Kohler 12RESL Operation Manual Download Page 44

TP-6517 1/11

44 Appendix

k

kilo (1000)

K

kelvin

kA

kiloampere

KB

kilobyte (2

10

bytes)

KBus

Kohler communication protocol

kg

kilogram

kg/cm

2

kilograms per square
centimeter

kgm

kilogram-meter

kg/m

3

kilograms per cubic meter

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

kWth

kilowatt-thermal

L

liter

LAN

local area network

L x W x H length by width by height
lb.

pound, pounds

lbm/ft

3

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

L

wa

sound power level, A weighted

LWL

low water level

LWT

low water temperature

m

meter, milli (1/1000)

M

mega (10

6

when used with SI

units), male

m

3

cubic meter

m

3

/hr.

cubic meters per hour

m

3

/min.

cubic meters per minute

mA

milliampere

man.

manual

max.

maximum

MB

megabyte (2

20

bytes)

MCCB

molded-case circuit breaker

MCM

one thousand circular mils

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

ms

millisecond

m/sec.

meters per second

MTBF

mean time between failure

MTBO

mean time between overhauls

mtg.

mounting

MTU

Motoren-und Turbinen-Union

MW

megawatt

mW

milliwatt

μ

F

microfarad

N, norm.

normal (power source)

NA

not available, not applicable

nat. gas

natural gas

NBS

National Bureau of Standards

NC

normally closed

NEC

National Electrical Code

NEMA

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

r

head Crimptite

r

(screw)

PHH

Phillips

r

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

psig

pounds per square inch gauge

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.

relay

rms

root mean square

rnd.

round

ROM

read only memory

rot.

rotate, rotating

rpm

revolutions per minute

RS

right side

RTU

remote terminal unit

RTV

room temperature vulcanization

RW

read/write

SAE

Society of Automotive
Engineers

scfm

standard cubic feet per minute

SCR

silicon controlled rectifier

s, sec.

second

SI

Systeme international d’unites,

International System of Units

SI/EO

side in/end out

sil.

silencer

SN

serial number

SNMP

simple network management
protocol

SPDT

single-pole, double-throw

SPST

single-pole, single-throw

spec

specification

specs

specification(s)

sq.

square

sq. cm

square centimeter

sq. in.

square inch

SS

stainless steel

std.

standard

stl.

steel

tach.

tachometer

TD

time delay

TDC

top dead center

TDEC

time delay engine cooldown

TDEN

time delay emergency to
normal

TDES

time delay engine start

TDNE

time delay normal to
emergency

TDOE

time delay off to emergency

TDON

time delay off to normal

temp.

temperature

term.

terminal

THD

total harmonic distortion

TIF

telephone influence factor

TIR

total indicator reading

tol.

tolerance

turbo.

turbocharger

typ.

typical (same in multiple
locations)

UF

underfrequency

UHF

ultrahigh frequency

UL

Underwriter’s Laboratories, Inc.

UNC

unified coarse thread (was NC)

UNF

unified fine thread (was NF)

univ.

universal

US

undersize, underspeed

UV

ultraviolet, undervoltage

V

volt

VAC

volts alternating current

VAR

voltampere reactive

VDC

volts direct current

VFD

vacuum fluorescent display

VGA

video graphics adapter

VHF

very high frequency

W

watt

WCR

withstand and closing rating

w/

with

w/o

without

wt.

weight

xfmr

transformer

Summary of Contents for 12RESL

Page 1: ...Residential Commercial Generator Sets Models 12RESM1 12 18RESL Controller DC RET Digital Control TP 6517 1 11d Operation...

Page 2: ...eadily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set...

Page 3: ...r Set 16 2 4 2 Stopping Generator Set 17 2 5 Exercising Generator Set 17 2 6 Faults 17 2 6 1 Shutdowns 17 2 6 2 Warnings 17 2 6 3 Resetting Controller after a Fault Shutdown 17 2 7 Battery Charger 19...

Page 4: ...e Oil Recommendation 33 4 3 4 Oil Change Procedure 33 4 3 5 Oil Cooler 34 4 4 Spark Plugs 34 4 5 Air Cleaner Service 35 4 6 Cooling System 35 4 7 Exhaust System 36 4 8 Battery 36 4 9 Battery Charger 3...

Page 5: ...r 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 n...

Page 6: ...tainer when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these mater...

Page 7: ...set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances w...

Page 8: ...NING 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 Notice NOTICE...

Page 9: ...he prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition Nameplate The following illustration shows a typical generator set nameplate Cop...

Page 10: ...eadquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Offic...

Page 11: ...sign and full pressure lubrication for maximum power torque and reliability under all operating conditions D Dependable maintenance free electronic ignition D Precision formulated cast iron constructi...

Page 12: ...eld connection terminal block location 11 Spark plug locations both sides 12 Oil drain hose 13 Oil drain valve 14 Oil filter 15 Exhaust 16 Equipment ground 17 Battery charger 18 DSAI lead location 19...

Page 13: ...2 RS 232 connector for application program updates 13 Engine starting battery location battery purchased separately 14 Oil drain hose 15 Nameplate location on base 16 Oil drain valve 17 Exhaust outlet...

