Kohler 15-60REOZK User Manual

TT-1701 2/17
INSTALLATION INSTRUCTIONS
Original Issue Date: 2/17
Model:
15--60REOZK with D ecision-Makerr 3000 Controllers Only
Market: Industrial
Subject: Electronic Governor Kit GM90661-KP1
Introduction
The electronic governor kit provides isochronous
governing by using the signal over CAN to control the
current input to the actuator. This kit is intended for use
with units having the Decision-Makerr 3000 controller
only.
Note: The electronic governors are shipped
unprogrammed and have no manual
adjustments. After installation, the governor
requires downloading software and changes to
the default settings.
The electronic governor kit includes an:
D Actuator (locate on top of injection pump).
D Electronic governor (locate inside the junction box).
See Figure 1 for specifications.
Specs
Supports CAN/J1939 bus interface
Operating Temperature
-- 4 0 _ to 85_C(--40_ to 185_F)
Power Input
9--30 VDC,
Reverse polarity protected
Output to Actuator Pulse--width--modulated, 6 A max.
Auxiliary Outputs 200 mA max.
Figure 1 Governor Specifications
Read the entire procedure before beginning. Install the
software onto a PC. Carefully follow these instructions
and any additional instructions that appear on the
screen during the download procedure. The
instructions provided here assume you know how to
operate a PC.
Loading incorrect or incomplete files may cause
permanent damage to the governor controller’s logic
circuit board. Verify that the downloaded files contain
the settings for your specific generator set and engine.
Do not attempt to modify the data files.
Required Tools and Equipment
Obtain the APECS Programming Interface Harness Kit
GM100177-KP1. See Figure 2.
Figure 2 Interface Harness
A PC with SiteTechtsoftware is required to make the
electronic governor functional. Use your SecurID to
access Kohler Power Resource Center, click on the
TechTools button, and follow the instructions to
download the files. Refer to TP-6701 SiteTecht
Software Operation Manual for more information.
A PC with Kohler ACT Tool software is also required
to make the electronic governor functional. Use your
SecurID to access Kohler Power Resource Center, click
on the TechTools button, and follow the instructions to
download the files.
Have two 8 mm wrenches available for adjusting the
throttle arm, a TP Torx Plusr driver for removing the
actuator cover, and a flex joint/universal joint for
installing the actuator.
Torx P lusr is a registered trademark of Acumentr Intellectual
Properties, LLC.

Kohler 15-60REOZK Specifications

General

Brand	Kohler
Model	15-60REOZK
Category	Cables and connectors
Language	English

Summary

Required Tools and Equipment

APECS Programming Interface Harness Kit

Obtain the APECS Programming Interface Harness Kit GM100177-KP1.

PC with SiteTech™ Software

Required for electronic governor functionality; access via Kohler Power Resource Center.

PC with Kohler ACT Tool Software

Required for electronic governor functionality; access via Kohler Power Resource Center.

Hand Tools for Actuator Installation

Includes 8 mm wrenches, TP Torx Plus® driver, and flex joint/universal joint.

Safety Precautions

Accidental Starting Warning

Disconnect battery cables, remove negative lead first, reconnect negative last.

Disabling the Generator Set

Press OFF/RESET, disconnect battery charger, remove battery cables (negative first).

Fire Safety and Fuel System Precautions

Avoid flames/sparks near fuel system; catch fuels in approved container.

Installation Procedure - Actuator

Remove Generator Set from Service

Shut down generator, disconnect charger, disconnect battery cables.

Install the Actuator

Clean area, remove old governor, install new actuator carefully to avoid runaway.

Install Actuator Cover Seal and Connect Leads

Install new cover seal, position actuator, align mounting holes, connect leads to actuator screws.

Connect Fuel Return Line

Install new O-ring on return line connector, apply grease, and install fuel return line.

Installation Procedure - Governor Kit and Wiring

Remove Air Cleaner Assembly

Remove air cleaner cover, element, and base for safety during installation.

Install Governor Kit Components

Mount electronic governor in junction box, connect governor harness to terminal strip.

Connect Interface Harness to Junction Box

Connect grey male connector to governor, grey female to existing harness, 7N and P terminals to TB12.

Connect PC for Software Configuration

Connect USB connector on harness to PC, use USB cable to connect PC to generator controller.

Software Configuration and Calibration

Configure Genset Personality Profile

Change ECM Model to Woodward APECS ECM using SiteTech™ software.

Activate Interface Harness Toggle

Turn the toggle switch on the interface harness to ON (1).

Download KACT Calibration

Start Kohler ACT Tool, accept license, select calibration file, and download.

Operation and Restoration

Start Generator Set and Throttle Arm Adjustment

Start generator, access Actuator Throttle Arm screen, adjust screws for target RPM.

Shut Down Generator Set

Turn interface harness toggle to OFF, then press OFF/RESET on controller.

Disconnect and Reconnect Components

Disconnect harness, unplug female connector, plug connector into electronic governor.

Reinstall Air Cleaner Assembly

Replace air cleaner base, element, and cover.

Final Generator Set Checks

Replace junction box cover, disconnect battery for 5 mins, reconnect battery and charger.

Troubleshooting and Testing

Remove Generator Set from Service for Troubleshooting

Follow standard procedure: shut down, disconnect charger, disconnect battery.

Test Actuator Coil Resistance and Isolation

Measure coil resistance (2.05 ±0.25 ohms) and isolation (>3 Megohm).

Manual Actuator Movement Test

Manually move actuator through range; check for binding or sticking.

Actuator Power Supply Test

Apply 12 VDC to actuator with diode; check for smooth full-fuel position operation.