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Kohler 12RESL Operation Manual Download Page 48

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2007, 2008, 2009, 2011 by Kohler Co. All rights reserved.

TP-6517 1/11d

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

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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