
Up and down arrow buttons (use for setup and adjustment only)
Generator set master switch

Figure 2-1

2.3.1

The controller attempts to start the generator set three

times (three crank cycles, 15 seconds crank and
15 seconds off). If the generator set does not start in
three attempts, the system shuts down on an overcrank
fault.
Local Stopping
1. Run the generator set at no load for at least
2 minutes to ensure adequate engine cooldown.

ADC 2100 User Interface

ADC 2100 Controls and Indicators

Figure 2-2 describes the controls and indicators located

on the ADC 2100.

2. Move the generator set master switch to the

OFF/RESET position. The engine stops.
Note: There is no engine cooldown time delay on the
ADC 2100 controller.

The LED display indicates generator set status. The

LED display is activated when the generator set master
Control or Indicator

Item

Description

LED display

Runtime hours

Displays total generator set runtime hours while the generator set is running and when no
other codes are displayed.

Crank indication

Displays CC_1, CC_2, or CC_3 to indicate the first, second, or third attempt to start the
engine. The last digit flashes during the crank cycle rest periods.

Fault codes

Flashes a 2- or 3-letter fault code to indicate various fault conditions. See Section 2.3.4.

Fuel

Displays FUEL during fuel pump priming procedure. See Section 3.5.4.

Software version
number

See Section 2.3.7.

Keypad

Select and arrow

buttons

The keypad is used for controller setup and adjustment only. Have setup and adjustments
performed only by an authorized distributor/dealer. The setup and adjustment functions are
password-protected.

Generator set master

switch

Three-position
switch

Switch functions as the generator set operation and controller reset switch.

Figure 2-2

16

ADC 2100 Controls and Indicators

Section 2 Operation

TP-6392 8/05

2.3.3

Remote/Automatic Operation

A remote switch or an automatic transfer switch (ATS)

can be used to start and stop the generator set.
Connect the remote start/stop switch or the ATS engine
start contacts to ADC 2100 engine start leads 3 and 4.
Move the generator set master switch to the AUTO
position.
Automatic Starting
With the generator set master switch in the AUTO
position, close the remote start contact connected to
engine start leads 3 and 4 to signal the generator set to
start.
The controller attempts to start the generator set three
times (three crank cycles, 15 seconds crank and
15 seconds off). If the generator set does not start in
three attempts, the system shuts down on an overcrank
fault.
Automatic Stopping

high engine temperature switch automatically resets

when the generator set cools. However, the fault does
not clear until the controller is reset.
The controller displays a fault code but the generator set
does not shut down under the high and low battery
voltage warning conditions.

2.3.5

Resetting the Controller after a

Fault Shutdown

Always identify and correct the cause of a fault

shutdown before resetting the controller. Use the
following procedure to reset the generator set controller
after a fault shutdown.
1. Move the generator set master switch to
OFF/RESET.
2. Disconnect the generator set from the load using
the line circuit breaker or ATS. See the safety
precautions at the beginning of this section before
proceeding.

With the generator set master switch in the AUTO

position, open the remote switch or contact to stop the
generator set.

3. Identify and correct the cause of the fault

shutdown. See the safety precautions at the
beginning of this section before proceeding. Refer
to Section 4, Troubleshooting.

If the generator set was started by a start signal from a

remote start/stop switch or ATS, moving the generator
set master switch on the ADC 2100 to the OFF/RESET
position also stops the generator set.

4. Start the generator set by moving the generator set

master switch to RUN. Test operate the generator
set to verify that the cause of the shutdown has
been corrected.

Note: There is no engine cooldown time delay on the

ADC 2100 controller.

5. Move the generator set master switch to

OFF/RESET.

2.3.4

6. Reconnect the generator set to the load using the

line circuit breaker or ATS.

Faults

Figure 2-3 lists fault codes displayed by the ADC 2100.

If the generator set shuts down on a fault condition, it
cannot be restarted until the fault condition is corrected
and the controller is reset. See Section 2.3.5 to reset the
controller after a fault shutdown. The controller resets
automatically after a battery voltage fault condition is
corrected.
The shutdown switches on the generator set
automatically reset when the problem is corrected. The

TP-6392 8/05

7. Move the generator set master switch to the AUTO

position for startup by remote transfer switch or
remote start/stop switch.
Note: The controllers LED display remains off
until an engine start command is received.
Opening and closing a remote start/stop contact also
resets the controller.

Section 2 Operation

17

Code

Fault

Description

Check

AF

Auxiliary fault
input shutdown

Input from a customer-supplied contact that closes on a fault

condition. The generator set shuts down 2 seconds after the
fault is detected and will not start when the fault is active (input
is grounded).

Check the condition and operation of

customer-supplied equipment connected
to the auxiliary fault input P21-6 on the
customer interface connector.

HE

High engine
temperature
shutdown

Shutdown occurs if the engine coolant temperature exceeds

the maximum temperature for more than 5 seconds. This
protective becomes active after the engine reaches the crank
disconnect speed.

Check for blocked air inlets and exhaust

outlets.

LCL

Low coolant level

Not used.

LOC

Loss of coolant

Not used.

LOP

Low oil pressure

shutdown

Shutdown occurs if a low oil pressure condition exists for more Check for leaks in the lubrication system.
than 5 seconds. This protective becomes active 30 seconds
Check the oil level and add oil if the level
after the engine has reached crank disconnect speed
is low.
(30 second inhibit).
Note: The low oil pressure shutdown does not protect against
low oil level. Check the oil level at the engine.

OC

Overcrank
shutdown

Shutdown occurs after 3 unsuccessful starting attempts. The

crank cycle is set for three starting attempts of 15 seconds
cranking and 15 seconds rest.

Check the fuel supply, spark plug, and

battery.
Check for loose connections.

The generator set also shuts down if no engine rotation is

Contact an authorized distributor/dealer for
sensed during cranking. Shuts down 1 second after the fault is service if problem continues.
detected.
OF

Overfrequency
shutdown

Shutdown occurs when the governed frequency exceeds 110% Contact an authorized distributor/dealer for
of the systems frequency setpoint for more than 5 seconds.
service if problem continues.
This protective becomes active 10 seconds after engine start
(10 second inhibit).

OS

Overspeed
shutdown

Shutdown occurs if the engine speed exceeds 115% of the

normal running speed for more than 0.3 seconds.

Contact an authorized distributor/dealer for

service if problem continues.

OU

Overvoltage
shutdown

Shutdown occurs if the voltage exceeds 120% of the system

nominal voltage for more than 2 seconds.

Contact an authorized distributor/dealer for

service if problem continues.

UF

Underfrequency
shutdown

Shutdown occurs when the governed frequency falls blow 90% Reduce the load and restart the generator
of the nominal system frequency for more than 5 seconds.
set.
This protective becomes active 10 seconds after engine start.
Contact an authorized distributor/dealer for
(10 second inhibit).
service if problem continues.

UU

Undervoltage
shutdown

Shutdown occurs if the voltage falls below 80% of the nominal

system voltage for more than 10 seconds.

Reduce the load and restart the generator

set.
Contact an authorized distributor/dealer for
service if problem continues.

HB

High battery
voltage warning

Fault code is displayed if the engine starting battery voltage

Check the battery rating and condition.
rises above 16 VDC for a 12 VDC system or above 30 VDC for
Check the battery charger operation.
a 24 VDC system for more than 10 seconds when the engine is
not running. This fault condition does not inhibit engine
starting.
The fault condition clears when the battery voltage returns to a
voltage within the limits for more than 10 seconds.

LB

Low battery
voltage warning

Fault code is displayed if the engine starting battery voltage

falls below 8 VDC for a 12 VDC system or below 16 VDC for a
24 VDC system for more than 10 seconds when the engine is
not running. This fault condition does not inhibit engine
starting.

Check the battery rating and condition.

Check the battery charger operation.
Charge or replace the battery.

The fault condition clears when the battery voltage returns to a

voltage within the limits for more than 10 seconds.

Figure 2-3

18

ADC 2100 Fault Codes

Section 2 Operation

TP-6392 8/05

2.3.6

For example, 01.18 will be displayed for software

version 1.18.

Power Down

The controller is powered by the generator set engine

starting battery.
If the ADC 2100 is not configured for the optional
Remote Digital Gauge (communication setting Cn00),
the controller powers down after 48 hours of no activity
when the master switch is in the AUTO position. (See
the Installation Manual for more information about ADC
2100 controller settings.) A start signal from a remote
start/stop switch or a transfer switch connected to
engine start leads 3 and 4 energizes the controller and
initiates the crank cycle. Moving the generator set
master switch to the RUN position also turns the
controller back on.
If the ADC 2100 is configured for the optional Remote
Digital Gauge (communications setting Cn01), the
controller remains active at all times when the generator
set master switch is in the AUTO position.
Note: The ADC 2100 consumes 250 mA when the
master switch is in the AUTO position with the
Remote Digital Gauge connected. Exercise the
generator set weekly and consider using a
battery charger to maintain the battery.

