California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Controller Identification Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice.
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting 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, or Explosion. maintained. To prevent accidents be aware of potential dangers and act Can cause severe injury or death.
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Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms. severe injury or death. Battery gases fire can cause severe injury or death. Carbon monoxide can cause severe can cause an explosion. Do not smoke Do not smoke or permit flames or nausea, fainting, or death.
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leaks, fuel accumulation, or sparks. Hazardous Noise WARNING Repair fuel systems before resuming generator set operation. CAUTION Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: Hazardous voltage. Backfeed to the utility system can Gasoline—Store gasoline only in cause property damage, severe approved...
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Short circuits. Hazardous WARNING WARNING voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments repairs. Hot engine and exhaust system. Remove all jewelry before servicing the Can cause severe injury or death.
Operation Manual Information in this publication represents data available Service Parts Controllers TP-6009 at the time of print. Kohler Co. reserves the right to Program Loader Software Installation TT-1285 change this publication and the products represented Remote Serial Annunciator (RSA)
Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.
Section 1 Specifications and Features 1.1 Introduction Figure 1-1 shows the 16-light (level 1) controller. The 16-light controller features include annunciator panel The specification sheets for each generator set provide lamps, analog meters, switches and controls, and fuses specific generator and engine information. Refer to the and terminal strips.
The 16-light controller with communications has a new New Application Program Software. Contact your circuit board GM28725 that is different in appearance local authorized distributor for application program and has additional functions from the earlier versions updates when instructed to do so during troubleshooting but is a direct replacement for earlier version circuit and/or when adding specific accessories.
1.2.5 Switches and Controls 1.2.6 Terminal Strips Figure 1-6 describes the switches and controls located Two terminal strips are mounted on the controller circuit on microprocessor controllers. board. See Figure 1-7 and Figure 1-8. Refer to Section 2.3.2, Prime Power Mode Operation, for information on enabling prime power mode.
1.2.7 DIP Switches Typically, the factory default settings have all the DIP switches in the closed position except the crank mode The controller circuit board contains eight DIP switches, selection switch SW3 which is open for cyclic cranking. see Figure 1-9. The overspeed selection switch SW1 is open on 50 Hz.
1.3 Expanded Decision-Makerr 1 Controller For identification of the expanded controller’s indicators and controls and their functions, refer to Figure 1-12. ADV-5849E-B 1. Frequency meter 8. Voltage adjustment control 9. Fault lamp 2. AC voltmeter 3. AC ammeter 10. 10-amp controller fuse 4.
Section 2 Operation 2.1 Prestart Checklist Ignition System. Ensure that the ends of all spark plug wires are properly seated onto the coil/distributor and To ensure continued satisfactory operation, perform the the spark plug. following checks or inspections before or at each Lamp Test.
Note: The 450--600REOZV_ Volvo-powered models Enabling and Disabling the Prime Power Mode. To have a delay in the starting cycle due to the enable the prime power mode, use jumpers to connect controller software. This is normal and only TB2-1P to TB2-2P, TB2-3P to TB2-4P, and TB2-3 to occurs on the initial start after the battery is TB2-4.
Use the following procedure to restart the generator set Fault Description after shutdown by an emergency stop switch. Refer to High engine The high engine temperature shutdown shuts Section 2.3.5, Controller Resetting After a Fault temperature down the unit 5 seconds after a fault. The Shutdown, to restart the generator set following a fault shutdown does not function during the first 30 seconds following startup.
2.4 Expanded Decision-Makerr 1 2.4.4 Controller Resetting After a Fault Shutdown Controller Use the following procedure to restart the generator set 2.4.1 Generator Set Starting after a fault shutdown. Local Starting. Move the generator set to the RUN 1. Disconnect the generator set from the load using position to immediately start the generator set.
Section 3 Scheduled Maintenance Under normal operating conditions, the generator set’s Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the alternator requires no normal service. Consult the generator set or connected equipment, disable the generator prestart checklist in Section 2.1 for a list of routine set as follows: (1) Move the generator set master switch to the checks.
3.3 Service Schedule Action System—Component Visually Inspect Check Change Clean Test Interval Fuel Day tank level Weekly Flexible lines and connections Weekly Fuel level switch Weekly Main tank supply level Weekly Solenoid valve operation Weekly Transfer pump operation Weekly Water in system, remove Weekly Filter(s) Quarterly...
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Service Schedule, continued Action System—Component Visually Inspect Check Change Clean Test Interval AC Electrical System Controller lamp test Weekly General Inspection Weekly Circuit breakers, fuses[ Monthly Wire abrasions where subject to motion Quarterly Safety and alarm operation Six Months Tighten control and power wiring connections Yearly Transfer switch main contacts[ Yearly...
3.4 Alternator Bearing Service Have an authorized service distributor/dealer perform service. 3.4.1 20- -300 kW Models Replace the end bracket bearing every 10,000 hours of operation in standby and prime power applications. Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage.
