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Kohler
Portable Generator
12RESM1
Kohler 12RESM1 Service Manual
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2004,
2008,
2009
by
Kohler
Co.
All
rights
reserved.
TP-6196
10/09a
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
KohlerPower
.com
Kohler
Power
Systems
Asia
Pacific
Head
qua
rters
7
Jurong
Pier
Road
Singapore
619159
Phone
(65)6264-6422,
Fa
x
(65)6264-6455
131
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
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Kohler 12RESM1 Specifications
General
Brand
Kohler
Model
12RESM1
Category
Portable Generator
Language
English
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