2.3.7

Controller Software Version

Number

The application software for controller operation is

factory-loaded onto the Advanced Digital Control. At
times, it may be necessary to check the software version
number for troubleshooting purposes. Use the following
procedure.

4. Move the generator set master switch to the

OFF/RESET position and release the Select
button.

2.4 Circuit Protection

If the generator set circuit breaker trips or the fuses blow
repeatedly, see Section 4, Troubleshooting, for possible
causes.

2.4.1

Line Circuit Breaker

A circuit breaker interrupts the generator output in the

event of a fault in the wiring between the generator and
the load. The line circuit breaker location is shown in
Figure 3-1. If the circuit breaker trips, reduce the load
and switch the breaker back to the ON position.

2.4.2

Fuses

The junction box contains three inline fuses. Always

identify and correct the cause of a blown fuse before
restarting the generator set. Refer to section 4,
Troubleshooting, for conditions that may indicate a
blown fuse.
Obtain service from an authorized
distributor/dealer.
Controller Fuse. A replaceable 10-amp fuse protects
the controller circuitry. If the controller display is dark,
check the battery and battery connections and then
check the controller fuse. Replace the fuse if it is blown.

on the ADC

Relay Fuse. A replaceable 10-amp fuse protects the

engine relays. If the generator set does not crank, check
the battery and battery connections and then check the
relay fuse. Replace the fuse if it is blown.

2. Move the generator set master switch to the Run

postion. The generator set will not start.

Auxiliary Winding Fuse. A replaceable 10-amp fuse

for 4 lead generator sets (20-amp fuse for 12 lead
generator sets) protects the alternator.

Displaying the Software Version Number

1. Press and hold the Select button
2100.

3. After approximately five seconds, the software

version number is shown on the ADC 2100 display.

TP-6392 8/05

Section 2 Operation

19

Notes

20

Section 2 Operation

TP-6392 8/05

Section 3 Scheduled Maintenance

3.1 General Maintenance
WARNING

NOTICE
Hardware damage. The engine and generator set may use
both American Standard and metric hardware. Use the correct
size tools to prevent rounding of the bolt heads and nuts.

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.
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.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, 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.

WARNING

Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.

TP-6392 8/05

Engine Service. Perform generator set engine service

at the intervals specified by the engine operation
manual.
Generator Set Exercise. Operate the generator set
without load once each week for 20 minutes. If the
transfer switch does not have an exercise option,
exercise the unit in the presence of an operator.
Generator Set Service. Perform generator set service
at the intervals specified by the generator set operation
manual.
If the generator set operates under dusty or dirty
conditions, use dry compressed air to blow dust out of
the alternator. With the generator set running, direct the
stream of air in through the cooling slots at the alternator
end.
Routine Maintenance. Refer to the following generator
set service schedule, the engine service schedule, and
the runtime hours shown on the ADC 2100 to determine
when to schedule routine maintenance. Service more
frequently generator sets that are subject to extreme
weather or dusty or dirty conditions.
Service Log. Use the Operating Hour Service Log
located in the back of this manual to document
performed services.
Service Schedule. Perform maintenance on each item
in the service schedule at the designated intervals for
the life of the generator set. For example, an item
requiring service every 100 hours or 3 months also
requires service after 200 hours or 6 months, 300 hours
or 9 months, and so on.

Section 3 Scheduled Maintenance

21

3.2 Service Schedule

SystemComponent

Check

Procedure
Change
Clean

Reference
Section

Test

FUEL
Day tank level

Flexible lines and connections

Main tank supply level

Fuel/water separator

M (drain)

Filter(s)

3.5

Drain tank and replace fuel

3.5

50 or M

Fuel piping

Tank vents and return lines for obstructions

Fuel injection system

Eng. S/M

LUBRICATION
Oil level
Crankcase breather [

3.4

1500

Change oil

Eng. S/M
3.4

First 50,
then 250

Replace filter(s)*

3.4

COOLING
Block heater operation

Coolant level

Flexible hoses and connectors

Water pump(s)

Fan and alternator belts

Air ducts, louvers *

Louver motors and controls

3.8

Radiator exterior *

3.9
Y

3.8

EXHAUST SYSTEM
Drain condensate trap

I/M

Leakage

3.7

Insulation, fire hazards

3.7

Flexible connector(s)

3.7

Excessive back pressure

Hangers and supports

I/M

3.7

Battery charger operation, charge rate

Recharge after engine start

Battery
charger
instructions

Battery electrolyte level

DC ELECTRICAL SYSTEM

Battery specific gravity, charge state

S

Clean and tighten battery terminals

Tighten DC electrical connections

* Service more frequently if operated in dusty areas.
[ Consult your local distributor/dealer for service.
w Do not break manufacturers seals or internally inspect these
devices.

22

Remove corrosion, clean and dry battery and rack

Section 3 Scheduled Maintenance

Battery
y
manufacturers
f

instructions

S
D: Daily, before operation
Y: Yearly
2Y: Every 2 years or 2000 hours
R: Replace as necessary
Number: Hours of operation

W:
M:
Q:
S:

Weekly
Monthly
Quarterly
Six months

TP-6392 8/05

Procedure
SystemComponent

Check

Change

Clean

Test

Reference
Section

AC ELECTRICAL SYSTEM
General Inspection

Circuit breakers, fuses w

Wire abrasions where subject to motion

Tighten control and power wiring connections

Wire-cable insulation breakdown

3Y or 500

3Y or 500

ENGINE AND MOUNTING

General inspection (check for leaks)
Air cleaner service *

W
S

Valve clearance

3 Y or 500

Bolt torque

3 Y or 500

3.6
Eng. S/M
3 Y or 500

Eng. S/M

REMOTE CONTROL SYSTEM, ETC.

Compartment condition *

Remote control

GENERATOR
General inspection

Rotor and stator [

Bearing condition [

Exciter [

S/M

S/M
X

S/M

Measure and record resistance readings of windings with

insulation tester (Megger, with SCR assembly or rectifier
disconnected) [
Blow dust out of generator*

GENERAL CONDITION OF EQUIPMENT

2 Y or 300

2 Y or 300

S/M

3.1

Any condition of vibration, leakage, unusual noise,

temperature, or deterioration
Run generator set (exercise)

Ensure that system is set for automatic operation

Interior of equipment room or outdoor weather housing *

* Service more frequently if operated in dusty areas.

[ Consult your local distributor/dealer for service.
w Do not break manufacturers seals or internally inspect these
devices.

TP-6392 8/05

2.2, 2.3
2.3

D: Daily, before operation

Y: Yearly
2Y: Every 2 years or 2000 hours
R: Replace as necessary
Number: Hours of operation

W:
M:
Q:
S:

Weekly
Monthly
Quarterly
Six months

Section 3 Scheduled Maintenance

23

3.3 Service Views

4

Service-Side View
10
11

12

13 14

15
16

17

2
18

1
19

20
27

26

25

24
28

23

22

Engine-End View
(With Radiator Removed)

29

21
30

ADV7031-A

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Fuses (F1, F2, and F3)

Advanced Digital Control (ADC 2100)
Alternator cooling air inlet
Run-Off/Reset-Auto switch
Runtime hour display
Air intake silencer/cleaner
Fuel inlet connection
Fuel/water separator
Lifting eye
Fuel return connection
Fuel filter
Oil fill (engine top)
Mechanical governor
Coolant overflow tube
Pressure cap (at radiator)

Figure 3-1

24

16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.

Oil fill (front gear cover)

Radiator
V-belt
Oil check/dipstick
Coolant overflow bottle
Lube oil filter
Oil drain
Fuel feed pump
Nameplate
Circuit breaker location
Remote customer interface connector
Load lead connection
Water inlet connection
Water outlet connection
Exhaust outlet

Service Views

Section 3 Scheduled Maintenance

TP-6392 8/05

3.4 Lubrication System

SAE
Service
Grade

See Figure 3-1 for the oil drain, oil check, oil fill, and oil
filter locations.

10W

20W

10W30

WARNING
15W40

#20

#30

Handling caustic engine fluids and

chemical products.
Can cause severe chemical burns,
nausea, fainting, or death.
Most chemicals such as used engine
oil, antifreeze/coolant, rustproofing
agent, inhibiting oil, degreasing
agent, spray paint, and adhesives are
hazardous to health. Read and follow
the user information found on the
packaging. Avoid inhalation and skin
contact. Use only in well-ventilated
areas and use a protective mask
when spraying. Store engine fluids
and chemical products in a locked
cabinet. Contact your local recycling
center for disposal information and
locations.
Used engine oil. Contact with used engine oil may cause
severe skin irritation. Repeated and prolonged skin
exposure may have other health risks. Used engine oil is a
suspected carcinogen. Avoid contact with skin. Thoroughly
wash your hands and nails with soap and water shortly after
handling used engine oil. Wash or dispose of clothing or rags
containing used engine oil. Dispose of used engine oil in a
responsible manner. Contact your local recycling center for
disposal information and locations.

