Kohler — ADC 2100 Controller Replacement Procedure

Repair & overhaul

From a Kohler service manual covering: 12RES, 8.5/12 RES, 8.5RES. Check it applies to your exact model before use.

Applies to: Kohler 12RES, Kohler 8.5RES, Kohler CH20 engine, Kohler CH 740 engine

Procedure

1. Remove the enclosure service-side door.
2. Place the generator set master switch in the OFF position.
3. Remove 4 roof screws; lift the roof up and off.
4. Disconnect power to the battery charger.
5. Disconnect the engine starting battery, negative lead first.
6. For inside-mounted controllers: remove front panel, remove controller compartment cover.
7. Disconnect wiring harness plugs P1, P15, and P16 from the ADC controller.
8. Loosen and remove four controller mounting screws; remove the controller.
9. Place the new controller into position and install the four mounting screws.
10. Attach connectors P1, P15, and P16 to the new controller.
11. Replace the controller compartment cover and the front panel.
12. For front-mounted controllers: remove four mounting screws, pull controller forward, disconnect plugs P1, P15, and P16.
13. Attach plugs to the new controller and install the four mounting screws.
14. Reconnect the battery, negative lead last; reconnect power to the battery charger.
15. Replace the roof and tighten the four roof screws.

Full service-parts list: Kohler 12RES →, Kohler 8.5RES →

Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

More Kohler repair guides →