Page 14: ...TP 6517 1 11 14 Section 1 Features Notes...

Page 15: ...ct the exhaust system components for cracks leaks and corrosion D Check for corroded or broken metal parts and replace them as needed D Check that the exhaust outlet is unobstructed Oil Level Maintain...

Page 16: ...dark and battery draw is minimized A remote start signal from a transfer switch or a remote start stop switch connected to controller leads 3 and 4 reactivates the controller Moving the generator set...

Page 17: ...y items restricting the air flow 2 6 Faults 2 6 1 Shutdowns Under the fault shutdown conditions listed in Figure 2 3 the generator set shuts down automatically and the controller displays a fault code...

Page 18: ...is sensed during cranking Shuts down 3 seconds after the fault is detected OF Overfrequency shutdown Shutdown occurs when the governed frequency exceeds 110 of the system s frequency setpoint for mor...

Page 19: ...process Figure 2 5 Charging Method Display Operating Condition Red ON Green OFF When the red LED is on it indicates the battery is discharged and the battery charger is recharging at the BULK rate st...

Page 20: ...TP 6517 1 11 20 Section 2 Operation Notes...

Page 21: ...evere injury or death Do not work on the generator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhau...

Page 22: ...m Tighten control and power wiring connections X Yearly Remote control system if equipped X Monthly Visible wear or damage X Quarterly Wire abrasions where subject to motion X X Six Months Wire cable...

Page 23: ...dation Use API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner Sel...

Page 24: ...heck the oil level Add oil to bring the level up to the F mark on the dipstick 4 Check for leaks a Check for oil leaks b Fix leaks and recheck the oil level c Reinstall the housing side panel 3 3 5 Oi...

Page 25: ...e Figure 3 4 and Figure 3 5 1 514 Figure 3 4 Checking the Spark Plug Gap 1 511 Figure 3 5 Adjusting the Spark Plug Gap 3 5 Air Cleaner Element and Precleaner The engine has a replaceable high density...

Page 26: ...ning knob and remove the cover 5 Remove the element cover nut element cover and the paper element with precleaner 6 Remove the precleaner from the paper element Note Do not wash the paper element or c...

Page 27: ...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...

Page 28: ...T 115 VAC 50 60Hz 1 6A OUTPUT 12 VDC 6 Amps MAX BAT 180 Amp Hr Max DATE 6 AMP AUTOMATIC BATTERY CHARGER R C US LISTED BATTERY CHARGER 53AB 2608KH 1 1 LED indicators 2 Mounting flanges 3 AC power cord...

Page 29: ...ator set master switch in the OFF RESET position 3 11 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install the spark plugs and ground t...

Page 30: ...TP 6517 1 11 30 Section 3 Scheduled Maintenance 12 kW Models Notes...

Page 31: ...ator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot duri...

Page 32: ...mote control system if equipped M Visible wear or damage Q Wire abrasions where subject to motion 6 months 6 months Wire cable insulation condition 3Y or 500 Engine and Mounting Visible wear or damage...

Page 33: ...Oil Check 4 3 3 Engine Oil Recommendation Use 5W 30 API American Petroleum Institute Service Class SG SH or SJ synthetic oil Synthetic oil oxidizes and thickens less than other oils and leaves the en...

Page 34: ...bris See Figure 4 2 for the oil cooler location The oil cooler is located under the No 2 cylinder shroud Remove the top mounting screw and loosen the two side screws then lift off the cylinder shroud...

Page 35: ...nt or damaged 4 When servicing the air cleaner check the air cleaner base and latch Make sure it is secured and not bent or damaged Also check the element cover for damage or improper fit Replace all...

Page 36: ...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...

Page 37: ...RY CHARGER 53AB 2608KH 1 1 LED indicators 2 Mounting flanges 3 AC power cord 2 5 2 3 4 4 Fuse 5 Battery leads 12 VDC Figure 4 8 6 Amp Float Equalize Battery Charger 4 10 Circuit Protection If the gene...

Page 38: ...ne stops 4 Place the generator set master switch in the OFF RESET position 4 11 3 Cylinder Lubrication 1 Remove the spark plugs 2 Pour one tablespoon of engine oil into each spark plug hole Install th...

Page 39: ...ection 2 6 If a fault code is displayed identify and correct the cause of the fault condition Then reset the controller See Section 2 6 3 Problem Possible Cause Corrective Action Controller LED displa...

Page 40: ...re insufficient Check the fuel supply and valves Engine malfunction Contact the distributor dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC c...

Page 41: ...off all DC equipment while charging Red and green LEDs stay on for more than 24 hours Onboard DC systems are drawing between 1 5 and 5 amps Turn off all DC equipment while charging One or more inopera...

Page 42: ...TP 6517 1 11 42 Section 5 Troubleshooting Notes...

Page 43: ...ter s Laboratories CUL Canadian Underwriter s Laboratories cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibe...

Page 44: ...ersize 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 Phi...

Page 45: ...Notes...

Page 46: ...Notes...

Page 47: ......

Page 48: ...CO Kohler Wisconsin 53044 Phone 920 457 4441 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 Headquart...

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