3.4.1

#40

--30

--20

--10

20

10

40

20

60

80

Operating Temperature

Figure 3-2

3.4.2

30

40

100

F
TP-5856-1

Engine Oil Selection

Oil Check

Check the oil level in the crankcase daily or before each

startup to ensure that the level is in the safe range. To
check the oil level, remove the dipstick and wipe the end
clean, reinsert as far as possible, and remove. Maintain
the oil level between the Min and Max marks on the
dipstick, as shown in Figure 3-3. See Figure 3-1 for
dipstick location.
Note: Do not operate the set if the oil level is below the
Min mark or above the Max mark.
1

Oil Specifications

Use oil that meets the American Petroleum Institute

(API) classification of CD or CF. Using an unsuitable oil
or neglecting an oil change may result in damage and a
shorter engine life. Figure 3-2 shows the recommended
Society of Automotive Engineers (SAE) viscosity
designation for given operating temperature ranges.
Note: Failure to observe the oil specifications may
cause inadequate lubrication/oil pressure and
cold-starting difficulties.

1-933

1. Max level
2. Min level

Figure 3-3

TP-6392 8/05

Oil Level Check

Section 3 Scheduled Maintenance

25

3.4.3

2. Replace the oil filter.

Oil Change

See the Service Schedule in Section 3.2 for oil change

and oil filter replacement intervals. Change the oil more
frequently if the generator operates under dirty, dusty
conditions. See Figure 3-4 for oil capacities.
Model
10REOD/REOZD

L
3.6

(Qts.)
(3.8)

15REOD/REOZD

4.7

(5.0)

20REOD/REOZD

5.8

(6.1)

Figure 3-4

Oil Capacities

Oil Change Procedure

a. Remove the oil filter by rotating

counterclockwise with an oil filter wrench.

it

b. Apply a light coat of clean oil to the rubber seal

of the new oil filter.
c. Install the new oil filter following the instructions
provided with the filter.
Note: Dispose of all waste materials (engine
oil, fuel, filter, etc.) in an environmentally
safe manner.
3. Fill with oil. Add new oil of the weight, grade, and
quantity specified in Section 3.4.

Whenever possible, drain the oil while it is still warm.

4. Check for leaks.
1. Drain the oil.
a. Place the generator set master switch in the
OFF position.
b. Disconnect the power to the battery charger, if
equipped.
c. Disconnect the generator set engine starting
battery, negative (--) lead first.
d. Place an oil collection container below the oil
drain and remove the oil drain plug.
e. Allow time for the engine oil to drain completely.
f. Replace the oil drain plug.

26

Section 3 Scheduled Maintenance

a. Check that the generator set master switch is in

the OFF position.
b. Reconnect the generator set engine starting
battery, negative (--) lead last.
c. Reconnect the power to the battery charger, if
equipped.
d. Start the generator set and check for leaks
around the oil filter.
e. Stop the generator set and tighten the oil filter to
stop any leaks.
x:sm:001:003:

TP-6392 8/05

3.5 Fuel System

WARNING

3.5.2

Fuel Filter

The quality and condition of the fuel largely determine

the filters useful life. Replace the fuel filter element as
listed in the service schedule. Figure 3-1 shows the
typical location of a fuel filter. Use the applicable
procedure below to replace the fuel filter.
Fuel Filter Cleaning/Replacement Procedure

Explosive fuel vapors.

Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
Fuel tanks. Explosive fuel vapors can cause severe injury
or death. Gasoline and other volatile fuels stored in day tanks
or subbase fuel tanks can cause an explosion. Store only
diesel fuel in tanks.
Draining the fuel system. Explosive fuel vapors can
cause severe injury or death. Spilled fuel can cause an
explosion. Use a container to catch fuel when draining the fuel
system. Wipe up spilled fuel after draining the system.

3.5.1

Fuel Specifications

Use a clean, good quality diesel fuel oil with a cetane

number of 45 or greater. Clean fuel prevents the diesel
fuel injectors and pumps from clogging.

1. Close the fuel supply valve.

2. Loosen the fuel filter by turning it counterclockwise.
Remove the fuel filter and use rags to clean up
spilled fuel oil. Dispose of the fuel filter in an
approved manner.
3. Clean the contact surface of the fuel oil filter
adapter.
4. Lightly lubricate the gasket surface of the new fuel
filter with fresh fuel oil. Thread the filter on the
adapter until the gasket makes contact;
hand-tighten the filter an additional one-half turn.
Wash hands after any contact with fuel oil.
5. Open the fuel supply valve.
6. Prime the fuel system. See Section 3.5.4, Priming
the Fuel System.

Fuel Recommendations
United States

ISO 8217 DMA, BS 2869 A1 or A2

United Kingdom BS 2869-1983, Part 2 Class A2

Germany

DIN 51 601-1978

Japan

JIS. No. K2204-2

Note: Never store diesel fuel in galvanized containers;

diesel fuel and the galvanized coating react
chemically to produce flaking that quickly clogs
filters or causes fuel pump or injector failure.
Note: Avoid storing fuel for more than one month. Take
special precautions to keep all dirt, water, and
other contaminants out of fuel to prevent the
growth of microbes. Microbes form slime that
clogs the fuel filter and lines.
Note: Do not run the generator set out of fuel because
the fuel lines will draw in air and necessitate
priming the fuel system before restarting the unit.

TP-6392 8/05

Section 3 Scheduled Maintenance

27

3.5.3

Fuel/Water Separator

These generator set models include a fuel/water

separator. The fuel/water separator helps to remove
water and sediment from the fuel system.
Fuel/Water Separator Draining Procedure

7. Install the bowl onto a new fuel/water separator

filter element.
8. Lubricate the bowl/element assembly with clean
fuel. Install the bowl/element onto the filter
mounting head.
9. Replace the water drain plug (if removed) and
close the vent.

At the interval specified in the service schedule, drain

the water from the fuel/water separator. Hold a suitable
container beneath the fuel/water separator and push up
on the drain valve. See Figure 3-5. Release the valve
when fuel (free of water) flows from the fuel/water
separator.

10. Remove the air bleed screw from the fuel/water

separator.

Fuel/Water Separators Element Replacement

Procedure

12. After fuel fills the water separator, allow fuel to flow
from the air bleed hole until all air is displaced (fuel
flows free of air bubbles).

At the interval specified in the service schedule, replace

the fuel/water separator element.

11. Open the fuel supply valve.

13. Replace the air bleed screw.

1. Close the fuel valve at the nearest point to the water

filter inlet or at the fuel tank.

2. Remove the water drain plug (or push up the drain

valve) and allow water and fuel to flow into a
suitable container.
Note: Depending upon the location of the fuel valve, a
considerable amount of fuel may drain out.
3. Remove the separators element from the mounting
head by twisting in a counterclockwise direction.
4. Remove the bowl from the fuel/water separator
element. Wipe the excess fuel from the bowl and
the O-ring. Do not discard the bowl or O-ring.
5. Inspect the components for wear or damage.
Replace parts as necessary.
6. Lubricate the O-ring with clean diesel fuel and
replace it in the bowl.

28

Section 3 Scheduled Maintenance

2
3

1. Air bleed screw

2. Drain plug
3. Drain valve

Figure 3-5

GM32181

Fuel/Water Separator

TP-6392 8/05

3.5.4

Priming the Fuel System

1

Prime the fuel system under the following conditions:

D Before starting the engine for the first time

D After running out of fuel and adding fuel to the tank
D After fuel system maintenance such as changing the

fuel filter, draining the fuel/water separator, or

replacing a fuel system component

Note: Do not open the air vent valve while priming the
fuel system. The fuel filter has an internal air
bleed port.
Do not crank the engine to prime the fuel system. Use
the following procedure.
Fuel System Priming Procedure

ADV7031-A

1. ADC 2100 control

2. Select button
3. Generator set master switch

Figure 3-6

ADC 2100 Control

1. Press and hold the Select button

located on
the ADC 2100. See Figure 3-1 and Figure 2-1.
2. Move the generator set master switch to the RUN
position. The controller displays the engine
runtime.
3. Continue to hold the Select button. After 10
seconds, the ADC 2100 will display Fuel and the
fuel priming pump will start.
4. Continue to hold the Select button for as long as
you want the fuel priming pump to function
(typically 10 seconds).
5. Release the Select button and move the Master
switch to the OFF/RESET position.
6. Place the Master switch to the RUN position to start
the unit.

TP-6392 8/05

Section 3 Scheduled Maintenance

29

3.6 Air Cleaner

3.7 Exhaust System

At the interval specified in the service schedule, inspect,

clean, or replace the air cleaner element. Clean the
element more frequently if the generator operates in
dirty, dusty conditions.
Check the element for
accumulated oil or dirt that could cause poor
performance. Replace a damaged air cleaner element.
Follow the procedure described below. At the time of
service, clean the air cleaner breather pipe and remove
all dust and foreign matter from the air cleaner housing.

