Kohler KG80 Maintenance Manual
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Kohler KG80 Maintenance Manual

Kohler KG80 Maintenance Manual

Industrial generator set
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Maintenance
Industrial Generator Set
Models:
KG80, KG80R, KG100, KG125, KG125R,
KG150, KG150R, KG180, KG200
TP-7173 10/20a

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Summary of Contents for Kohler KG80

  • Page 1 Maintenance Industrial Generator Set Models: KG80, KG80R, KG100, KG125, KG125R, KG150, KG150R, KG180, KG200 TP-7173 10/20a...
  • Page 2 WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Product Identification Information Product identification numbers determine service parts.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............................5 Introduction ....................................11 Service Assistance................................... 12 Section 1. Service Schedule ........................... 13 Safety Precautions ..............................13 Generator Set Service ............................14 1.2.1 Alternator Service ............................ 14 1.2.2 Engine Service ............................14 Section 2.
  • Page 4 TP-7173 10/20...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
  • Page 6 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area.
  • Page 7 Engine Backfire/Flash Fire WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
  • Page 8 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels.
  • Page 9 Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hazardous voltage.
  • Page 10 Airborne particles. WARNING Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. Servicing the generator set when it is operating. Exposed moving parts will cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.

  • Page 11: Introduction

    Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

  • Page 12: Service Assistance

    (86) 10 6518 7950  Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7951  Look at the labels and decals on your Kohler product (86) 10 6518 7952 or review the appropriate literature or documents Fax: (86) 10 6518 7955 included with the product.

  • Page 13: Service Schedule

    Section 1. Service Schedule 1.1 Safety Precautions WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery.

  • Page 14: Generator Set Service

    1.2.2 Engine Service Perform engine service at the intervals specified in the engine operation manual. Contact an authorized Kohler distributor/dealer to obtain engine literature. Refer to the engine operation manual (listed in Related Literature) for typical engine maintenance procedures and maintenance intervals such as: ...
  • Page 15 Action System—Component Visually Inspect Check Change Clean Test Interval Daily ⚫ ⚫ Oil level Daily ⚫ ⚫ Coolant level Daily Leakage Daily Any condition of vibration, leakage, noise, temperature, Daily or deterioration Clean and tighten battery terminals Daily Weekly Flexible lines and connections Weekly Air cleaner to room/enclosure Weekly...
  • Page 16 Service Schedule, continued Action System—Component Visually Inspect Check Change Clean Test Interval Yearly Tighten control and power wiring connections Yearly Air ducts, louvers Yearly Fuel piping Yearly Louver motors and controls Yearly Radiator exterior Yearly Water supply to the heat exchanger Yearly Excessive back pressure Yearly...

  • Page 17: Controller Maintenance

    Have an authorized Kohler service representative service the controller. Section 3. ECU Diagnostic Port KG80-KG200 generator sets have a diagnostic port located on the junction box. Use the following for general informational purposes only. Contact an authorized service distributor/dealer for service or diagnostic equipment.
  • Page 18 TP-7173 10/20...

  • Page 19: Alternator Maintenance

    Section 4. Alternator Maintenance This section covers alternator maintenance for several different types of alternators. Refer to the instructions that correspond to the relevant alternator models.  Refer to the generator set specification sheet for alternator models.  Have an authorized distributor/dealer perform service. WARNING Accidental starting.

  • Page 20: Check The Operation

    4.1 Check the Operation  Check the operation at regular intervals (no abnormal noise or vibration).  Check the tightness of all nuts and bolts. Pay particular attention to the electrical connections. 4.2 Check the Ventilation  Ensure that air flow is not reduced by partial blocking of the air inlet and discharge grids by mud, fiber, grease, etc. ...

  • Page 21: Gaseous Fuel Systems

    Section 5. Gaseous Fuel Systems Gaseous fuel systems apply to Kohler-powered generator set models. This section describes natural gas and liquefied petroleum gas (LPG) fuel systems that are not covered in the engine operation manual or engine service manual. WARNING Explosive fuel vapors.

