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Kohler 20-2250 kW

Kohler 20-2250 kW
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Industrial Generator Sets
Models:
20--2250 kW
Controllers:
Decision-Makerr 3+, 16-Light
Software (Code) Version 1.10 or higher
Decision-Makerr 1
TP-6161 1/12g
Operation

Table of Contents

Questions and Answers:

Kohler 20-2250 kW Specifications

General IconGeneral
BrandKohler
Model20-2250 kW
CategoryPortable Generator
LanguageEnglish

Summary

Operation and Product Overview

Industrial Generator Sets

Specifies the type of generator sets covered in the manual.

Model and Controller Information

Indicates the range of generator set power outputs and supported controllers.

Product Identification Information

Recording Identification Numbers

Details for recording generator set and controller information for service.

Safety Precautions and Instructions

General Safety Warnings

Covers accidental starting, battery handling, and fuel fire hazards.

Hazardous Environments and Materials

Warnings regarding battery gases, exhaust fumes, fuel vapors, and noise.

Electrical Safety and Grounding

Precautions for hazardous voltage, moving parts, grounding, and backfeed.

Specific Electrical and Mechanical Hazards

Warnings for short circuits, testing live circuits, heavy lifting, and hot parts.

Introduction and Resources

Manual Overview and Related Literature

Introduces the manual's purpose and lists related technical literature.

Accessing Technical Tools

Guidance on using KOHLERnet for technical resources and software updates.

Service Assistance

Global Support Contact Information

Provides contact details for Kohler Power Systems technical support worldwide.

Section 1 Specifications and Features

Decision-Maker 3+, 16-Light Controller Features

Details the features and components of the 16-light controller.

Annunciator Lamps, Fuses, and Meters

Explains auxiliary fault lamp, fuses, and analog meters/gauges.

Controller Switches and Terminals

Details switches, controls, and terminal strips for controller configuration and connection.

DIP Switch Configuration

Explains the function and settings of the controller's DIP switches for various configurations.

Expanded Decision-Maker 1 Controller

Controls and Indicators Overview

Identifies controls and indicators for the Expanded Decision-Maker 1 controller.

Section 2 Operation

Prestart Checks and Generator Exercising

Covers prestart checks and the procedure for weekly generator set exercising.

Prime Power Mode and Emergency Stops

Details prime power mode and emergency stop procedures.

Fault Shutdown Conditions and Resetting

Lists fault conditions causing shutdown and the procedure for resetting the controller.

Expanded Controller Operations

Starting, Stopping, and Fault Handling

Covers starting, stopping, and fault handling for the Expanded Decision-Maker 1 controller.

Section 3 Scheduled Maintenance

Alternator and Engine Service Guidelines

Guidelines for alternator cleaning and engine service.

Maintenance Schedule for Key Systems

Detailed schedule for fuel, lubrication, and cooling system components.

Maintenance Schedule for Electrical and Other Systems

Continuation of the service schedule covering electrical, remote control, and alternator maintenance.

Bearing Service and Fuel System Air Bleeding

Instructions for bearing service and bleeding air from diesel fuel systems.

Fuel Tank Alarms and Gas Fuel Systems

Inner Fuel Tank Alarms and Gas Fuel System Overview

Details on fuel tank alarms and an introduction to gas fuel systems.

Gas Fuel Conversion and Changeover Kits

Natural GasLPG Conversion and Dual Fuel Kits

Information on converting fuels and using dual-fuel system changeover kits.

Cooling System Maintenance

Coolant Checks and Component Inspections

Procedures for checking coolant levels and inspecting cooling system components.

Cooling System Drainage, Flush, and Refill Procedures

Detailed steps for draining, flushing, cleaning, and refilling the cooling system.

Fan Bearings and Battery Maintenance

Radiator Fan Bearing Lubrication and Battery Overview

Lubrication procedure for fan bearings and initial battery maintenance information.

Detailed Battery Safety and Handling

Comprehensive safety warnings and procedures for battery handling, acid cleanup, and connections.

Battery Cleaning and Specific Gravity Checks

Battery Cleaning, Electrolyte Level, and Specific Gravity

Instructions for cleaning batteries, checking electrolyte levels, and specific gravity.

Battery Charging and Diesel Engine Controls

Battery Charging and Detroit Diesel System Introduction

Guidance on battery charging and an introduction to Detroit Diesel engine control systems.