WARNING

Carbon monoxide.
Can cause severe
fainting, or death.

nausea,

The exhaust system must be

leakproof and routinely inspected.

Air Cleaner Element Cleaning or Replacement

Procedure
1. Lift the locking lever and rotate the air cleaner cover
counterclockwise to remove it. See Figure 3-7.
2. Slide the air cleaner element from the tube.
3. Tap the element lightly against a flat surface to
dislodge loose surface dirt. Do not clean the
element in any liquid or use compressed air as
these will damage the filter element.
4. Wipe the cover and base with a clean rag to remove
any dirt.

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 unless the exhaust
gas is piped safely outside. Never operate the generator set
where exhaust gas could accumulate and seep back inside a
potentially occupied building.

At the interval specified in the service schedule, inspect

the exhaust system.
Inspection Points

5. Ensure tight clamps at the inlet/outlet connections.

Check for exhaust leaks and blockages. Check the
muffler and piping condition and check for tight exhaust
system connections.

6. Slide the air cleaner element into the tube.

7. Position the cover with the dust ejector pointing
down. Rotate the cover clockwise until the locking
lever snaps into place.
1

Inspect the exhaust system components for cracks and

corrosion (exhaust manifold, exhaust line, exhaust
clamps, and muffler).
D Check for corroded or broken metal parts and replace

them as needed.
2

D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace the exhaust clamps

and/or hangers as needed.
D Check that the exhaust outlet is unobstructed.
3

D Check the exhaust gas color. If the exhaust is blue or

black, contact your local distributor/dealer.

D Visually inspect for exhaust leaks (blowby). Check

4
1.
2.
3.
4.

Locking lever
Cover
Dust ejector
Element

Figure 3-7

30

GM39826

for carbon or soot residue on exhaust components.

Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.

Air Cleaner Components

Section 3 Scheduled Maintenance

TP-6392 8/05

3.8.2

3.8 Cooling System

WARNING

Hot coolant and steam.

Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
Checking the coolant level. Hot coolant can cause severe
injury or death. Allow the engine to cool. Release pressure
from the cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick cloth and
then slowly turn the cap counterclockwise to the first stop.
Remove the cap after pressure has been completely released
and the engine has cooled. Check the coolant level at the tank
if the generator set has a coolant recovery tank.

3.8.1

Draining the Cooling System

The radiator contains a coolant drain valve to drain the

cooling system. When draining the coolant, remove the
radiators pressure cap: this will allow the entire system
to drain and will prevent air pockets from forming and
restricting coolant passage to the block.
Note: Pay special attention to the coolant level. After
the coolant drains, allow time for complete refill of
the engine water jacket. Check the coolant level
as described earlier.

3.8.3

Filling the Cooling System

1. Remove the radiators pressure cap.

2. Close the radiators and/or engine blocks coolant
drain valve(s) and tighten the hose clamps.
Note: Do not add coolant to a hot engine. Adding
coolant to a hot engine can cause the cylinder
block or cylinder head to crack. Wait until engine
has cooled.

Checking the Cooling System

To prevent generator shutdown or damage because of

overheating, keep the cooling air inlets clean and
unobstructed at all times. Inspect the radiators exterior
for obstructions and remove dirt and foreign material
with a soft brush or cloth to avoid damaging the radiator
fins. Check the hoses and connections for leaks and
replace any cracked, frayed, or spongy hoses.
When checking the coolant level, also check the rubber
seal of the radiators pressure cap. Replace a cracked
or deteriorated cap. See Section 3.8.5. Remove dirt
and other debris from the pressure cap and filler neck.
See Figure 3-8 for the thermostat rating.
Thermostat Rating
All Models

Figure 3-8

82_C (179_F)

Thermostat Rating

3. Fill the radiator with the recommended coolant

mixture of 50% ethylene glycol and 50% clean,
softened water to inhibit rust/corrosion and prevent
freezing. See Figure 3-9 for coolant capacities.
Note: A coolant solution of 50% ethylene glycol
provides freezing protection to --37C (--34F)
and overheating protection to 129C (265F). A
coolant solution with less than 50% ethylene
glycol may not provide adequate freezing and
overheating protection. A coolant solution with
more than 50% ethylene glycol can cause engine
or component damage. Do not use alcohol or
methanol antifreeze or mix them with the
specified coolant.
Consult the engine
manufacturers operation manual for engine
coolant specifications.
4. Replace the radiators pressure cap.
5. Operate the engine until the thermostat opens and
the radiator upper hose becomes warm.

Model
10REOD/REOZD

Engine,
L (Qts.)

Engine & UnitMounted Radiator,

L (Qts.)

1.8 (1.9)

4.1 (4.3)

15REOD/REOZD

2.0 (2.1)

9.1 (9.6)

20REOD/REOZD

2.7 (2.8)

9.3 (9.8)

Figure 3-9

TP-6392 8/05

Coolant Capacities

Section 3 Scheduled Maintenance

31

6. Stop the engine and allow it to cool.

3.9 Belt Check

7. Remove the radiators pressure cap.

Check the belt tension at the intervals specified in the

service schedule. If the tension is not within
specification, adjust as necessary using the following
procedure.

8. Add coolant to the radiator to just below the

overflow tube on the filler neck.
9. Replace the radiators pressure cap.
10. Maintain the coolant level in the coolant overflow
bottle between the High and Low markings.
Note: Periodically check the coolant level by
removing the radiators pressure cap. Do
not rely solely on the level in the coolant
overflow bottle. Add fresh coolant until the
level is just below the overflow tube opening.

Note: Also check the fan belt for cracks or tears and
replace the belt if necessary.
Adjust the tension of the alternator/fan belt so that the
belt can be depressed about 12.7 mm (0.5 in.) when
applying finger pressure. Use the following procedure
to adjust the belt.
2
1

3.8.4

Flushing and Cleaning

For optimum protection, drain, flush, and refill the

cooling system at the interval listed in the service
schedule.
4

Flushing and Cleaning Procedure

1. Remove the pressure cap and open the radiators
coolant drain valve and let the system drain
completely. Remove the pressure cap to simplify
draining.

2. Drain, clean, and flush the coolant overflow bottle.

3. Flush the system with clean water.
4. Close the radiators coolant drain valve.
5. Fill the system with the recommended coolant.

Battery charging alternator pulley

Adjusting screw
Check the alternator belt tension here
Alternator pivot screw

Figure 3-11 Belt Tension

6. Replace the pressure cap.

3.8.5

1.
2.
3.
4.

Belt Tensioning Procedure

Pressure Cap

The cooling system utilizes a pressure cap to raise the

boiling point of the coolant, enabling higher operating
temperatures. If the cap leaks, replace it with a cap of the
same rating. See Figure 3-10.

1. Disconnect the battery, negative lead first.

2. Loosen the pivot and adjusting screws.
3. While prying the battery charging alternator
outward, tighten the adjusting screw.

Pressure Cap Rating

10REOD/REOZD

97 kPa (14 psi)

15REOD/REOZD
20REOD/REOZD

83--110 kPa (12--16 psi)

Figure 3-10 Pressure Cap Rating

(for inline radiator models)

32

Section 3 Scheduled Maintenance

4. Tighten the pivot screw.

5. Recheck and adjust as necessary.
6. Reconnect the battery, negative lead last.

TP-6392 8/05

3.10 Battery

WARNING

Consult the battery manufacturers

regarding battery care and maintenance.

instructions

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
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.

TP-6392 8/05

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.
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. 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.

Section 3 Scheduled Maintenance

33

3.11 Storage Procedure

3.11.3 Fuel System

Perform the following storage procedure before taking a

generator set out of service for three months or longer.
Follow the engine manufacturers recommendations, if
available, for fuel system and internal engine
component storage.

Prepare the fuel system for storage as follows:

x:sm:002:001

3.11.1 Lubricating System

Prepare the engine lubricating system for storage as
follows:
1. Run the generator set for a minimum of 15 minutes
to bring it to normal operating temperature.

Diesel-Fueled Engines
1. Fill the fuel tank with #2 diesel fuel.
2. Condition the fuel system with compatible
additives to control microbial growth.
3. Change the fuel filter/separator and prime the fuel
system.
x:sm:002:004

3.11.4 Exterior
Prepare the exterior for storage as follows:

2. Stop the generator set.

3. With the engine still warm, drain the oil from the
crankcase.
4. Remove and replace the oil filter.
5. Refill the crankcase with oil suited to the climate.
6. Run the generator set for two minutes to distribute
the clean oil.
7. Stop the generator set.

