Related Manuals for Kohler 15REYG
Summary of Contents for Kohler 15REYG
- Page 1 Operation Commercial Generator Sets Models: 15REYG 30REYG Controller: Advanced Digital Control (ADC 2100) TP-6728 10/11b...
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Page 2: Product Identification Information
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. -
Page 3: Table Of Contents
Table of Contents Product Identification Information ............Safety Precautions and Instructions . - Page 4 Notes Table of Contents TP-6728 10/11...
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Page 5: Safety Precautions And Instructions
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. - Page 6 Battery gases. Explosion can cause Servicing the fuel system. A flash Generator set operation. Carbon severe injury or death. Battery gases fire can cause severe injury or death. monoxide can cause severe nausea, can cause an explosion. Do not smoke Do not smoke or permit flames or fainting, or death.
- Page 7 Fuel System Gas fuel leaks. Explosive fuel WARNING vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas or WARNING natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to Moving parts.
- Page 8 Disconnecting the electrical load. Short circuits. Hazardous Heavy Equipment Hazardous voltage cause voltage/current can cause severe severe injury or death. Disconnect injury or death. Short circuits can WARNING the generator set from the load by cause bodily injury and/or equipment turning off the line circuit breaker or by damage.
- Page 9 Notice NOTICE This generator set has been rewired from its nameplate voltage 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from authorized service...
- Page 10 Notes 10 Safety Precautions and Instructions TP-6728 10/11...
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Page 11: Introduction
TP-6724 Information in this publication represents data available Service Manual (Generator Set) TP-6198 at the time of print. Kohler Co. reserves the right to * One Parts Catalog combines generator and engine change this publication and the products represented information. -
Page 12: Service Assistance
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. -
Page 13: Section 1 Service Views
Section 1 Service Views Oil Makeup Kit for 30 kW Generator Sets (optional) ADV-7962 Units with Customer Connection Box 1. Air cleaner 18. Spark plugs 2. ECM and EPR (electronic fuel pressure regulator) 19. Oil fill (on valve cover) 3. Pressure cap (engine coolant fill) 20. - Page 14 Notes Section 1 Service Views TP-6728 10/11...
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Page 15: Section 2 Operation
Drive Belt(s). Check the belt condition of the water Note: Have setup and adjustments of the ADC 2100 pump and battery charging alternator belt(s). performed only by an authorized Kohler Exhaust System. Check for exhaust leaks and distributor/dealer. The setup and adjustments blockages. -
Page 16: Controls And Indicators
The LED display indicates generator set status as shown in Figure 2-2. The display is active when generator set is reconnected to a different voltage and/or frequency, refer to an authorized Kohler the master switch is in the RUN or AUTO position and distributor/dealer... -
Page 17: Fault Warnings And Shutdowns
2.3.4 Fault Warnings and Shutdowns Shutdown switches on the generator set automatically reset when the problem is corrected. For example, the high engine temperature switch automatically resets Warnings. The controller displays a fault code but the when the generator set cools. However, the fault does generator set does not shut down under the high battery voltage (HB) and low battery voltage (LB) warning not clear until the controller is reset. - Page 18 Code Fault Description Check Auxiliary fault Input from a customer-supplied switch that Check the cause of the auxiliary fault. input shutdown closes when the fault is active. The generator set shuts down 0.3 seconds after the fault is detected and will not start when the fault is active (input is grounded).
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Page 19: Resetting Controller After A Fault Shutdown
2.3.5 Resetting Controller after a Fault 2.3.6 Controller Power Down Shutdown The ADC 2100 is powered by the generator set engine starting battery. Always identify and correct the cause of a fault shutdown before resetting the controller. Use the When the generator set master switch is in the AUTO following procedure to reset the generator set controller position, the controller may power down after a period of after a fault shutdown. - Page 20 Notes Section 2 Operation TP-6728 10/11...