  • Page 22: Gaseous Fuel System Concept (Single Fuel)

    5.1 Gaseous Fuel System Concept (Single Fuel) The gaseous fuel system uses a fuel solenoid valve to control the fuel flow to the direct acting electronic pressure regulator (DEPR). The generator set-mounted DEPR reduces the fuel pressure as fuel passes to the fuel mixer. The fuel mixer controls the ratio of fuel to air under varying load and speed conditions.
  • Page 23 5.1.1.1 Fuel Conversion Connections For KG80–KG125, KG80R–KG125R (Kohler Engines KG6208TSD and KG6208THD), use the following: See Figure 4 and Figure 5. Natural Gas Operation  Disconnect the black fuel connector (J7).  Disconnect 49 and N17.  Connect the white fuel connector (J8).
  • Page 24 Natural Gas LPG Vapor To ECM To ECM controller controller Auto Changeover Natural Gas and LPG Vapor To ECM controller ADV-9052D-D Figure 5 Gaseous Fuel Connections Wiring Diagram, KG80–KG125/KG80R–KG125R TP-7173 10/20...
  • Page 25 For KG150, KG180, and KG200 (Kohler Engine KG10V08T), use the following: To change the fuel type, change the wiring harness connections. The engine ECM has fuel tables and spark advance curves programmed for both natural gas and LPG. Use the following fuel connection tables and wiring diagrams to determine the applicable connections for your generator set model.

  • Page 26: Fuel System Changeover Kits (Dual Fuel)

    Natural Gas LPG Vapor To ECM and To ECM and controller controller ADV-9116 Figure 7 Gaseous Fuel Connections Wiring Diagram, Single Fuel 5.2 Fuel System Changeover Kits (Dual Fuel) A changeover fuel system kit provides automatic changeover from natural gas to LPG vapor. The primary and secondary fuels each have a fuel solenoid valve.

  • Page 27: Dual Fuel Reset Box

    KG80–KG125, KG80R–KG125R Dual Fuel Operation The dual fuel system for the KG80–KG125 and KG80R–KG125R includes an LPG indicator light and a reset switch. This LPG indicator light turns on when the NG fuel valve closes and the LPG fuel valve opens, indicating that the fuel source has switched.
  • Page 28 KG150, KG180, and KG200 (Kohler Engine KG10V08T) Dual Fuel Operation The automatic changeover dual fuel systems that include a dual-fuel reset box allow the system to switch to LPG fuel automatically if the natural gas supply is not available. If the natural gas fuel supply is sufficient, the fuel system will change back to natural gas automatically when the LPG fuel supply runs low or when the generator set stops and restarts.

  • Page 29: Dual Fuel Connections

    5.2.2 Dual Fuel Connections KG150, KG180, and KG200 (Kohler Engine KG10V08T) Dual Fuel Connections See the following dual-fuel connections with the APM603. Be sure to review the wiring diagram for special applications. The dual fuel kits are factory installed. Use the following fuel connection tables and wiring diagrams to determine the applicable connections for your generator set model.

  • Page 30: Fuel System Maintenance

    5.3 Fuel System Maintenance Routine service items include draining water/sediment from piping at petcock or pipe end cap, checking for fuel leakage at pipe connections, checking flexible sections for cracking or chafing, and keeping components clean including fuel regulator vent holes.

  • Page 31: Lubrication System

    Section 6. Lubrication System 6.1 Oil Change Refer to the Engine Operation and Maintenance Manual for oil change intervals and oil specifications. Kohler recommends the use of Kohler Genuine oil and filters. Section 7. Air Cleaner System The air cleaner requires periodic maintenance. See the maintenance schedule. A dusty environment or conditions may require the use of a heavy duty air filter and/or more frequent maintenance.

  • Page 32: Air Cleaner Restrictor Indicator

    7.2 Air Cleaner Restrictor Indicator The air cleaner restriction gauge mounted on the air cleaner(s) helps determine the air cleaner change interval. The air cleaner restriction gauge monitors air flow and continuously displays restriction readings indicated as vacuum (see Figure 13). Increased restriction indicates a clogged air cleaner element. As maximum allowable restriction is reached, the gauge window turns red indicating the air cleaner element needs replacement.

  • Page 33: Cooling System

    Section 8. Cooling System WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery. Disabling the generator set.