1. Clean the exterior surface of the generator set.

2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.
3. To prevent impurities from entering the air intake
and to allow moisture to escape from the engine,
secure a cloth over the air intake.
4. Mask electrical connections.
5. Spread a light film of oil over unpainted metallic
surfaces to inhibit rust and corrosion.

8. Check the oil level and adjust, if needed.

x:sm:002:006a

x:sm:002:002

3.11.2 Cooling System

3.11.5 Battery

Prepare the cooling system for storage as follows:

Perform battery storage after all other storage

procedures.

1. Check the coolant freeze protection using a

coolant tester.
2. Add or replace coolant as necessary to ensure
adequate freezing protection. Use the guidelines
included in the engine operation manual.
3. Run the generator set for 10--15 minutes to
redistribute added coolant.

1. Place the generator set master switch in the OFF

position.
2. Disconnect the battery(ies), negative (--) lead first.
3. Clean the battery.
Refer to the battery
manufacturer for the battery cleaning procedure.
4. Place the battery in a cool, dry location.

x:sm:002:003

5. Connect the battery to a float/equalize battery

charger or charge it monthly with a trickle battery
charger.
Refer to the battery charger
manufacturers recommendations.
Maintain a full charge to extend battery life.

34

Section 3 Scheduled Maintenance

TP-6392 8/05

Section 4 Troubleshooting
This section contains generator set troubleshooting,
diagnostic, and repair information.
Use the following charts as a quick troubleshooting
reference. The table groups generator set faults and
suggests likely causes and remedies. The table also
refers you to more detailed information including
sections of this manual, the generator set service
manual (S/M), the generator set installation manual
(I/M), and the engine service manual (Engine S/M) to
correct the indicated problem.
Corrective action and testing often require knowledge of
electrical and electronic circuits. To avoid additional
problems caused by incorrect repairs, have an
authorized service distributor/dealer perform service.

4.1 Fault Codes

The Advanced Digital Control displays fault codes to aid
in troubleshooting. Fault codes, descriptions, and
recommended actions are listed in Figure 2-3.
Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Section 2.3.5.

4.2 Controller Troubleshooting

Figure 4-1 contains troubleshooting, diagnostic, and
repair information for the Advanced Digital Control.

Maintain a record of repairs and adjustments performed

on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
authorized distributor/dealer. Use the record to help
describe the problem and repairs or adjustments made
to the equipment.
x:gt:001:002a:

Problem

Possible Cause

Controller LED display

is off

No power to the controller:

Figure 4-1

TP-6392 8/05

Corrective Action

The controller automatically powers down if the

generator set has not run for 48 hours or longer (if
the optional Remote Digital Display is not
connected).

Controller display will automatically activate when a remote

start command is received or the generator set master
switch is moved to the RUN position.

Controller fuse (F3) is blown.

Replace the fuse. If the fuse blows again, contact the

distributor/dealer.

Low or no battery voltage.

Check connections.
Check generator set battery.

Generator set master switch is in the OFF/RESET

position.

Move generator set master switch to the AUTO or RUN

position.

Generator set master switch in AUTO but no start

command has been received since last controller
reset.

No action required. Controller display will activate when a

remote start command is received or the generator set
master switch is moved to the RUN position. Use the
remote switch to start generator set and activate the
controller display, if desired.

Controller Troubleshooting Chart

Section 4 Troubleshooting

35

Cranks but
does not start

Does not
crank

Section 4 Troubleshooting

Coolant level low

Thermostat inoperative
Cooling water pump inoperative

Tighten or replace the belt. Replace the water pump.

Replace the thermostat.

Restore the coolant to normal operating level.

Restore the coolant to normal operating level and reset the

controller.

Low coolant level shutdown

Allow the engine to cool down. Then troubleshoot the cooling

system.

Clean the air openings.

High temperature shutdown

Air openings clogged

Check the remote switch position.

Troubleshoot the controller.[

Replace the controller master switch.

Replace the blown auxiliary winding fuse. If the fuse blows

again, troubleshoot the controller.[

Auxiliary winding fuse (F1) blown

Reset the controller circuit breaker.

Replace the blown relay interface board fuse. If the fuse blows
again, troubleshoot the controller.[

Relay interface board fuse (F2) blown

Controller master or start/stop switch

inoperative

Replace the blown controller fuse. If the fuse blows again,

troubleshoot the controller.[

Controller fuse (F3) blown

Controller circuit breaker tripped

Move the generator set master switch to the correct position

(RUN or AUTO).

Recommended Actions

Generator set master switch in the

OFF position

Probable Causes

Remote stop command received from

a remote switch or ATS

Low oil
pressure

Controller fault

High fuel
consumption

Excessive or
abnormal noise

Eng. O/M or S/M

Eng. S/M

Section 3.8

Sections 3.8 and

2.3.5

Section. 3.8, and

Eng. O/M

Gen. S/M

Section 2

Section 2, W/D

Section 2, W/D

Section 2, W/D

Section 2

Section or
Publication
Reference*

* Sec./Sectionnumbered section of this manual; ATSAutomatic Transfer Switch; Eng.Engine; Gen.Generator Set; I/MInstallation Manual; O/MOperation Manual; S/MService Manual;
S/SSpec Sheet; W/DWiring Diagram
[ Have an authorized service distributor/dealer perform this service.

Cooling System

Starts hard

No or low
output voltage

Stops
suddenly

Controller

Lacks power

Trouble Symptoms

Overheats

36

TP-6392 8/05

TP-6392 8/05

Section 4 Troubleshooting

37

Stops
suddenly

No or low
output voltage

Starts hard

Cranks but
does not start

Does not
crank

Lacks power
x

x
x

High fuel
consumption

Low oil
pressure

Reset the controller. If the overspeed fault occurs again, contact

the distributor/dealer.

Overspeed shutdown

Tighten all loose hardware.

Adjust the valves.[

Inspect the exhaust system. Tighten the loose exhaust system

components.[

Exhaust system not securely installed

Vibration excessive

Inspect the exhaust system. Replace any leaking exhaust

system components.[

Exhaust system leak

Valve clearance incorrect

Reduce the electrical load. See the generator set specification

sheet for ratings.

Engine overload

Check the compression.[

Clean or replace the filter element.

Compression weak

Air cleaner clogged

Replace the starter or starter solenoid.

Check the fault code. Correct the fault condition and then reset
the controller.

Fault shutdown
Starter/starter solenoid inoperative

Disconnect the engine harness connector(s) then reconnect it to W/D

the controller.

Engine harness connector(s) not

locked tight

Eng. S/M

Section 3, I/M

Section 3, I/M

S/S

Eng. S/M

Section 2

Eng. S/M

Section 2

Section 3, S/S

Recharge or replace the battery. The spec sheet provides

recommended battery CCA rating.

Battery weak or dead

Section 3

Verify that the battery connections are correct, clean, and tight.

Recommended Actions

Battery connections loose, corroded,

or incorrect

Probable Causes

Section or
Publication
Reference*

* Sec./Sectionnumbered section of this manual; ATSAutomatic Transfer Switch; Eng.Engine; Gen.Generator Set; I/MInstallation Manual; O/MOperation Manual; S/MService Manual;
S/SSpec Sheet; W/DWiring Diagram
[ Have an authorized service distributor/dealer perform this service.

Engine

Electrical System (DC circuits)

Overheats

Trouble Symptoms
Excessive or
abnormal noise

Cranks but
does not start

Does not
crank

Section 4 Troubleshooting

x
x

Stator inoperative (open or grounded)

Change the oil. Use oil with a viscosity suitable for the operating Section 3.4
climate.

Crankcase oil type incorrect for

ambient temperature

Section 3.4

Section 3.4
Check the oil level.

Restore the oil level. Inspect the generator set for oil leaks.

Gen. S/M

Low oil pressure shutdown

Oil level low

Tighten loose components.[

Gen. S/M

Gen. S/M, W/D

* Sec./Sectionnumbered section of this manual; ATSAutomatic Transfer Switch; Eng.Engine; Gen.Generator Set; I/MInstallation Manual; O/MOperation Manual; S/MService Manual;
S/SSpec Sheet; W/DWiring Diagram
[ Have an authorized service distributor/dealer perform this service.

Lube System

Test and/or replace the rotor.[

Main field (rotor) inoperative (open or

grounded)

Test and/or replace the stator.[

Check for continuity.

Wiring, terminals, or pin in the exciter

field open

Vibration excessive

Move the transfer switch test switch to the AUTO position.

Transfer switch test switch in the OFF

position

ATS O/M

Reset the controller. If the overcrank fault occurs again, contact

the distributor/dealer.

Overcrank shutdown

Eng. S/M

Eng. S/M

Eng. S/M

Section 3.5.4

Eng. S/M

Reset the breaker and check for AC voltage at the generator

side of the circuit breaker.

Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[
(diesel only)

Section or
Publication
Reference*

Section 3.5

AC output circuit breaker open

x
x

Adjust the fuel injection timing.[

Fuel injection timing out of adjustment

(diesel only)

x
x

Clean, test, and/or replace the inoperative fuel injector.[

Prime the diesel fuel system.