3.5.2 Subbase Inner Fuel Tank Alarm Resetting Procedure Use the following procedure to reset the alarm after a This kit provides for both audible and visual alarm from a fault alarm. location remote from the generator set if a leak is detected in the inner fuel tank of the double-wall 1.
LPG Liquid Withdrawal Operation Disconnect lead 73A from the fuel solenoid valve. Connect lead 73B to the fuel solenoid valve (LPG liquid withdrawal) Connect lead 65 to lead N5 (ground). Auto Changeover Natural Gas/LPG Vapor Operation Disconnect lead 65 from N5. Connect lead N5 to LFP2 relay common terminal.
Emissions certified models use a single electronic- WARNING controlled pressure regulator (EPR) for both fuels. A tee fitting connects both fuels together upstream of the EPR. During operation when using the secondary fuel, it is normal for a small amount of secondary fuel to seep back through the primary fuel solenoid valve.
Check the condition and tension of the radiator fan 3.7.5 Cooling System Refilling and water pump belt(s). Follow the belt tension Procedure procedure in this manual and/or the engine operation manual. See the generator set spec sheet for coolant capacity. Check the pressure cap seal and replace a cracked or Note: Do not add coolant to a hot engine.
13. Maintain the coolant level in the coolant recovery tank between the high and low marks. Note: Air pockets often form in the engine water jacket when the coolant system is refilled. Check the coolant level in the coolant recovery tank after each generator set operation and add coolant as necessary until the coolant level stabilizes.
3.9 Radiator Fan Bearing Lubrication The following procedure applies only to 1200--2250 kW generator sets. Lubricate the radiator fan shaft and idler shaft bearings at every engine oil change to avoid bearing damage. Lubricate the bearings every 200 hours of operation when the generator set runs in ambient temperatures below 29°C (85°F) or when the generator set runs in a dusty and/or humid environment.
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Battery gases. Explosion can cause severe injury or Note: Some units require a reflective heat shield death. Battery gases can cause an explosion. Do not smoke insulative sleeve on the battery cables and other or permit flames or sparks to occur near a battery at any time, wires that are fastened to the starter solenoid.
1-046 1. Filler caps 2. Electrolyte level Figure 3-14 Battery Electrolyte Level Inspection KW-272000-B 1. To positive (+) terminal on starter solenoid. 3.10.3 Specific Gravity Check 2. To ground (--) terminal on or near starter motor. 3. To positive (+) terminal on second starter solenoid. Use a battery hydrometer to check the specific gravity of 4.
Note: If the generator set is in a temporary prime power Correction ° ° application in which the generator set has periods 71.1 + .032 of inactivity, the controller circuitry may drain the + .030 battery. If there is no power source for a battery 65.6 + .028 Example No.
Figure 3-18 John Deere Engine Control Box stored codes. Follow the instructions provided with the software. See Figure 3-19 for the Kohler-branded D300, D350, D400, D450, and D500 engine control box features. Code Types Active code. A code flashing on the SEL lamp indicates a fault currently exists.
3.13 Storage Procedure Gas-Fueled Engines 1. Start the generator set. Perform the following storage procedure before taking a generator set out of service for three months or longer. 2. With the generator set running, shut off the gas Follow the engine manufacturer’s recommendations, if supply.
3.13.6 Battery 4. Place the battery in a cool, dry location. Perform battery storage after all other storage 5. Connect the battery to a float/equalize battery procedures. charger or charge it monthly with a trickle battery charger. Refer battery charger 1.
Section 4 Troubleshooting This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed diagnostic, and repair information. on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an Use the chart on the following page to diagnose and authorized distributor/dealer.
Section 5 Generator Set Reconnection To change the voltage of 10- or 12-lead generator sets, WARNING use the following voltage reconnection procedure. Adjust the governor and voltage regulator for frequency changes. Consult the generator set service manual for frequency adjustment information. Voltage reconnection.
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Figure 5-1 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5875A-M Section 5 Generator Set Reconnection TP-6161 1/12...
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Figure 5-2 20--300 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875B-M TP-6161 1/12 Section 5 Generator Set Reconnection...
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Figure 5-3 60 (with Oversize Alternator)--300 kW Wound Field Alternators, ADV-5875C-M Section 5 Generator Set Reconnection TP-6161 1/12...
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4. Remove the controller cover and reposition the 6. Reconnect the starting battery, negative (--) lead meter scale lamp jumper (see Figure 5-5) to match last. Place the generator set master switch in the the position for desired voltage (shown in RUN position to start the generator set.
