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Manuals
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Kohler Manuals
Portable Generator
20REOZK
Operation
Kohler 20REOZK Operation
Industrial generator set 10-1000 kw
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Product Identification Information
Table of Contents
Safety Precautions and Instructions
Accidental Starting
Exhaust System
Fuel System
Hot Parts
Introduction
List of Related Materials
Service Assistance
Section 1. Specifications and Features
Introduction
Controller Features
Switches and Controls
Annunciator Lamps
Digital Display
Controller Fault Diagnostics
Digital Display Circuit Board and Connections
Main Logic Circuit Board
Terminal Jumper
Communication Ports
Fuses
Controller Logic Specifications
Status Event and Fault Specifications
Voltage Regulator and Calibration Specifications
Voltage Regulator Adjustments
Section 2. Operation
Prestart Checklist
Exercising Generator Set
Operations in Cold Weather Climates
Controller Operation
Starting
Stopping (User Stopping and Fault Shutdown)
Emergency Stop Switch Resetting
System Status Lamps
System Fault Warning Lamp with Digital Displays
System Fault Shutdown Lamp with Digital Displays
Status and Notice Digital Displays
Controller Resetting (Following System Shutdown or Warning)
Powering up the Engine Control Module (ECM)
Menu Displays
Monitoring and Programming Setup
PC Communications
Modbus® Communications
Reviewing Menu Displays
Error Messages
Overview
Engine Metering
Generator Metering (and Calibration)
Genset Information
Genset Run Time
Genset System
Genset Calibration
Voltage Regulator
Digital Inputs
Digital Outputs
Analog Inputs
Battery Charger 1 and 2
Event Log
Volt Select
Section 3. Scheduled Maintenance
Alternator Service
Engine Service
Service Schedule
Alternator Bearing Service
Kw Models
300-1000 Kw Models with 4M/5M/7M Single-Bearing Alternator
Diesel Fuel Systems
Bleeding Air from Fuel System
Gaseous Fuel Systems
Gaseous Fuel System Concept (Single Fuel)
LPG Liquid Withdrawal Fuel System Concept
Natural Gas and LPG Conversion
Fuel System Changeover Kits (Dual Fuel)
Fuel Conversion Connections
Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
Air Cleaner Restriction Indicator (if Equipped)
Cooling System
Coolant Level Check
Cooling System Component Inspection
Procedure to Drain Cooling System
Procedure to Flush and Clean Cooling System
Procedure to Refill Cooling System
Battery
Clean Battery
Electrolyte Level Inspection
Specific Gravity Check
Charge Battery
Storage Procedure
Lubrication System
Cooling System
Diesel Fuel System Storage
Gaseous Fuel System Storage
Exterior
Alternator
Battery
Section 4. General Troubleshooting
General Troubleshooting Chart
Controller Display and Voltage Regulation Troubleshooting Chart
Section 5. Voltage Reconnection
Introduction
Voltage Reconnection Procedure
Voltage Reconnection Procedure
Section 6. Accessories
Accessories and Connections
Battery Chargers
Battery Charger Kit with Alarm Option
Common Fault/Failure (32A) Relay
Four-Input/Fifteen-Output Module
Gas Fuel Valve Kit
Two-Input/Five-Output Module
Manual Key Switch
Low Fuel (Level/Pressure) Switch
Manual Speed Adjust (Engine RPM Menu)
Prime Power Switch Kit
Remote Emergency Stop Kit
Lockable Emergency Stop Switch
Remote Reset Feature
Remote Serial Annunciator
Run Relay Kit
Shunt-Trip Line Circuit Breaker
Accessory Connections
Appendix A. Abbreviations
Appendix B. Programmer-Defined Settings
Appendix C. Voltage Regulator Definitions and Adjustments
Appendix D. Alternator Protection
Appendix E. Controller Displays from the Engine ECM
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Operation
Industrial Generator Set
Models:
10-1000 kW
Controller:
®
APM402/Decision-Maker
3000
TP 6694 2/25p
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Table of Contents
Troubleshooting
Section 4. General Troubleshooting
117
General Troubleshooting Chart
118
Controller Display and Voltage Regulation Troubleshooting Chart
123
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Summarization of Contents
Operation
Product Identification Information
Identification Number Recording
Details for recording generator set, controller, and engine identification numbers.
Section 1. Specifications and Features
Introduction and Controller Features
Overview of generator sets and detailed features of the controller unit.
Controller Logic Specifications
Details on controller logic, status events, fault specifications, and voltage regulator.
Section 2. Operation
Prestart Checks and Cold Weather Operation
Essential prestart checks and guidelines for operating in cold weather conditions.
Controller Operation
Procedures for starting, stopping, handling faults, and system status indications.
Menu Displays and Navigation
Explanation of controller menu structure, display options, and navigation methods.
Monitoring and Programming Setup
Guidance on using PC communications, Modbus®, and reviewing menu displays for setup.
Safety Precautions and Instructions
General Safety Definitions
Defines safety alert symbols: Danger, Warning, Caution, and Notice.
Specific Hazard Warnings
Covers hazards like accidental starting, battery safety, fuel, noise, and voltage.
Introduction
Manual Overview and Abbreviations
Provides a general introduction to the manual and lists common abbreviations used.
SiteTech™ Software Usage
Explains the role and usage of SiteTech™ software for controller programming.
List of Related Materials
Service Assistance
Section 3. Scheduled Maintenance
Alternator and Engine Service
Routine service procedures for the alternator and engine components.
Fuel System Maintenance
Procedures for maintaining diesel and gaseous fuel systems.
Cooling System Maintenance
Guidelines for checking and maintaining the generator set's cooling system.
Battery Maintenance and Storage
Procedures for battery maintenance, checking specific gravity, and storage.
Storage Procedures
Steps for preparing the generator set for long-term storage.
Section 4. General Troubleshooting
General Troubleshooting Chart
A guide to diagnosing and correcting common generator set problems.
Controller Display and Voltage Regulation Troubleshooting Chart
Specific troubleshooting for controller display issues and voltage regulation problems.
Section 5. Voltage Reconnection
Introduction to Voltage Reconnection
Explains procedures for changing generator set voltage configurations.
Voltage Reconnection Procedure
Step-by-step instructions for reconnecting the generator set to a different voltage.
Section 6. Accessories
Accessory Overview and Connections
Lists available accessories and general connection guidelines.
Battery Charger Accessories
Details on available battery chargers and their connection kits.
Relay and Module Accessories
Information on common fault relays and input/output modules.
Control and Monitoring Accessories
Describes key switches, low fuel switches, speed adjust, and remote control accessories.
Appendix A. Abbreviations
Appendix B. Programmer-Defined Settings
Appendix C. Voltage Regulator Definitions and Adjustments
Underfrequency Unloading Definitions
Explains underfrequency unloading function, setpoint, and slope.
Three-Phase Sensing
Describes how the voltage regulator senses alternator output voltage.
Voltage Adjust and Frequency Setpoint
Details on adjusting output voltage and setting frequency for unloading.
Appendix D. Alternator Protection
Appendix E. Controller Displays from the Engine ECM
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