Fuel or fuel injectors dirty or faulty

(diesel only)

Troubleshoot the fuel solenoid.[

Clean or replace the fuel filter.

Add fuel and move the fuel valve to the ON position.

Recommended Actions

Air in fuel system (diesel only)

Fuel filter restriction

Fuel tank empty or fuel valve shut off

Probable Causes

Low oil
pressure

High fuel
consumption

Fuel solenoid inoperative

Excessive or
abnormal noise

Generator

Starts hard

No or low
output voltage

Stops
suddenly

Fuel System

Lacks power

Trouble Symptoms

Overheats

38

TP-6392 8/05

Section 5 Reconnection/Adjustments
5.1 Four-Lead Reconnection
The following information illustrates the reconnection of
four-lead generator sets. In all cases, conform to the
National Electrical Code (NEC).
NOTICE
Voltage reconnection. Affix a notice to the generator set after
reconnecting the set to a voltage different from the voltage on
the nameplate. Order voltage reconnection decal 246242
from an authorized service distributor/dealer.

5.1.1

100--120-Volt Configurations

5.1.2

100--120/200--240-Volt
Configurations

The 100--120/200--240-volt configuration does not use

a jumper lead. If the unit was originally wired for straight
100--120 volt, 3-wire, remove the jumper lead (see
Figure 5-1 for location). Select a two-pole circuit
breaker. Application of two single-pole circuit breakers
does not conform to NEC requirements for supplying a
200--240-volt load, even if the breakers are
mechanically attached together. Leads L1 and L2 are
for different phases; never connect them together.

If the installation requires a factory two-pole circuit

breaker, do not connect the load-side terminals of the
circuit breaker together; see Figure 5-1.
If the
installation requires a 100--120-volt, 2-wire system, use
a single-pole circuit breaker. See Figure 5-2. When
connecting stator phase leads together, size the output
lead (L1) to handle the amperage. Use a jumper lead on
the line side of the circuit breaker to balance the load of
the generator set.

L0 (Neutral)

Ground
Load
Side

Line
Side

L0
GRD.
L1
Single-Pole
Circuit
Breaker

L0
GRD.

Ground

L1
L2

Load
Side
Line
Side

L0 (Neutral)

Stator Leads
60 Hz

Two-Pole
Circuit
Breaker

L0--L1

Figure 5-2

100--120 Volt

50 Hz
100--120 Volt

100--120 Volt, 2-Wire Configuration

Jumper
lead
4

1
60 Hz

L0--L1
L0--L2

Figure 5-1

TP-6392 8/05

100--120 Volt
100--120 Volt

50 Hz
100--120 Volt
100--120 Volt

100--120-Volt, 3-Wire Configuration

Section 5 Reconnection/Adjustments

39

5.1.3

L0 (Neutral)

200--240-Volt Configurations

L0
GRD.

Ground

L1
L2

Load
Side

The 200--240-volt configuration does not use a jumper

lead. If the unit was originally wired for straight 100--120
volt, 3-wire, remove the jumper lead (see Figure 5-1 for
location). See Figure 5-4.

Factory
Two-Pole
Circuit
Breaker

Line
Side

L0 (Neutral)

L0
GRD.

Ground

L1

Load
Side

100--120/200--240-Volt,
3-Wire

Line
Side

Single-Pole
Circuit
Breaker

Stator Leads
60 Hz
L0--L1
L0--L2
L1--L2

100--120 Volt
100--120 Volt
200--240 Volt

50 Hz

Tape to insulate
from ground

100--120 Volt
100--120 Volt
200--240 Volt
4

Figure 5-3

100--120/200--240-Volt, 3-Wire
Configuration

Stator Leads
60 Hz
L0--L1

Figure 5-4

40

Section 5 Reconnection/Adjustments

200--220--240 Volt
2 Wire
50 Hz

200-240 Volt 200--220--240 Volt

200--220--240-Volt, 2-Wire Configuration

TP-6392 8/05

NOTICE

5.2 Twelve-Lead Reconnection

The reconnection procedure that follows details voltage
reconnections only. If the generator set requires
frequency changes, adjust the governor and voltage
regulator. See the generator set service manual for
information regarding frequency adjustment.

Voltage reconnection. Affix a notice to the generator set after

reconnecting the set to a voltage different from the voltage on
the nameplate. Order voltage reconnection decal 246242
from an authorized service distributor/dealer.

Twelve-Lead Reconnection Procedure

In all cases, follow National Electrical Code (NEC)

guidelines.

1. Move generator set start/stop switch to the STOP

position.

Reconnect the stator leads of the generator set to

change output phase or voltage. Refer to the following
procedure and connection schematics. Follow all safety
precautions at the front of this manual and in the text
during reconnection procedure.

2. Disconnect engine starting battery, negative (--)

lead first. Disconnect power to battery charger, if
equipped.
3. Use Figure 5-5 to determine generator set voltage
configuration. Note original voltage and reconnect
as needed.

Generator Connections
Single-Phase

3-Phase Delta

Some sets not rated for

single phasesee manuals

Not
Used

110/220 Volt 50 Hz
120/240 Volt 60 Hz
Remove V9 from terminal strip and tape

110/220 Volt 50 Hz
120/240 Volt 60 Hz

3-Phase WYE
3-Phase WYE

190-208 Volt 50 Hz
208-240 Volt 60 Hz

Notes:
CTs not used on all generator sets.
Current transformers dot or HI toward generator.

Figure 5-5

TP-6392 8/05

380-416 Volt 50 Hz
416-480 Volt 60 Hz

EM-250000

12-Lead Generator Reconnection

Section 5 Reconnection/Adjustments

41

5.3 ADC 2100 Adjustment after

Reconnection

5.3.1

Configuration Mode Time Out

The controller will automatically exit the configuration

mode without saving any changes after about 1 minute if
no buttons are pressed. Start the configuration
procedure over again from the beginning if the controller
exits the configuration mode before the settings have
been saved.

5.3.2

Configuration Mode

Follow the instructions in Figure 5-10 to enter the

configuration mode.
The settings are shown in
Figure 5-7. An X in the Display column in Figure 5-10
indicates a number from 0 to 9.

Figure 5-6

Advanced Digital Control (ADC 2100)

The controller is factory-set for the generator set voltage

and frequency and normally does not require
adjustment. If adjustment is necessary, follow the
procedures in this section to set the system voltage and
frequency parameter (Uu) and then adjust the output
voltage.

Press the Select button to step through to the Save

mode as shown in Figure 5-12. When SAVE is
displayed, press the up arrow to save the new settings or
the down arrow to discard the changes and exit the
configuration mode without saving.
Pressing the Select button when SAVE is displayed
returns to the first parameter, system voltage/frequency
(Uu).

Note: The unit configuration (UC), engine type (EC),

and engine data input type (ED) are factory set
and should only be changed by an authorized
Kohler dealer/distributor. Incorrect settings will
make your unit non-functional.

Parameter
Units system
y
voltage
g
and
d frequency
f
Also see Figure 5-8
58

Unit configuration
Engine type
Engine
g
data input
p types
yp
Battery Voltage
Communications

Setting
Uu01
Uu03
Uu04
Uu06
Uc01
Ec02
Ed01
Ed02
Bt12
Cn00
Cn01

*
*
*
*
*

Definition
Single phase, 60 Hz, 120/240 VAC
Three phase, 50 Hz, 115/230 or 200/400 VAC
Three phase, 60 Hz, 138/277 or 240/480 VAC
Single phase, 50 Hz, 115/230 VAC
Standby generator set
10/15/20REOD/REOZD
Units with standard oil pressure switch
Units with optional oil pressure sender installed (i.e. for Remote Digital Gauge)
Battery voltage 12 VDC
No CAN communications
J1939 (use for Remote Digital Gauge)

* Factory settings.

Figure 5-7

42

Controller Parameters

Section 5 Reconnection/Adjustments

TP-6392 8/05

Voltage Connection
60 Hz, Single phase
60 Hz,, Three phase
p

50 Hz, Single phase

50 Hz,, Three phase
p

Figure 5-8

5.3.3

VAC
120/240
120/208
127/220
120/240
139/240
220/380
277/480
110/220
110/190
110/220
220/380
230/400
240/416

Voltage
Part #
333702
333700
333701
333703
333704
333705
333708
333803
333800
333802
333805
333806
333807

ADC
2100
Setting
Uu01

Uu04

Grounding electrical equipment. Hazardous voltage can

cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of
electrocution.

Voltage Adjustment Procedure

Uu06

Uu03

Uu Parameter Settings for Available

Voltage Connections

Voltage Adjustment

After setting the system voltage parameter Uu, check

the output voltage and adjust, if necessary, using the
following procedures.
Follow the instructions in
Figure 5-13 to adjust the voltage, gain, and volts/Hz
while the engine is running. An X in the Display column
in Figure 5-13 indicates a number from 0 to 9. Use the
up arrow to increase a setting or the down arrow to
decrease the setting.
Pressing the Select button when SAVE is displayed
returns to the first parameter, voltage adjust (1P).