Section 6 Accessories 6.1 Accessories Kit Description Audiovisual Alarm Several electrical accessories and controls help Common Failure Relay (Terminal 32A) finalize installation, add convenience to operation and Controller (Customer) Connection service, and establish state and local code compliance. Engine Prealarm Senders for NFPA 110 Fastcheckr Diagnostic Tester Accessories vary with each generator set model and Float/Equalize Battery Charger (with alarms)
6.1.1 Audiovisual Alarm (DEC 3+) Front View Side View An audiovisual alarm warns the operator of fault shutdowns and prealarm conditions (except battery charger fault and low battery voltage) from a remote location. Audiovisual alarms include an alarm horn, an alarm silence switch, and a common fault lamp.
6.1.3 Controller (Customer) Connection junction box. With the exception of a few terminals the remote terminal strip is identical to that of the controller. Kit (DEC 3+) Connect all accessories (except the emergency stop kit) to the controller connection kit terminal strips. See The controller connection kit allows easy connection of controller accessories without accessing the controller Figure 6-6.
6.1.5 FASTCHECKr Diagnostic Tester 6.1.6 Float/Equalize Battery Charger Kit (DEC 3+) with Alarm Option (DEC 3+) The FASTCHECKr diagnostic tester simulates engine The float/equalize battery charger with alarm option operation to identify faults in the controller and engine provides battery charging to the engine starting circuitry.
6.1.8 Low Fuel (Level/Pressure) Switch 6.1.10 Remote Annunciator Kit (DEC 3+) (DEC 3+) A remote annunciator provides convenient monitoring of the generator set’s condition from a remote location. Some gaseous-fueled models offer a low fuel pressure See Figure 6-12. The remote annunciator includes an switch as part of the Engine Prealarm Senders kit.
6.1.12 Remote Serial Annunciator (DEC 3+) RSA II is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA is a remote serial annunciator Figure 6-15 and Figure 6-16 that monitors the condition of the generator set and/or ATS from a remote location.
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/Aux. GM32644-B 1. Communication circuit board GM47242 or GM49791-1 Note: Circuit board GM 49791-2 is a gauge driver and is not a communications circuit board. Figure 6-17 16-Light Controller with Installed Comm. Module (controller top view) An RSA annunciator can be used for a single generator set or with a combination of a generator set and automatic transfer switch.
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System Monitoring LEDs and Functions Common System Generator Communication Common Fault Fault Ready LED Running LED Status LED Fault LED Output Horn Fault and Status Condition Overcrank Shutdown Red SF Green Red SF High Engine Temperature Warning * Yellow Red SF Green Green Red SF...
6.1.13 Remote Speed Adjustment 6.1.14 Run Relay Kit Potentiometer Kit (Non-ECM The run relay kit includes three sets of contacts that Models) energize only during generator set operation. The run relay kit can control air intake louvers, radiator louvers, The remote speed adjustment potentiometer kit alarms, and other signaling.
6.1.16 Shunt-Trip Line Circuit Breaker 6.1.17 Single-Relay Dry Contact Kit (DEC 3+) A shunt-trip line circuit breaker provides a 12- or 24-DC volt solenoid within the line circuit breaker case that can The single-relay dry contact kit uses one set of contacts energize the trip mechanism.
6.1.18 Ten-Relay Dry Contact Kit ten-relay dry contact kit. Typically, lamps, audible alarms, or other devices signal the fault conditions. (DEC 3+) Refer to Figure 6-31 for an internal view of the contact The ten-relay dry contact kit provides normally open and kit.
6.1.19 Twenty-Relay Dry Contact Kit (450 kW and Larger Models Only) (DEC 3+) The twenty-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user-provided accessories allowing remote monitoring of the generator set.
6.2 Accessory and Prime Power Terminal Strip Connections (DEC 3+) The 16-light controller circuit board has terminal strips for use in connecting a controller connection kit. Do not connect accessories directly to the controller terminal strip(s). Connect accessories to either a controller LED4 connection kit or dry contact kit.
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Terminal on TB1 (TB1A) or TB3 (TB1B) Purpose Ground. Emergency stop relay (K4). Connect emergency stop across terminals TB1-1 and 1A. * Emergency stop relay (K4) coil; negative side. Connect emergency stop across terminals TB1-1 and 1A. * Ground terminal. Overcrank (OC) signal.
6.3 Communication Module Kit The communication module circuit board location may also be occupied by an interface circuit board with and Gauge Driver Circuit gauge drivers required for some models*. Do not Board confuse the function of these circuit boards. * See the Introduction section and refer to Tech Tools, Engine When a remote serial annunciator (RSA) is connected to Electronic Module (ECM) for the latest applications.
6.3.1 Communication Modules (Circuit Board) Versions GM47242 Circuit Board. This is the communication module for all models except the 450/500REOZVB models and is superceded by GM49791-1. Figure 6-42. GM47242- 1. P9 connector, 10-position 2. SW2 DIP switches (set to open position) 3.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
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Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute μF kilogram microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...
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For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6161 1/12g 7 Jurong Pier Road Singapore 619159 E 2004, 2005, 2006, 2007, 2008, 2012 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...
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