Kohler KD2000 Operating Instructions Manual
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Kohler KD2000 Operating Instructions Manual

Apm802 controller industrial generator sets
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Operation
Industrial Generator Sets
Models:
KD800- -KD3250
Controller:
APM802
TP-7070 7/18d

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Table of Contents
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Summary of Contents for Kohler KD2000

  • Page 1 Operation Industrial Generator Sets Models: KD800- -KD3250 Controller: APM802 TP-7070 7/18d...
  • Page 2 WARNING: This product can expose you WARNING: Breathing diesel engine to chemicals, including carbon monoxide exhaust exposes you to chemicals known to and benzene, which are known to the State the State of California to cause cancer and of California to cause cancer and birth birth defects or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 ......... . 3.8.9 Radiator Fan Bearing Lubrication (KD2000--KD3250) ....
  • Page 5 Table of Contents, continued 3.11 Storage Procedure ........... . . 3.11.1 Storage Safety .
  • Page 6 Notes TP-7070 7/18...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be Explosion. aware of potential dangers and act Can cause severe injury or death.
  • Page 8 Battery gases. Explosion can cause Combustible materials. A fire can Carbon monoxide symptoms. severe injury or death. Battery gases cause severe injury death. Carbon monoxide can cause severe can cause an explosion. Do not smoke Generator set engine fuels and fuel nausea, fainting, or death.
  • Page 9 The fuel system. Explosive fuel Engine noise. Hazardous noise can Grounding electrical equipment. vapors can cause severe injury or cause hearing loss. Generator sets Hazardous voltage will cause severe death. Vaporized fuels are highly not equipped with sound enclosures injury or death. Electrocution is explosive.
  • Page 10 Hot Parts Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install WARNING a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into utility electrical system can cause severe injury or death to utility personnel Hot coolant and steam.

  • Page 11: Introduction

    Information in this publication represents data available engine fault codes in addition to the generator set at the time of print. Kohler Co. reserves the right to controller. The engine operation and service literature change this publication and the products represented provide information for identifying engine fault codes.
  • Page 12 Nameplate Location Generator sets and their components (engine, alternator) are identified with decals or nameplates. For future reference during routine maintenance or to order service parts, copy the model number, serial number, and specification number from the generator set nameplate into the spaces provided in the product information section on the inside front cover of this manual.

  • Page 13: Service Assistance

    Visit the Kohler Co. website at KOHLERPower.com. Fax: (65) 6264-6455 China Look at the labels and decals on your Kohler product North China Regional Office, Beijing or review the appropriate literature or documents Phone: (86) 10 6518 7950 included with the product.
  • Page 14 Notes Service Assistance TP-7070 7/18...

  • Page 15: Section 1 Specifications And Features

    Screen Size: 305 mm (12 inches) Viewing Angle: 140 _ horizontal and vertical Languages: English, French Note: Have setup and adjustments of the controller performed only by an authorized Kohler distributor. The setup and adjustments are password protected. TP-7070 7/18...
  • Page 16 Human-Machine Interface (HMI) 11601000945 Note: Covers have been removed for illustration. 1. APM802 controller human-machine interface (HMI) 8. USB ports, qty. 2 (on the back of the HMI) 2. Emergency stop switch 9. Controller touchscreen 3. Key switch 10. Fault indicator/display button 4.

  • Page 17: Connections

    1.3.1 Connections 1.3.2 Modbus Connections Use RS-485 cable for Modbus RTU connections. DANGER Belden #9841 or equivalent shielded, twisted-pair cable is recommended. See Figure 1-3. See the generator set wiring diagram for the Modbus connection location on TB10. The controller also supports Modbus TCP over Hazardous voltage.

  • Page 18: Optional Keyswitch And Manual Start/Stop Button

    1.4 NFPA Requirements 1.3.3 Optional Keyswitch and Manual Start/Stop Button In order to meet NFPA 110, Level 1 requirements, the Some controllers are equipped with the optional generator set controller monitors the engine/generator functions and faults shown below. keyswitch and manual start/stop button shown in Figure 1-4.