1. With the generator set off, connect a digital

voltmeter to the output leads or an electrical outlet
on the load side of the generator set. Set the meter
to measure voltage.
2. Start the generator set by moving the generator set
master switch to the RUN position.
3. Use the ADC controller to adjust the voltage
(parameter 1P) until the output voltage reaches the
desired value. See Figure 5-9.
Measured
g , VAC
Voltage,

Approximate
Voltage Change per Step, VAC
Coarse Adjust

Fine Adjust

5
7

0.5
0.7

85--132
180--251

Figure 5-9

Voltage Adjustment

4. Adjust the voltage stability (gain, parameter 2P) to

minimize light flicker.
5. Readjust the voltage, if necessary.

Note: A digital multimeter that measures voltage and

frequency is required for these adjustments.

WARNING

Hazardous voltage. Moving rotor.

Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.

6. Adjust the volts/Hz (parameter 3P) until the voltage

level measured by the voltmeter begins to drop.
When the volts/Hz is set correctly, the generator
(as load is applied) attempts to maintain normal
output until the engine speed drops below the
cut-in frequency.
7. Readjust the voltage stability (gain, parameter 2P),
if necessary.
8. Readjust the voltage (parameter 1P), if necessary.
9. Stop the generator set.

Short circuits. Hazardous voltage/current can 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.

TP-6392 8/05

Section 5 Reconnection/Adjustments

43

Controller Configuration Mode (Use with Figure 5-7, Controller Parameters):

Hold the Select button:

Display:
Move the generator set master switch to the RUN
position. (The generator set engine will not start.)

Wait about 5 seconds until the display shows the

program version number. (The number may be
different than the one shown here.)

1 1 8

Press the down arrow key and then the up arrow

key 3 times to enter the configuration mode.
(This is the controller password.)

Uu 0 x

Now release the Select button.

Press:
or

To set the voltage/frequency setting for 60 Hz or

50 Hz models.

Uu 0 x

To step to the next parameter, unit configuration

Uc.
or

To set the unit configuration setting, if necessary.

Uc 0 x

To step to the next parameter, engine type Ec.

or

To set the engine type, if necessary.

E c 0 x

To step to the next parameter, advanced

configuration mode or save mode selection.

Ad n c

Now either save your settings or enter the Advanced Configuration Mode to
set the engine data inputs, battery voltage, and communications.
Press:
To enter advanced configuration mode.
Go to Figure 5-11.

E d 0 x

To proceed to the save mode without

entering the advanced configuration mode.
Go to Figure 5-12.

S AV E

OR:
or

Note: Shaded boxes show which number in the controller display changes when the up or down arrow
key is pressed. x denotes any number from 0 to 9.
Figure 5-10 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)

44

Section 5 Reconnection/Adjustments

TP-6392 8/05

Pressing the up arrow key at the Adnc display (See Figure 5-10) puts you
into the Advanced Configuration Mode.
Press:
or

E d 0 x

To set the engine data input type.

To enter battery voltage selection mode.

or

To toggle between 12 and 24 VDC.

12-volt models

B t 1 2

To enter communications selection mode.

To set the communications parameter.

or
To enter SAVE mode. Go to Figure 5-12.

C n 0 x
S AV E

Note: Shaded boxes show which number in the controller display changes when the up or down arrow
key is pressed. x denotes any number from 0 to 9.
Figure 5-11 Advanced Configuration Mode (engine data input types, battery voltage, and engine
communications)

There are 3 options when the display says SAVE:

Press:
To return to the first parameter, system voltage/frequency
Uu, to check or change settings before saving. See
Figure 5-10.

S AV E
Uu 0 x

or
To save changes.

Y E S

To discard changes without saving.

n o

or

Yesor no flashes when the up or down arrow is pressed and then

the controller exits the configuration mode. The display returns to
the runtime hours.

x x x x

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the
last saved settings when the master switch is moved to the OFF/RESET position.
* x in the runtime hours display above denotes any number from 0 to 9.
Now move the master switch to OFF/RESET.
Figure 5-12 Save Mode (after configuring generator set parameters)
TP-6392 8/05

Section 5 Reconnection/Adjustments

45

Output Voltage Adjustment Mode:

Display :*

Move the generator set master switch to the RUN position. The generator set
engine starts and the controller display shows the engine runtime hours.

x x x x

Hold:

Wait about 5 seconds until the display changes from runtime hours
to the program version number.

x. x x

Press the down arrow key and then the up arrow key 3 times to enter the
adjustment mode. (This is the controller password.)

1 P x x

The controller is now in the voltage coarse adjustment mode.

Press:
or

To raise or lower the voltage in large increments

(approximately 5--7 volts per step).

To enter fine voltage adjustment mode.

or

1 P x x

1 P x x

To raise or lower the voltage in smaller increments

(approximately 0.5--0.7 volts per step).

To enter coarse voltage stability (gain) adjustment mode.

2 P x x
or

To raise or lower the voltage stability (gain) in large

increments.

To enter fine voltage stability (gain) adjustment mode.

or

To raise or lower the voltage stability (gain) in smaller

increments.

To enter volts/Hz adjustment mode.

or

2 P x x

3 P 0 x

To raise or lower the volts/Hz: 00=low; 09= high

See Figure 5-12 to save.

* Shaded boxes show which character in the controller display changes for each adjustment. x in the
examples above denotes any number from 0 to 9. The actual values may vary from model-to-model.

TP6196

Figure 5-13 Output Voltage Adjustments

46

Section 5 Reconnection/Adjustments

TP-6392 8/05

Section 6 Wiring Diagrams

WARNING

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.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or connected equipment, 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.

TP-6392 8/05

WARNING

Hazardous voltage. Moving rotor.

Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
breakers of all power sources before servicing the equipment.
Configure the installation to electrically ground the generator
set, transfer switch, and related equipment and electrical
circuits to comply with applicable codes and standards. Never
contact electrical leads or appliances when standing in water
or on wet ground because these conditions increase the risk of
electrocution.

Section 6 Wiring Diagrams

47

GM39874-A

Figure 6-1
48

Wiring Diagram, GM39874-A

Section 6 Wiring Diagrams

TP-6392 8/05

ADV7030A-

Figure 6-2
TP-6392 8/05

Schematic, ADV-7030, Sheet 1

Section 6 Wiring Diagrams

49

ADV7030B-

Figure 6-3
50

Schematic, ADV-7030, Sheet 2

Section 6 Wiring Diagrams

TP-6392 8/05

Figure 6-4

TP-6392 8/05

Accessory Connection, GM33846-A

Section 6 Wiring Diagrams

51

Notes

52

Section 6 Wiring Diagrams

TP-6392 8/05

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp
ABDC
AC
A/D
ADC
adj.
ADV
AHWT
AISI
ALOP
alt.
Al
ANSI

AO
API
approx.
AR
AS
ASE
ASME
assy.
ASTM
ATDC
ATS
auto.
aux.
A/V
avg.
AVR
AWG
AWM
bat.
BBDC
BC
BCA
BCI
BDC
BHP
blk.
blk. htr.
BMEP
bps
br.
BTDC
Btu
Btu/min.
C
cal.
CARB
CB
cc
CCA
ccw.
CEC
cert.
cfh

ampere
after bottom dead center
alternating current
analog to digital
analog to digital converter
adjust, adjustment
advertising dimensional
drawing
anticipatory high water
temperature
American Iron and Steel
Institute
anticipatory low oil pressure
alternator
aluminum
American National Standards
Institute
(formerly American Standards
Association, ASA)
anticipatory only
American Petroleum Institute
approximate, approximately
as required, as requested
as supplied, as stated, as
suggested
American Society of Engineers
American Society of
Mechanical Engineers
assembly
American Society for Testing
Materials
after top dead center
automatic transfer switch
automatic
auxiliary
audiovisual
average
automatic voltage regulator
American Wire Gauge
appliance wiring material
battery
before bottom dead center
battery charger, battery
charging
battery charging alternator
Battery Council International
before dead center
brake horsepower
black (paint color), block
(engine)
block heater
brake mean effective pressure
bits per second
brass
before top dead center
British thermal unit
British thermal units per minute
Celsius, centigrade
calorie
California Air Resources Board
circuit breaker
cubic centimeter
cold cranking amps
counterclockwise
Canadian Electrical Code
certificate, certification, certified
cubic feet per hour