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Page 21: Section 3 Scheduled Maintenance
Can cause severe injury or death. Maintenance and Service Parts. Obtain maintenance service parts from authorized Kohler Do not work on the generator set until distributor/dealer. it cools. 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. -
Page 22: Service Schedule
3.2 Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set. Reference Before 100 Hr. 300 Hr. 400 Hr. Section Starting (3 Mo.) (6 Mo.) (Yearly) Perform Service at Intervals Indicated (X) Weekly Fuel System Check the fuel level and fill as necessary (LP) -
Page 23: Lubrication System
3.3 Lubrication System 3.3.4 Oil Additions Adding some oil between oil changes is normal. The 3.3.1 Oil Specifications amount varies with generator set usage. Open the oil fill cap and pour in a small amount of oil using a funnel or Use oil that displays the American Petroleum Institute other suitable pouring device. -
Page 24: Air Cleaner
Note: Dispose of all waste materials (engine 3.4 Air Cleaner oil, fuel, filter, etc.) in an environmentally safe manner. At the interval specified in the service schedule, inspect, clean, or replace the air cleaner element. Clean the 3. Fill with oil. See Figure 3-1 for oil selection and element more frequently in dirty, dusty conditions. -
Page 25: Exhaust System
3.5 Exhaust System 3.6 Cooling System WARNING WARNING Hot coolant and steam. Carbon monoxide. Can cause severe injury or death. cause severe nausea, fainting, or death. Before removing the pressure cap, stop the generator set and allow it to exhaust system must cool. -
Page 26: Draining Cooling System
3.6.2 Draining Cooling System 5. Add coolant to the radiator to just below the overflow tube on the filler neck. See Section 1, The radiator contains a coolant drain valve to drain the Service Views, for the overflow tube location. cooling system. -
Page 27: Ignition System
3.7 Ignition System 6. Check the spark plug gap before installing any spark plug. See Figure 3-7 and Figure 3-8. Attain Service the spark plugs at the interval specified in the a correct gap when the feeler (or wire) passes service schedule using the following procedure. -
Page 28: Battery
7. Use a gapping tool to gently bend side electrode 3.8 Battery closer to or farther from the center electrode to set the correct gap. See Figure 3-10. Position the side Consult battery manufacturer’s instructions electrode directly over the center electrode. regarding battery care and maintenance. -
Page 29: Belt Check
Battery short circuits. Explosion can cause severe injury 4. Tighten the pivot screw. or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator 5. Recheck and adjust as necessary. set installation or maintenance. Remove all jewelry before servicing the equipment. - Page 30 Notes Section 3 Scheduled Maintenance TP-6728 10/11...
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Page 31: Section 4 Troubleshooting
Section 4 Troubleshooting 4.1 Introduction dark, check the battery and battery connections and then check the controller fuse. Use the following charts to diagnose and correct Engine Fuses. Four engine fuses are located in the common problems. First check for simple causes such engine fuse box. -
Page 32: Generator Set Troubleshooting
7. Repeat steps 4 through 6 to step through the last 20 4.4 Generator Set Troubleshooting faults. Press the Select button to return to the most recent fault, if desired. Figure 4-2 contains generator set troubleshooting, diagnostic, and repair information. Check for loose 8. -
Page 33: Controller Troubleshooting
4.5 Controller Troubleshooting Figure 4-3 contains troubleshooting, diagnostic, and repair information for the Advanced Digital Control. Problem Possible Cause Corrective Action Controller LED Controller may power down if the generator set Controller display will automatically activate when a display is off has not run in the last hour of 48 hours, remote start command is received or the generator depending on the controller’s Cn parameter... - Page 34 Notes Section 4 Troubleshooting TP-6728 10/11...
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Page 35: Appendix A Abbreviations
(2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6728 10/11 Appendix 35... - Page 36 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
- Page 37 Notes TP-6728 10/11...
- Page 38 Notes TP-6728 10/11...
- Page 40 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-6728 10/11b 7 Jurong Pier Road Singapore 619159 E 2009, 2010, 2011 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455...