  • Page 19: Parameter Settings

    Generators starting maximum delay (Dead Bus synchronizing) Generator cooling time 300 s (5 min.) Generator immobilization time Ventilation time after generator stopped 10 s * Parameter settings not applicable for KD2000--KD3250 Figure 1-6 Factory Settings TP-7070 7/18 Section 1 Specifications and Features...

  • Page 20: Base Module Inputs And Outputs

    1.6 Base Module Inputs and Outputs The inputs and outputs on the base module are factory set. See Figure 1-7 and Figure 1-8 for base module input and output factory settings. For optional input/output module settings, see Section 5, Accessories. Note: Make customer connections to TB10 in the connection box.

  • Page 21: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and To ensure continued satisfactory operation, perform the check for tight exhaust system connections. following checks or inspections before or at each Inspect the exhaust system components (exhaust startup, as designated, and at the intervals specified in manifold, exhaust line, flexible exhaust, clamps,...

  • Page 22: Exercising Generator Set

    2.2 Exercising Generator Set 2.3 Operation in Cold Weather Climates DANGER Cold weather operation is generally considered ambient temperatures below freezing 0C (32F). The following items are recommended for cold weather starting and/or operation when the unit is located in an enclosure or unheated structure.

  • Page 23: Generator Set Operation

    2.4 Generator Set Operation 2.4.4 Emergency Stop Use the controller emergency stop switch for immediate 2.4.1 Start Signal emergency shutdown. A start signal includes the following: The emergency stop switch bypasses the engine cooldown cycle and immediately shuts down the Remote start signal via contacts 3 and 4 when the generator set.

  • Page 24: Controller Operation Modes

    2.5 Controller Operation Modes Note: To disable the generator set before servicing, shut down generator set, place The controller operation includes several types of Out-of-Service mode, and disconnect the starting and stopping functions. There are three primary batteries negative (--) lead first. modes of operation, selected from the controller touchscreen or the optional keyswitch: 2.5.2...

  • Page 25: Auto Mode (Standby Or System Ready)

    1. Remove the load from the generator set. When the start signal is removed, the generator set will continue to run through the engine cooldown cycle, and 2. Wait five minutes to allow the engine to cool down. then shut down. 3.

  • Page 26: Load Shed

    2.6 Load Shed threshold #9. Load 1 (output #0) is shed first . Additional outputs are activated every 5 seconds as shown in The manual key switch/load shed module is available as Figure 2-3 until the total load drops to the threshold an optional kit.

  • Page 27: Hmi Screen Layout

    2.7 HMI Screen Layout 2.7.1 Home Screen The home screen of the APM802 controller’s human-machine interface (HMI) contains status messages, navigation buttons, data displays, and controls described briefly in the following sections. See Figure 2-5. 1. Top bar 2. Control Panel 3.

  • Page 28: Generator View

    2.7.3 Generator View The generator view displays engine mechanical data and alternator electrical data. When in manual mode, the Engine Start button also appears. See Figure 2-7. 1. Engine start appears in Manual mode only 2. Engine and mechanical view 3.

  • Page 29: Control Panel

    2.7.4 Control Panel 2.7.5 Custom View Button The control panel includes the generator set master On medium voltage units equipped with thermocouple switch and other controls. See Figure 2-8. modules, touch the custom view button to see alternator temperature readings from the thermocouple modules. If no thermocouple modules are installed, 32_F (or 0_C) is displayed for all temperatures.

  • Page 30: Operator Login

    2.8 Operator Login Some functions require logging in as an operator. 1. Touch the Operator button. See Figure 2-12. 2. Use the virtual keypad to enter the login (1966). Note: When logging on as operator 1966, a password is not required. When logged in as an Operator, the Modify button appears on screens where settings can be changed.

  • Page 31: Data Displays

    2.9 Data Displays 2.9.1 Generator Mechanical Values Favorites Overview display It is possible to display up to 6 mechanical values at the same time. By default, the following values are displayed: Working hours counter (number of operating hours) Fuel level (daily service tank or main tank) Starter battery voltage Coolant temperature (HT coolant temperature in the case of a dual circuit engine)
  • Page 32 Detailed View From an overview display of 6 mechanical values, we switch to a detailed display of 3 mechanical values. Pressing any area on an information bar on one of the mechanical value pages gives access to a detailed view Three tabs also appear: Fuel, Engine, and Cooling.

