Kohler 20-2250 kW

Table of Contents
TP-6161 1/12 Table of Contents 3
Product Identification Information 2............................................................
Safety Precautions and Instructions 5........................................................
Introduction 9...............................................................................
Service Assistance 10........................................................................
Section 1 Specifications and Features 11......................................................
1.1 Introduction 11..........................................................
1.2 Decision-Makerr 3+, 16-Light Controller Features 11.........................
1.2.1 Annunciator Panel Lamps 12......................................
1.2.2 Auxiliary Fault Lamp 13...........................................
1.2.3 Fuses 13.......................................................
1.2.4 Analog Meters and Gauges 13.....................................
1.2.5 Switches and Controls 14.........................................
1.2.6 Terminal Strips 14................................................
1.2.7 DIP Switches 15.................................................
1.3 Expanded Decision-Makerr 1 Controller 16..................................
Section 2 Operation 17.......................................................................
2.1 Prestart Checklist 17.....................................................
2.2 Generator Set Exercising 17...............................................
2.3 Decision-Makerr 3+, 16-Light Controller Features 17.........................
2.3.1 Normal Operation 17.............................................
2.3.2 Prime Power Mode Operation 18..................................
2.3.3 Emergency Stopping 18..........................................
2.3.4 Fault Shutdowns 19..............................................
2.3.5 Controller Resetting After a Fault Shutdown 19.......................
2.4 Expanded Decision-Makerr 1 Controller 20..................................
2.4.1 Generator Set Starting 20.........................................
2.4.2 Generator Set Stopping 20........................................
2.4.3 Fault Shutdowns 20..............................................
2.4.4 Controller Resetting After a Fault Shutdown 20.......................
Section 3 Scheduled Maintenance 21..........................................................
3.1 Alternator Service 21.....................................................
3.2 Engine Service 21.......................................................
3.3 Service Schedule 22.....................................................
3.4 Alternator Bearing Service 24..............................................
3.4.1 20--300 kW Models 24............................................
3.4.2 350--2250 kW Models with Single- Bearing Alternator 24..............
3.4.3 1250--2250 kW Model with Two- Bearing Alternator 24................
3.5 Diesel Fuel Systems 24...................................................
3.5.1 Bleeding Air from Fuel System 24..................................
3.5.2 Subbase Inner Fuel Tank Alarm 25.................................
3.6 Gas Fuel Systems 25.....................................................
3.6.1 Gas Fuel System Concept (Single Fuel) 25..........................
3.6.2 LPG Liquid Withdrawal Fuel System Concept 25.....................
3.6.3 Natural Gas and LPG Conversion 26...............................
3.6.4 Fuel System Changeover Kits (Dual Fuel) 26........................
3.6.5 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
(125/150REZG models) 28........................................
3.7 Cooling System 28.......................................................
3.7.1 Coolant Level Check 28...........................................
3.7.2 Cooling System Component Inspection 28...........................
3.7.3 Cooling System Drainage Procedure 29.............................
3.7.4 Cooling System Flush and Clean Procedure 29......................
3.7.5 Cooling System Refilling Procedure 29..............................