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Kohler
Portable Generator
12RES
Kohler 12RES Service
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Residential/Commercial
Generator
Sets
Models:
8.5RES
12RES
12RESL
12RESM1
12RESNT
12TRES
Controllers:
ADC
2100
ADC-RES
DC
2200
DC-RET
TP-6196
10/09a
Service
2
Table of Contents
Table of Contents
3
Safety Precautions and Instructions
7
Fuel System
8
Hot Parts
10
Introduction
11
List of Related Materials
11
Service Assistance
12
Section 1 Specifications
13
Introduction
13
Controller Specifications
13
Engine Features
13
Engine Specifications
14
Torque Specifications
14
Alternator Specifications
15
Service Views
16
Section 2 Scheduled Maintenance
19
Service Schedule
19
Lubrication System
21
Low Oil Pressure Shutdown
21
Oil Level Check
21
Engine Oil Recommendation
21
Oil Change Procedure
21
Oil Cooler
22
Spark Plugs
22
Air Cleaner Element and Precleaner
23
Cooling System
24
Exhaust System
24
Battery
24
Cleaning Battery
25
Battery Charger
25
Storage Procedure
26
Lubricating System
26
Fuel System
26
Internal Engine Components (Gas/Gasoline-Fueled Engines)
26
Exterior
26
Battery
26
Section 3 Troubleshooting
27
Introduction
27
Initial Checks
27
Troubleshooting Chart
27
Controller Troubleshooting
33
Section 4 ADC 2100 and DC 2200 Controllers
35
Introduction
35
Controller Display and Keypad
36
Sequence of Operation
37
Starting Sequence, Master Switch Moved to RUN
37
Starting Sequence, Remote Start
37
Running Sequence
37
Stopping Sequence, Master Switch Moved to OFF/RESET
37
Stopping Sequence, Remote Stop
37
Faults
37
Warnings
37
Shutdowns
37
ADC 2100 Controller Configuration and Adjustment
40
Controller Time out
40
Controller Configuration
40
Voltage and Frequency Adjustments
41
Controller Application Program
41
Controller Configuration Mode
42
Continuous Power Mode Jumper
46
Master Switch
48
Relay Interface Board (RIB)
48
Controller Replacement
49
Section 5 ADC-RES and DC-RET Controller
53
Introduction
53
Controls and Display
54
Master Switch
54
LED Display
54
Keypad
55
Sequence of Operation
56
Starting Sequence, Master Switch Moved to RUN
56
Starting Sequence, Remote Start
56
Running Sequence
56
Stopping Sequence, Master Switch Moved to OFF/RESET
56
Stopping Sequence, Remote Stop
56
Standby Mode
56
Sleep Mode
56
Faults
57
Warnings
57
Shutdowns
57
Controller Configuration and Adjustment, ADC-RES
59
Controller Time out
59
Voltage and Frequency Adjustments
59
Controller Application Program Version Number
59
System Parameters
60
Voltage and Frequency Adjustments
62
Voltage Adjustment
62
Frequency Adjustment
63
Controller Relays
66
Optional Relay Board
67
Relay Board Troubleshooting
67
Relay Board Replacement Procedure
69
Controller Replacement
70
Section 6 Component Testing and Adjustment
73
Theory of Operation
73
Separate Excitation
73
Stator
74
Main Field (Rotor)
77
Slip Rings
78
Brushes
78
Voltage
79
Voltage Regulation
79
Voltage Adjustment
79
Volts Per Hertz (Hz) Adjustments (Droop)
81
Voltage Connections, Single-Phase
81
Voltage Connections, 3-Phase
82
Silicon Controlled Rectifier Module
82
Electromechanical Governor System
84
Governor System/Magnetic Pickup Operation Test
85
Hunting/Surging
85
Frequency Adjustment
88
Controller Fault Shutdown Functions
91
Fault Shutdown Switches
92
Gas Piping
93
Fuel Conversion
94
Digital Spark Advance Ignition
95
Fuel Metering Valve Adjustment
96
Digital Spark Advance Ignition
96
Fuses
98
Disassembly
101
Appendix A Abbreviations
123
Appendix B Common Hardware Application Guidelines
125
Appendix C General Torque Specifications
126
Appendix D Common Hardware Identification
127
Appendix E Common Hardware List
128
Other manuals for Kohler 12RES
Operation And Installation Instructions
56 pages
Service Manual
132 pages
Operation Guide
36 pages
Installation
44 pages
Operation And Installation
56 pages
Operation
48 pages
Installation Manual
56 pages
4
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Kohler 12RES Specifications
General
Voltage
120/240 V
Frequency
60 Hz
Power Output
12, 000 watts
Phase
Single
Starting System
Automatic
Transfer Switch
Optional
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