  • Page 33: Generator Electrical Values

    2.9.2 Generator Electrical Values Overview display Six electrical values are displayed and shown as meters. See Figure 2-18. 1. Curve button Figure 2-20 Detailed Electrical Values 2.9.3 Curve Display When you zoom into each mechanical or electrical value, the Curve button appears. Touch the Curve 1.
  • Page 34 On any curve displayed on the screen, inserting a USB key into the HMI port makes the USB key button appear. See Figure 2-23. Pressing this button automatically saves: A curve data file (.csv) containing the information (data points) described in Section 2.9.4. An image of the selected window in png format.

  • Page 35: Saved Electrical And Mechanical Data

    2.9.4 Saved Electrical and Mechanical Data The recording on a USB stick provides a curve data file All of this information is saved according to 4 different (.csv) containing the information shown in Figure 2-25. time periods: Depending on the engine type and sensors installed on 10 minutes: record values every 1 second the generator set, some of the 14 mechanical values 4 hours: record values every 30 seconds...

  • Page 36: Events

    2.10 Events The controller displays status, alarm (warning), and fault (shutdown) messages. See Figure 2-26 for a list of possible alarms and faults. Internal Alarm Fault Internal Alarm Fault Number Description (Warning) (Shutdown) Number Description (Warning) (Shutdown) M3.10 Common fault M3.117 Engine coolant temperature fault...

  • Page 37: Faults And Alarms

    2.10.1 Faults and Alarms Press the Alarm (!) button shown in Figure 2-27 to view a list of generator set events, including status messages, alarms, and faults. A status message communicates the state of the generator set (example: appearance of Stop mode). An alarm (warning) signals an impending problem (example: coolant temperature alarm).
  • Page 38 1. Alarm button with number of alarms (press to display list) 5. Date and time of event 2. Pull down tab (press to show full display of additional alarms) 6. Reset button (X) 3. Description 7. Active (on) 4. Internal variable number 8.

  • Page 39: Resetting An Alarm

    2.10.2 Resetting an Alarm 2.10.3 Resetting a Fault An alarm indicates that a problem has occurred, but the A fault turns off when the cause of the alarm is resolved generator is still able to run. Always correct an alarm by one of the two following methods: condition before it leads to a fault that will shut down the The operator has corrected the condition that is...

  • Page 40: Consulting Status Messages

    2.10.4 Consulting Status Messages Present/Not present Reviewing the status messages is possible at any time. Open/Close Depending on the status type, the APM802 will log On/Off different messages: Start/End Appearance After pressing the Alarm (!) button, and if no fault or Disappearance alarm is present, select Status messages history in Appearance/Disappearance...

  • Page 41: Full Event Log

    2.10.5 Full Event Log To view all events (status messages, alarms, and faults, active or reset), select Full event log from drop-down list A, and select All from drop-down list B. See Figure 2-37 for an example of the full event log. 1.

  • Page 42: Applications

    2.11 Applications Touch the Applications button in the top bar to open the Applications screen. See Figure 2-38. From this screen, you can access the screens listed in Figure 2-39. Note that access to some screens requires logging on as an operator. 1.

  • Page 43: Reference

    Reference Customer case name (for example: computer center) APM identification Option of assigning a name to the HMI (for example: GS parking number 1) Kohler reference Reference Commercial case reference (manufacturer’s side) Genset serial number Generator set serial number associated with the HMI...

  • Page 44: Region Settings

    2.11.2 Region Settings 1. Select user language 3. Modify 2. Set the date and time 4. Date and time adjustment window appears after touching the Modify key Figure 2-41 Region Settings Screen Title Description and Possible Settings (or selections) Pressure Selection of the pressure display: bar, PSI Temperature Selection of the temperature display: _C , _F...