TP-6392 8/05

cfm
CG
CID
CL
cm
CMOS

cubic feet per minute

center of gravity
cubic inch displacement
centerline
centimeter
complementary metal oxide
substrate (semiconductor)
cogen.
cogeneration
com
communications (port)
coml
commercial
Coml/Rec Commercial/Recreational
conn.
connection
cont.
continued
CPVC
chlorinated polyvinyl chloride
crit.
critical
CRT
cathode ray tube
CSA
Canadian Standards
Association
CT
current transformer
Cu
copper
cu. in.
cubic inch
cw.
clockwise
CWC
city water-cooled
cyl.
cylinder
D/A
digital to analog
DAC
digital to analog converter
dB
decibel
dBA
decibel (A weighted)
DC
direct current
DCR
direct current resistance
deg.,
degree
dept.
department
dia.
diameter
DI/EO
dual inlet/end outlet
DIN
Deutsches Institut fur Normung
e. V. (also Deutsche Industrie
Normenausschuss)
DIP
dual inline package
DPDT
double-pole, double-throw
DPST
double-pole, single-throw
DS
disconnect switch
DVR
digital voltage regulator
E, emer. emergency (power source)
EDI
electronic data interchange
EFR
emergency frequency relay
e.g.
for example (exempli gratia)
EG
electronic governor
EGSA
Electrical Generating Systems
Association
EIA
Electronic Industries
Association
EI/EO
end inlet/end outlet
EMI
electromagnetic interference
emiss.
emission
eng.
engine
EPA
Environmental Protection
Agency
EPS
emergency power system
ER
emergency relay
ES
engineering special,
engineered special
ESD
electrostatic discharge
est.
estimated
E-Stop
emergency stop
etc.
et cetera (and so forth)
exh.
exhaust

ext.
F
fglass.
FHM
fl. oz.
flex.
freq.
FS
ft.
ft. lb.
ft./min.
g
ga.
gal.
gen.
genset
GFI

external
Fahrenheit, female
fiberglass
flat head machine (screw)
fluid ounce
flexible
frequency
full scale
foot, feet
foot pounds (torque)
feet per minute
gram
gauge (meters, wire size)
gallon
generator
generator set
ground fault interrupter

GND,
gov.
gph
gpm
gr.
GRD
gr. wt.
HxWxD
HC
HCHT
HD
HET

ground
governor
gallons per hour
gallons per minute
grade, gross
equipment ground
gross weight
height by width by depth
hex cap
high cylinder head temperature
heavy duty
high exhaust temperature,
high engine temperature
hexagon
mercury (element)
hex head
hex head cap
horsepower
hour
heat shrink
housing
heating, ventilation, and air
conditioning
high water temperature
hertz (cycles per second)
integrated circuit
inside diameter, identification
International Electrotechnical
Commission
Institute of Electrical and
Electronics Engineers
improved motor starting
inch
inches of water
inches of mercury
inch pounds
incorporated
industrial
internal
internal/external
input/output
iron pipe
International Organization for
Standardization
joule
Japanese Industry Standard
kilo (1000)
kelvin

hex
Hg
HH
HHC
HP
hr.
HS
hsg.
HVAC
HWT
Hz
IC
ID
IEC
IEEE
IMS
in.
in. H2O
in. Hg
in. lb.
Inc.
ind.
int.
int./ext.
I/O
IP
ISO
J
JIS
k
K

Appendix 53

kA
KB
kg
kg/cm2

kiloampere
kilobyte (210 bytes)
kilogram
kilograms per square
centimeter
kgm
kilogram-meter
kilograms per cubic meter
kg/m3
kHz
kilohertz
kJ
kilojoule
km
kilometer
kOhm, k kilo-ohm
kPa
kilopascal
kph
kilometers per hour
kV
kilovolt
kVA
kilovolt ampere
kVAR
kilovolt ampere reactive
kW
kilowatt
kWh
kilowatt-hour
kWm
kilowatt mechanical
L
liter
LAN
local area network
L x W x H length by width by height
lb.
pound, pounds
lbm/ft3
pounds mass per cubic feet
LCB
line circuit breaker
LCD
liquid crystal display
ld. shd.
load shed
LED
light emitting diode
Lph
liters per hour
Lpm
liters per minute
LOP
low oil pressure
LP
liquefied petroleum
LPG
liquefied petroleum gas
LS
left side
Lwa
sound power level, A weighted
LWL
low water level
LWT
low water temperature
m
meter, milli (1/1000)
M
mega (106 when used with SI
units), male
m3
cubic meter
m3/min. cubic meters per minute
mA
milliampere
man.
manual
max.
maximum
MB
megabyte (220 bytes)
MCM
one thousand circular mils
MCCB
molded-case circuit breaker
meggar
megohmmeter
MHz
megahertz
mi.
mile
mil
one one-thousandth of an inch
min.
minimum, minute
misc.
miscellaneous
MJ
megajoule
mJ
millijoule
mm
millimeter
mOhm,
m
milliohm
MOhm,
M
megohm
MOV
metal oxide varistor
MPa
megapascal
mpg
miles per gallon
mph
miles per hour
MS
military standard
m/sec.
meters per second
MTBF
mean time between failure

54 Appendix

MTBO
mtg.
MW
mW
F
N, norm.
NA
nat. gas
NBS
NC
NEC
NEMA

mean time between overhauls

mounting
megawatt
milliwatt
microfarad
normal (power source)
not available, not applicable
natural gas
National Bureau of Standards
normally closed
National Electrical Code
National Electrical
Manufacturers Association
NFPA
National Fire Protection
Association
Nm
newton meter
NO
normally open
no., nos. number, numbers
NPS
National Pipe, Straight
NPSC
National Pipe, Straight-coupling
NPT
National Standard taper pipe
thread per general use
NPTF
National Pipe, Taper-Fine
NR
not required, normal relay
ns
nanosecond
OC
overcrank
OD
outside diameter
OEM
original equipment
manufacturer
OF
overfrequency
opt.
option, optional
OS
oversize, overspeed
OSHA
Occupational Safety and Health
Administration
OV
overvoltage
oz.
ounce
p., pp.
page, pages
PC
personal computer
PCB
printed circuit board
pF
picofarad
PF
power factor
ph.,
phase
PHC
Phillips head crimptite (screw)
PHH
Phillips hex head (screw)
PHM
pan head machine (screw)
PLC
programmable logic control
PMG
permanent-magnet generator
pot
potentiometer, potential
ppm
parts per million
PROM
programmable read-only
memory
psi
pounds per square inch
pt.
pint
PTC
positive temperature coefficient
PTO
power takeoff
PVC
polyvinyl chloride
qt.
quart, quarts
qty.
quantity
R
replacement (emergency)
power source
rad.
radiator, radius
RAM
random access memory
RDO
relay driver output
ref.
reference
rem.
remote
Res/Coml Residential/Commercial
RFI
radio frequency interference
RH
round head
RHM
round head machine (screw)

rly.
rms
rnd.
ROM
rot.
rpm
RS
RTV
SAE
scfm
SCR
s, sec.
SI
SI/EO
sil.
SN
SPDT
SPST
spec,
specs
sq.
sq. cm
sq. in.
SS
std.
stl.
tach.
TD
TDC
TDEC
TDEN
TDES
TDNE
TDOE
TDON
temp.
term.
TIF
TIR
tol.
turbo.
typ.
UF
UHF
UL
UNC
UNF
univ.
US
UV
V
VAC
VAR
VDC
VFD
VGA
VHF
W
WCR
w/
w/o
wt.
xfmr

relay
root mean square
round
read only memory
rotate, rotating
revolutions per minute
right side
room temperature vulcanization
Society of Automotive
Engineers
standard cubic feet per minute
silicon controlled rectifier
second
Systeme international dunites,
International System of Units
side in/end out
silencer
serial number
single-pole, double-throw
single-pole, single-throw
specification(s)
square
square centimeter
square inch
stainless steel
standard
steel
tachometer
time delay
top dead center
time delay engine cooldown
time delay emergency to
normal
time delay engine start
time delay normal to
emergency
time delay off to emergency
time delay off to normal
temperature
terminal
telephone influence factor
total indicator reading
tolerance
turbocharger
typical (same in multiple
locations)
underfrequency
ultrahigh frequency
Underwriters Laboratories, Inc.
unified coarse thread (was NC)
unified fine thread (was NF)
universal
undersize, underspeed
ultraviolet, undervoltage
volt
volts alternating current
voltampere reactive
volts direct current
vacuum fluorescent display
video graphics adapter
very high frequency
watt
withstand and closing rating
with
without
weight
transformer

TP-6392 8/05

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record of
operating hours on your generator set and the dates
Operating Hours
Date
Run

TP-6392 8/05

Hours
Run

Total
Hours

required services were performed. Enter hours to the

nearest quarter hour.
Service Record

Service
Date

Service

Appendix 55

Notes

56 Appendix

TP-6392 8/05

Notes

TP-6392 8/05

57

Notes

58

TP-6392 8/05

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems.com

TP-6392 8/05
E 2005 by Kohler Co. All rights reserved.

Kohler Power Systems

Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455