Engine Diagnostics and Control Systems

DDEC Diagnostics and General Engine Controls

Details on accessing DDEC diagnostics and general engine control system features.

Generator Set Storage Procedures

System Preparation for Long-Term Storage

Steps for preparing the generator set, including lubricating system, cooling, fuel, and components, for storage.

Battery Storage Procedures

Instructions for storing batteries properly after generator set storage preparation.

Section 4 Troubleshooting

Troubleshooting Guide Introduction

Overview of the troubleshooting section and how to use the diagnostic chart.

Controller and Cooling System Troubleshooting

Troubleshooting common problems related to the controller and cooling system.

Engine and Fuel System Troubleshooting

Troubleshooting common engine and fuel system problems.

Alternator and Lubrication System Issues

Troubleshooting common alternator and lubrication system problems.

Section 5 Generator Set Reconnection

Voltage Reconnection Procedures and Safety

Steps and safety precautions for changing generator set voltage configurations.

Single-Phase Alternator Wiring Diagrams

Wiring diagrams for single-phase alternators and voltage reconnection options.

Multi-Phase Alternator Wiring Diagrams

Wiring diagrams for various multi-phase alternators and voltage reconnection options.

Pilot-Excited Alternator Wiring Diagrams

Wiring diagrams for pilot-excited and permanent magnet alternators.

Voltage Adjustment Procedures

Instructions for adjusting generator set output voltage after reconnection.

Section 6 Accessories

Overview of Optional Accessories

Introduction to accessories that enhance generator set functionality and convenience.

Alarm and Failure Relay Kits

Details on audiovisual alarms and common failure relay kits for fault notification.

Controller Connection and Prealarm Senders

Kits for easy accessory connection and prealarm senders for critical engine monitoring.

Diagnostic Tools and Protection Devices

Information on diagnostic testers, battery chargers, and line circuit breakers.

Fuel Switches, Prime Power, and Remote Monitoring

Details on low fuel switches, prime power feature, and remote annunciator kits.

Remote Emergency Stop and Serial Annunciator

Kits for remote emergency shutdown and serial annunciator panels.

Remote Serial Annunciator (RSA II) Details

RSA II Illustrations and Controller Module Connection

Illustrations and details on RSA II and its communication module connection.

System Monitoring LEDs and Functions Explained

Table explaining the status and functions of system monitoring LEDs for RSA II.

RSA Wiring Connections Overview

Wiring Diagrams for RSA Unit Connections

Wiring diagram for connecting RSA units to various controllers and networks.

RSA Wiring Connections to 6000 Controllers

Wiring diagrams illustrating RSA connections to 6000 genset controllers.

RSA Wiring Connections to ATS Controllers

Wiring diagrams for ATS controllers and their connections to RSA units.

RSA Wiring for Converters and PCs

Diagrams showing connections for converters, PCs, and modems with RSA units.

RSA Wiring to Annunciators and Networks

Wiring diagrams for remote serial annunciator connections.

Speed Adjustment and Relay Kits

Remote Speed Potentiometer and Run Relay Kits

Kits for remote speed adjustment and run relay functions.

Shunt-Trip Breaker and Dry Contact Kits

Details on shunt-trip circuit breakers and single-relay dry contact kits for fault signaling.

Ten-Relay Dry Contact Kit

Kit with ten relays for activating multiple warning devices and remote monitoring.

Twenty-Relay Dry Contact Kit

Kit with twenty relays for activating multiple warning devices and remote monitoring on larger models.

Accessory and Prime Power Terminal Connections

Connecting Accessories to Terminal Strips

Guide to connecting accessories and prime power options to controller terminal strips.

16-Light Controller Terminal Strip Identification

Diagrams identifying terminal assignments for the 16-light controller.

General Accessory Wiring Diagram

Wiring diagram illustrating general accessory connections.

Specific Accessory Wiring Diagrams

Wiring diagrams for specific accessories like remote annunciators and dry contact kits.

Communication Module and Gauge Driver Boards

Communication Module and Gauge Driver Board Information

Information on communication module boards and gauge driver boards for controller connectivity.

Communication Module Circuit Board Versions

Details on different versions of communication and gauge driver circuit boards.

Appendix A Abbreviations

List of Abbreviations Used

A comprehensive list of abbreviations used throughout the manual.

Continued Abbreviations List

Continuation of the list of abbreviations used in the manual.

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