  • Page 45: Hmi Settings

    2.11.3 HMI Settings 1. Touch the Modify button 2. Slide to adjust the screen brightness during normal operation 3. Slide to adjust brightness during standby operation Figure 2-43 HMI settings The sliders on this screen allow adjustment of the screen brightness during operation and standby. The two sliders are independent.
  • Page 46 The Home button on the Remote HMI looks different the search for base modules connected to the ring is in than the Home button on the local HMI. progress. Figure 2-44. At the end of the search, the IP addresses of the modules connected to the Ethernet ring are shown (see Figure 2-46).

  • Page 47: Restart

    2.11.4 Restart 2.11.6 Firmware Update Press the Restart icon to bring the window shown in Pressing the Firmware update icon carries out an Figure 2-48 to the front. Confirm the restart by pressing update of the HMI firmware. OK, or cancel the procedure by pressing Cancel. The update requires that a USB key is inserted into the This operation will trigger a complete restart of the HMI port provided on the bottom of the HMI.

  • Page 48: Screenshot

    2.11.7 Screenshot Go into the screen to be copied and press the camera button. The screenshot is automatically saved to the Before taking a screenshot, it is necessary to insert a USB key in the directory “E:\apm802\screenshot. USB key in the port provided on the bottom of the HMI module.

  • Page 49: Ladder Tools

    2.11.8 Ladder Tools Pressing the Ladder tools icon takes you to the screen shown in Figure 2-53. See Figure 2-38 for the location Ladder is a standardized graphic language which is very of the Ladder tools icon on the applications screen. similar to a ladder diagram.
  • Page 50 1. Input line title 2. Electrical connection 3. Input internal variable 4. Normally closed contact 5. Input variable Figure 2-54 Inputs Network Figure 2-55 Outputs network Section 2 Operation TP-7070 7/18...

  • Page 51: Save Parameters

    2.11.9 Save Parameters 2.11.10 Upload Parameters 1. Insert a USB key into the port on the bottom of the An authorized service technician can obtain and load HMI module. See Figure 2-50. parameter files following the instructions in the controller service manual. 2.

  • Page 52: Menus

    2.12 Menus Figure 2-57 shows the architecture of the screens accessible from the Menu button. Menu > 1- -Settings 2- -Measurements 3- -History 4- -Diagnostic 5- -Configuration 6- -Hardware Power thresholds Mechanical Archiving Variables Application Installation 5.1.1 6.1.1 Timers * Generator electrical Binary inputs General...
  • Page 53 Menu Access Some menus are view-only and do not allow modifications. Some menus require the operator password to view and/or modify. See Figure 2-58 for menu access information. 1 - - Settings User Operator * 5.3 Regulation 1.2 Power thresholds View Modify * 5.3.1 Regulation parameters...

  • Page 54: Menu 1--Settings

    2.12.1 Menu 1- -Settings Changing Settings Pressing the Modify button brings up text entry fields for The 1--Settings menu can be accessed via the key with settings that can be changed. See Figure 2-59. the same name. Pressing in the text entry field brings up the 1.2 Power Thresholds alphanumeric keypad shown in Figure 2-60.
  • Page 55 Screen 1.2- -Power thresholds The 1.2--Power thresholds screen is used to set up to 10 active power thresholds. Threshold 9 is used for load shed. 1. Threshold reached = green (in this example, thresholds #1 to #4 are reached or exceeded) 2.
  • Page 56 Screen 1.6- -Auxiliaries The 1.6--Auxiliaries screen is used to set the auxiliary parameters for the generator set fuel warning levels. Figure 2-62 Auxiliaries screen Title Description and possible settings (or selections) Fuel pumps Low fuel level fault (%) Low fuel level at which the fault is triggered, expressed as a percentage Low fuel level warning (%) Low fuel level at which the alarm is triggered, expressed as a...
  • Page 57 Screen 1.8 Parameters The 1.8--Parameters screen is used to set the engine speed (RPM). The speed can be adjusted by ±10RPM. Figure 2-63 Parameters Screen TP-7070 7/18 Section 2 Operation...

