Section 2 Operation; Prestart Checklist; Exercising Generator Set; Controller Operation - Kohler Decision-Maker 3000 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering engine.
Air Inlets. Check for clean and unobstructed air inlets.
Battery. Check for tight battery connections. Consult
the battery manufacturer's instructions regarding
battery care and maintenance.
Coolant Level. Check the coolant level according to the
cooling system maintenance information.
Note: Block Heater Damage. The block heater will fail
if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
the system before energizing the block heater.
Drive Belts. Check the belt condition and tension of the
radiator fan, water pump, and battery charging
alternator belt(s).
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, exhaust line, flexible exhaust, clamps,
silencer, and outlet pipe) for cracks, leaks, and
corrosion.
D
Check for corroded or broken metal parts and replace
them as needed.
D
Check for loose, corroded, or missing clamps and
hangers. Tighten or replace the exhaust clamps
and/or hangers as needed.
D
Check that the exhaust outlet is unobstructed.
D
Visually inspect for exhaust leaks (blowby). Check
for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.
TP-6694 7/11

Section 2 Operation

Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.

2.2 Exercising Generator Set

Operate the generator set under load once each week
for one hour. Perform the exercise in the presence of an
operator when the generator set does not have an
automatic transfer switch with an exercise option.
During the exercise period apply a minimum of 35% load
based on the nameplate standby rating, unless
otherwise instructed in the engine operation manual.
The operator should perform all of the prestart checks
before starting the manual exercise procedure. Start
the generator set according to the starting procedure in
Section 2.3, Controller Operation. While the generator
set is operating, listen for a smooth-running engine and
visually inspect generator set for fluid or exhaust leaks.
The generator set controller does not provide weekly
scheduled exercise periods. For scheduled exercise
periods, refer to the automatic transfer switch (if
equipped) literature.

2.3 Controller Operation

The controller operation includes several types of
starting and stopping functions as detailed in the
following paragraphs. The controller master control
switch buttons, lamps, and alarm horn functions are
summarized in Figure 2-1.
Section 2 Operation 27