  • Page 34: Cooling System Component Inspection

    8.2 Cooling System Component Inspection To prevent generator set shutdown or damage caused by overheating:  Keep the cooling air inlets clean and unobstructed.  Test antifreeze before cold weather periods.  Inspect the radiator’s exterior for obstructions. Remove dirt and foreign material using a soft brush or cloth to avoid damaging the radiator fins.

  • Page 35: Procedure To Refill Cooling System

    Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose clamps. Note: If possible, fill the radiator from the bottom to avoid air pockets. Fill the cooling system with the recommended Kohler coolant mixture. Refer to the engine operation manual for specifications. Replace the pressure cap.
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  • Page 37: Battery System

    Section 9. Battery system WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.

  • Page 38: Clean Battery

    9.1 Clean Battery Clean the battery and cables and tighten the battery terminals according to the service schedule recommendations. Clean the battery by wiping it with a damp cloth. Keep the electrical connections dry and tight. If corrosion exists, disconnect the cables from the battery and remove the corrosion with a wire brush. Clean the battery and cables with a solution of baking soda and water.

  • Page 39: Specific Gravity Check

    9.3 Specific Gravity Check Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps. Holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer.

  • Page 40: Charge Battery

    9.4 Charge Battery Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application. The engine battery-charging alternator charges the battery while the generator set is running. Refer to the battery charger operation manual for installation, operation, and service procedures.

  • Page 41: Storage Procedure

    Prepare the engine lubricating system for storage as follows. Note: Kohler recommends the use of Kohler genuine oil and filters. Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature. Stop the generator set.

  • Page 42: Cooling System

    10.2 Cooling System Prepare the cooling system for storage as follows: Check the coolant freeze protection using a coolant tester. Add or replace coolant as necessary to ensure adequate freezing protection. Use the guidelines included in the engine operation manual. Run the generator set for 30 minutes to redistribute added coolant.

  • Page 43: Battery

    10.5 Battery WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area. Isolate the battery charger from explosive fumes. Perform battery storage after all other storage procedures. Confirm that the generator set is stopped.
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  • Page 45: Appendix A. Abbreviations

    Appendix A. Abbreviations A, amp ampere blk. black (paint color), block (engine) D/A digital to analog ABDC after bottom dead center blk. htr. block heater digital to analog converter alternating current BMEP brake mean effective pressure decibel analog to digital bits per second dB(A) decibel (A weighted)
  • Page 46 (2 bytes) max. maximum gallons per minute KBus Kohler communication protocol megabyte (2 bytes) grade, gross kilogram MCCB molded-case circuit breaker equipment ground kg/cm kilograms per square one thousand circular mils centimeter gr.
  • Page 47 N, norm. normal (power source) permanent magnet generator silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) not available, not applicable potentiometer, potential s, sec. second Systeme international d’unites, nat. gas natural gas parts per million International System of Units National Bureau of Standards PROM programmable read-only...
  • Page 48 ultrahigh frequency user interface Underwriter’s Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) univ. universal uniform resource locator (web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt...

  • Page 49: Appendix B. Common Hardware Application Guidelines

    Appendix B. Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure 18 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.
  • Page 50 Entry hole types Cap screw Standard nut and SAE washer G-585 Exit hole types Weld nuts: above 1/2 in. dia. Whiz nut or spiralock: up to 1/2 Hardware in. dia. Hardware Figure 19 Acceptable Hardware Combinations TP-7173 10/20...

  • Page 51: Appendix C. Torque Specifications

    Appendix C. Torque Specifications American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled Size into Aluminum Grade 2 Grade 5 Grade 8 8-32 (18 in. lb.) (27 in. lb.) 10-24 (28 in. lb.) (43 in. lb.) 10-32 (32 in.
  • Page 52 TP-7173 10/20...

  • Page 53: Appendix D. Operating Hours And Service Log

    Appendix D. Operating Hours and Service Log Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed. Enter hours to the nearest quarter hour. Operating Hours Service Record Total Date Run Hours Run...
  • Page 54 Operating Hours Service Record Date Run Hours Run Total Hours Service Date Service TP-7173 10/20...
  • Page 55 TP-7173 10/20...
  • Page 56 TP-7173 10/20a KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLERPower.com © 2020 Kohler Co. All rights reserved.

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