  • Page 58: Menu 2--Measurements

    2.12.2 Menu 2- -Measurements The 2--Measurements menu can be accessed via the button with the same name. This gives access to the screens listed below. Screen 2.2 -- Mechanical Screen 2.3 -- Generator electrical Screen 2.6 -- Harmonics Note: The measurements menus are view-only; no modifications are possible from these menus. Screen 2.2- -Mechanical The 2.2--Mechanical screen gives an overview of all the mechanical values for the associated generator.
  • Page 59 Screen 2.3- -Generator electrical The 2.3--Generator electrical screen gives a detailed view of all the electrical values for the associated generator (on generator HMI only). 1. Display for 3 phases 2. Phase sequence indication : Green = Correct; Red = Inverse; Off = Not Activated 3.
  • Page 60 Screen 2.6- -Harmonics The 2.6--Harmonics screen is used to monitor the change in harmonics in real time on the generator set. 1. Harmonics 2. Line-to-neutral voltage 3. Current Figure 2-66 Harmonics Screen Section 2 Operation TP-7070 7/18...

  • Page 61: Menu 3--History

    2.12.3 Menu 3- -History The 3--History menu can be accessed via the key with the same name. It gives access to Screen 3.1 -- Archiving. Screen 3.1- -Archiving The 3.1--Archiving screen is used to store certain parameters in the controller’s memory. 1.

  • Page 62: Menu 4--Diagnosis

    2.12.4 Menu 4- -Diagnosis Screen 4.1- -Variables The 4.1--Variables screen is used to read all the system The 4--Diagnosis menu can be accessed via the key variables, regardless of whether these are logic or with the same name. it gives access to the 5 screens analog variables.
  • Page 63 Type Enter on screen keypad Enter on external keypad Complete write access examples Logic input variable I0.0.0 Analog input variable I5.21 Internal variable (input or M3.112 output) M1.0 M1.1 Logic output variable Q0.0.0 Analog output variable Figure 2-69 Sample Variable Identification Refer to the example in Figure 2-68 and the variables listed in Figure 2-70.
  • Page 64 Screen 4.2- -Binary inputs The 4.2--Binary inputs screen is used to get a quick overview of the following logic states: Eighteen binary inputs for the base module Eight binary inputs for each remote module connected to the base module Red = Not Active (off) Green = Active (on) 1.
  • Page 65 Screen 4.3- -Binary outputs The 4.3--Binary outputs screen is used to get a quick overview of the following logic states: Eighteen base module outputs Four outputs for each extension module connected to the base module Red = Not Active (off) Green = Active (on) 1.
  • Page 66 Screen 4.4- -Regulation & protection The 4.4--Regulation and protection screen is used to read all the internal variables for the regulation and protection modules. 1. Entry field for a variable name 2. Value or status of the variable 3. Numeric keypad for entering the variable name Figure 2-73 Regulation and Protection Screen The process for entering a regulation or protection variable is the same as for the 4.1--Mapping screen.
  • Page 67 Screen 4.5- -Regulation The 4.5--Regulation screen is used to read all of the internal variables for the regulation modules. 1. Entry field for a variable name 2. Value or status of the variable 3. Regulation status Figure 2-74 Regulation Screen The virtual numeric keypad appears after the variable entry field has been pressed.

  • Page 68: Menus 5 And 6

    2.12.5 Menus 5 and 6 Except for menu 6.5, communication, menus 5 and 6 are view-only menus that can be seen when logged in as an operator (1966). The view-only menus are not shown in this document. 2.12.6 Menu 6.5-Communication Screen 6.5.1- Ethernet The 6.5.1-Ethernet screen defines the computer addresses for the Ethernet connections for the base module and the HMI module.
  • Page 69 Screen 6.5.2-Serial link The 6.5.2-Serial link screen defines the specifications of the RS485 type serial link available on the base module. Figure 2-77 Serial Link Screen The screen is accessible for modification at the operator level. Figure 2-78 shows the range of possible settings and the factory default settings, which are configured for communication with the RSA III remote serial annunciator.
  • Page 70 Notes Section 2 Operation TP-7070 7/18...

  • Page 71: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 Introduction WARNING This section deals with general maintenance of the generator set and accessories. This section may refer to other literature procedures additional information. Hot engine and exhaust system. Can cause severe injury or death. Refer to Appendix B, Operating Hour Service Log for a means to document maintenance.
  • Page 72 WARNING WARNING Hot coolant and steam. Can cause severe injury or death. Explosive fuel vapors. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to Use extreme care when handling, cool. Then loosen the pressure cap storing, and using fuels.
  • Page 73 Battery acid cleanup. Battery acid can cause severe WARNING injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution.

  • Page 74: Service Schedule

    Some items may not apply to all generator sets. R Replace as necessary. X Action * Service more frequently if operated in dusty areas. ] Service must be performed by an authorized Kohler service representative. Section 3 Scheduled Maintenance TP-7070 7/18...
  • Page 75 * Service more frequently if operated in dusty areas. [ Do not break manufacturer’s seals or internally inspect these devices. ] Alternator service must be performed by an authorized Kohler service representative. Meggerr is a registered trademark of Biddle Instruments.

  • Page 76: Apm802 Controller Maintenance

    If battery power is low, an alarm, M3.212 APM INTERNAL BATTERY WARNING, appears on the controller. Have an authorized Kohler service representative service the Explosive fuel vapors. controller. Can cause severe injury or death.

  • Page 77: Fuel/Water Separator

    3.5.1 Fuel/Water Separator Fuel/water separators (fuel prefilters) ensure clean fuel is delivered to the engine by removing contaminants and water. Providing clean fuel prevents clogged injectors and allows the engine to run more efficiently. In a fuel/water separator, water collects in the lower cavity of the filter.

  • Page 78: Manual Primer Pump

    3.5.2 Manual Primer Pump 7. Remove the water drain plug (or push up the drain valve) and allow water and fuel to flow into a The manual primer pump, located on the fuel/water suitable container. separator, allows the operator to pump fuel through the Note: Depending upon the location of the fuel fuel system without cranking the engine.

  • Page 79: Bleeding Air From Fuel System

    3.5.3 Bleeding Air from Fuel System Refer to the safety precautions for preventing accidental starts and disabling the generator set. Trapped air in the fuel system causes difficult starting and/or erratic engine operation. The fuel system uses a. Remove the load from the generator set. an automatic bleed line which allows fuel and air to flow b.

  • Page 80: Lubrication System

    3.6 Lubrication System 3.6.2 Automatic Oil Replenishment System (Optional Kit) 3.6.1 Oil Change The engine oil change interval varies for different engines, applications, and oil type. Identify the following for your application and then refer to the Engine Operation and Maintenance Manual for oil change intervals and oil specifications.

  • Page 81: Oil Analysis

    3.6.3 Oil Analysis Sampling Point Sampling is carried out at a representative point in the The engine oil analysis interval varies for different system, preferably just after the machine is shut down. engines, applications, and oil types. Refer to the Engine Operation and Maintenance Manual for oil analysis Always sample at the designated sampling point(s).
  • Page 82 Sampling Methods Recommended Tests The recommended tests for the analysis are shown in Method 1: Sampling with a Syringe Figure 3-6 and Figure 3-7. 1. Read and follow the safety precautions in Spectrometric Analysis (wear) Units Section 3.1. Iron (Fe) DIN 51399-1:2012-5 mg/kg 2.

  • Page 83: Air Cleaner System

    3.7 Air Cleaner System 4. For heavy-duty filters: The air cleaner requires periodic maintenance. See the a. Release the cover clips (KD2000--KD2500) or maintenance schedule. A dusty environment or remove the wingnut (KD2800--KD3250) and conditions may require the use of a heavy duty air filter remove the cover.

  • Page 84: Cooling System

    3.8 Cooling System DANGER KD series generator sets in the range of 800--2500 kW use two-slab radiators with a multi--core construction and expansion tanks. The multi-core construction allows the isolation of cooling circuits and improves the serviceability of the product. Hazardous voltage.

  • Page 85: Coolant Level Check

    Note: The drain valve(s) are typically located along the bottom of the skid. See Check the pressure cap seal and replace a cracked or Figure 3-11. Models KD2000--KD3250 have deteriorated cap. Remove dirt and other debris from two drains, one for each coolant circuit, on the pressure cap and filler neck.

  • Page 86: Procedure To Flush And Clean Cooling System

    1. Drain valve for high and low temperature cooling circuits 2. Drain valve for hoses Figure 3-12 Radiator Drain Valves, KD2000--KD3250 6. On models KD2000- -KD3250, use the engine drainage ports to drain coolant from the high temperature and low temperature water pumps and the oil cooler.

  • Page 87: Procedure To Refill Cooling System

    Then check the coolant at the interval specified in the 5. For models KD2000- -KD3250, use the manual service schedule. engine venting ports to bleed trapped air from the system. Refer to the engine operation manual for 13.

  • Page 88: Coolant Analysis

    Sampling is carried out at a representative point in the Percentage of coolant/water system, preferably just after the machine is shut down. Physicochemical analysis (reserve alkalinity, density, On KD2000--KD3250 models, take the sample etc.) through the engine venting/bleeding ports, or through Conductivity.

  • Page 89: Radiator Maintenance

    3.8.8 Radiator Maintenance Sampling Method 1. Read and follow the safety precautions in Use the following list for radiator maintenance: Sections 3.1 and 3.8.1. Periodically check for leakage from the core or tank 2. Place a basin under the drain point. connections.

  • Page 90: Radiator Fan Bearing Lubrication (Kd2000--Kd3250)

    3.8.9 Radiator Fan Bearing Lubrication a. Remove the load from the generator set. (KD2000- -KD3250) b. Shut down the generator set. Note: The following content on fan bearing lubrication c. Place the generator set controller into does not apply to models KD800--KD1750.

  • Page 91: Notched V-Belt Adjustment (Kd2000--Kd3250)

    3.8.10 Notched V-Belt Adjustment (KD2000- -KD3250) For models KD2000- -KD3250, use the following procedure to adjust the tension on the six notched V-belts which turn the fan pulley. Note: The following content on fan bearing adjustment does not apply to models KD800- -KD1750. On...
  • Page 92 72.6--75.6 70--75 N @ 9 mm 5. Engine pulley Belt (16--17 lbs. @ 0.4 in.) KD2800 to KD3250 Figure 3-20 Tension Adjustment, KD2000--KD3250 Frequency (Hz) Deflection New Belt 62.7--64.9 89--95 N @ 12 mm 6. Make the necessary adjustments until belt tension (20--21 lbs @ 0.5 in.)

  • Page 93: Battery Systems

    3.9 Battery Systems WARNING Refer to this section for general battery information and maintenance. All generator set models use a negative ground with a 24-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator set spec sheet for Explosion.

  • Page 94: Absorbed Glass Mat (Agm) Battery

    Battery short circuits. Explosion can cause severe injury damp cloth. Keep the electrical connections dry and or death. Short circuits can cause bodily injury and/or tight. equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before If corrosion exists, disconnect the cables from the servicing the equipment.

  • Page 95: Alternator Maintenance

    3.10 Alternator Maintenance Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all This section covers alternator maintenance for several applicable codes and standards. Electrically ground the different types of alternators and voltage regulators.

  • Page 96: Checking The Installation

    To make adjustments to the voltage regulator settings, 4. Check for corrosion or abrasion on the air outlet contact an authorized Kohler distributor. Have an grids . authorized distributor/dealer perform service. Note: For models that use the DER2 voltage regulator, the potentiometers (VOLT, STAB, Hz, AMP.) are...

  • Page 97: Storage Procedure

    3.11 Storage Procedure DANGER Perform the following storage procedure before taking a generator set out of service for three months or longer. Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine component storage. Hazardous voltage. Moving parts. Will cause severe injury or death.

  • Page 98: Controller

    3.11.2 Controller 3.11.5 Diesel Fuel System If the generator set is stored in a location where the Prepare the fuel system for storage as follows: temperature drops below --20_C (--4_F), connect power 1. Fill the fuel tank. to the controller heater. 2.

  • Page 99: Alternator Storage

    3.11.7 Alternator Storage 3.11.8 Battery WARNING WARNING Risk of fire. Explosion. Can cause severe injury or death. Can cause severe injury or death. Relays in the battery charger Combustible materials. A fire can cause severe injury or cause arcs or sparks. death.
  • Page 100 Notes 100 Section 3 Scheduled Maintenance TP-7070 7/18...

  • Page 101: Section 4 Troubleshooting

    Section 4 Troubleshooting 4.1 Introduction 4.2 Generator Set and Controller This section contains generator set, controller, general Refer to the following charts for generator set and engine, customer connection panel controller troubleshooting. Some of the corrective troubleshooting, diagnostic, and repair information. actions may reference the alternator and/or controller This section may refer to other literature for procedures service...

  • Page 102: General Troubleshooting Chart

    102 Section 4 Troubleshooting TP-7070 7/18...
  • Page 103 TP-7070 7/18 Section 4 Troubleshooting...
  • Page 104 104 Section 4 Troubleshooting TP-7070 7/18...
  • Page 105 TP-7070 7/18 Section 4 Troubleshooting...
  • Page 106 Notes TP-7070 7/18...

  • Page 107: Section 5 Accessories

    Section 5 Accessories 5.1 Accessories and Connections 5.2 Accessory Connections Factory-installed accessories are available to help Connect external optional accessories including finalize installation, add convenience to operation and alarms, battery chargers, thermocouples, and remote service, and establish state and local code compliance. switches to the terminal block or modules in the customer connection box.

  • Page 108: Input And Output Modules

    The factory default input and output settings are 3. Analog input connections 0 -- 3 undefined. I/O settings can be loaded by an authorized service technician. Contact your Kohler distributor with Figure 5-4 Analog Input/Output Module your requirements for inputs and outputs.

  • Page 109: Digital Input/Output Module

    Different I/O settings for the optional I/O module can be Output DO0 Load 1 Undefined loaded by an authorized service technician. Contact Output DO1 Load 2 Undefined your Kohler distributor with your requirements for digital Output DO2 Load 3 Undefined inputs and outputs. Output DO3 Load 4 Undefined...

  • Page 110: Thermocouple Input Module

    5.3.3 Thermocouple Input Module Up to three thermocouples can be connected to the Thermocouple Module. Type PT100 thermocouples can be connected. See Figure 5-9 for thermocouple specifications. See Figure 5-11 and Figure 5-12 for connections. Medium voltage (larger than 600 volts) units are equipped with two thermocouple modules with the settings shown in Figure 5-10.

  • Page 111: Remote Serial Annunciator

    5.4 Remote Serial Annunciator RSA III is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA III is a remote serial annunciator (Figure 5-13, Figure 5-14, and Figure 5-15) that monitors the condition of the generator set and/or ATS from a remote location.
  • Page 112 System Monitoring LEDs and Functions Common System Generator Communications Common Fault Fault Ready LED Running LED Status LED Fault LED Output Horn Fault and Status Condition Overcrank (Shutdown) Red SF Red SF Green Red SF High Engine Temperature (Warning) Yellow SF Red SF Green Green...

  • Page 113: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per hour electrostatic discharge ABDC after bottom dead center cubic feet per minute est. estimated alternating current center of gravity E-Stop emergency stop analog to digital cubic inch displacement...
  • Page 114 (2 bytes) nat. gas natural gas room temperature vulcanization KBus Kohler communication protocol National Bureau of Standards read/write kilogram normally closed Society of Automotive Engineers kg/cm kilograms per square National Electrical Code...

  • Page 115: Appendix B Operating Hour Service Log

    Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed. Enter hours to the operating hours on your generator set and the dates nearest quarter hour. Operating Hours Service Record Date Hours Total...
  • Page 116 Operating Hours Service Record Date Hours Total Service Hours Date Service 116 Appendix TP-7070 7/18...
  • Page 117 Notes TP-7070 7/18...
  • Page 118 Notes TP-7070 7/18...
  • Page 119 TP-7070 7/18...
  • Page 120 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-7070 7/18d For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2017, 2018 by Kohler Co. All rights reserved.

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Kd3250Kd1250Kd800Kd1750Kd1000

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