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Kohler 20-300 kW - User Manual

Kohler 20-300 kW
76 pages
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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

  • K
    Kathleen CoxAug 20, 2025
    What to do if my Kohler Portable Generator battery is weak?
    • K
      Kevin MorganAug 20, 2025
      If your Kohler Portable Generator's battery is weak or dead, you should recharge or replace the battery. Refer to the spec sheet for the recommended battery CCA rating.
  • D
    David HarrellAug 22, 2025
    What to do if my Kohler 20-300 kW has low coolant?
    • S
      Sarah CastilloAug 22, 2025
      If your Kohler Portable Generator indicates a low coolant level, restore the coolant to the normal operating level.
  • L
    Larry PerryAug 25, 2025
    What should I do if the controller fuse blows in my Kohler 20-300 kW?
    • P
      pfloresAug 25, 2025
      If the controller fuse blows in your Kohler Portable Generator, replace the blown controller fuse. If the fuse blows again after replacement, troubleshoot the controller to determine the underlying issue.
  • A
    Anthony MayAug 26, 2025
    How to fix loose battery connections on my Kohler 20-300 kW Portable Generator?
    • B
      buckleyisaacAug 26, 2025
      To address loose, corroded, or incorrect battery connections on your Kohler Portable Generator, verify that the battery connections are correct, clean them, and ensure they are tight.
  • J
    John SheaAug 28, 2025
    What to do if my Kohler 20-300 kW has a fault shutdown?
    • A
      Allen TorresAug 28, 2025
      If your Kohler Portable Generator experiences a fault shutdown, reset the fault switches and then troubleshoot the controller to identify the cause of the shutdown.
  • S
    stevenandersonAug 29, 2025
    How to fix a clogged air opening on my Kohler 20-300 kW?
    • R
      Robert WilliamsonAug 29, 2025
      If the air openings of your Kohler Portable Generator are clogged, clean the air openings to ensure proper ventilation.
  • S
    Stacy JosephAug 31, 2025
    What to do if my Kohler 20-300 kW Portable Generator's starter or starter solenoid is inoperative?
    • H
      hobbsjoshuaSep 1, 2025
      If the starter or starter solenoid in your Kohler Portable Generator is inoperative, replace the starter or the starter solenoid.
  • S
    Sarah ClarkSep 2, 2025
    What should I do if my Kohler 20-300 kW Portable Generator's controller interface to the engine ECM is not working?
    • E
      Elizabeth TaylorSep 2, 2025
      If there are issues with the controller interface to the engine ECM in your Kohler Portable Generator, check the engine ECM and electrical wiring.
  • M
    Mark AguirreSep 4, 2025
    What to do if the controller master switch is inoperative on my Kohler 20-300 kW Portable Generator?
    • O
      Omar MorganSep 4, 2025
      If the controller master switch is inoperative on your Kohler Portable Generator, replace the controller master switch.
  • V
    victoria38Sep 6, 2025
    What to do if my Kohler Portable Generator's engine harness connector(s) are not locked?
    • S
      stephensullivanSep 6, 2025
      If the engine harness connector(s) are not locked tight on your Kohler Portable Generator, disconnect the engine harness connector(s) and then reconnect them to the controller.

Summary

Operation

Product Identification Information

Safety Precautions and Instructions

Accidental Starting

Details precautions to prevent accidental starting of the generator set.

Battery Safety

Covers hazards associated with battery handling, acid, and explosion risks.

Battery Acid Cleanup

Provides instructions for safely cleaning up spilled battery acid.

Battery Gases

Warns about explosion risks from battery gases and proper ventilation.

Battery Short Circuits

Highlights dangers of short circuits and proper disconnection procedures.

Engine Backfire;Flash Fire

Warns about fire hazards related to fuel and sparks.

Combustible Materials

Advises on handling flammable fuels and explosion risks.

Exhaust System

Emphasizes the hazard of carbon monoxide from exhaust.

Fuel System

Warns about explosive fuel vapors and safe handling practices.

Hazardous Noise

Hazardous Voltage;Moving Parts

Hazardous Voltage

Warns about severe injury or death from electrical hazards.

Backfeed to the Utility System

Addresses the danger of backfeed to the utility system.

Grounding Electrical Equipment

Emphasizes the importance of proper grounding for electrical safety.

Installing the Battery Charger

Details safety precautions for installing battery chargers.

Connecting the Battery and Battery Charger

Provides safe connection procedures for batteries and chargers.

Short Circuits

Hazardous Voltage;Current

Warns about severe injury or death from short circuits.

Engine Block Heater

Handling the Capacitor

Hazardous Voltage

Warns about severe injury or death from touching charged capacitors.

Electrical Backfeed to the Utility

Hazardous Backfeed Voltage

Explains the danger of backfeed to utility personnel.

Testing Live Electrical Circuits

Hazardous Voltage or Current

Details precautions for testing live electrical circuits.

Airborne Particles

Severe Injury or Blindness

Warns about risks from airborne particles and protective measures.

Servicing the Generator Set When It Is Operating

Exposed Moving Parts

Warns about severe injury or death from moving parts.

Heavy Equipment

Unbalanced Weight

Warns about injury or damage from improper lifting.

Hot Parts

Hot Coolant and Steam

Warns of severe injury or death from hot coolant and steam.

Hot Engine and Exhaust System

Warns of severe injury or death from hot engine and exhaust components.

Servicing the Alternator

Warns about hot parts in the alternator.

Servicing the Exhaust System

Warns about hot engine and exhaust system components.

Service Assistance

Section 1 Specifications and Features

1.2 Decision-Maker 3+, 16-Light Controller Features

Details the features of the Decision-Maker 3+, 16-Light controller.

1.3 Expanded Decision-Maker 1 Controller

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

1.2.1 Annunciator Panel Lamps

1.2.2 Auxiliary Fault Lamp

1.2.7 DIP Switches

Section 2 Operation

2.1 Prestart Checklist

Lists checks and inspections to perform before or at each startup.

2.3 Decision-Maker 3+, 16-Light Controller Features

Details the features of the Decision-Maker 3+, 16-Light controller.

2.4 Expanded Decision-Maker 1 Controller

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

2.3.1 Normal Operation

2.3.2 Prime Power Mode Operation

2.3.3 Emergency Stopping

2.3.4 Fault Shutdowns

2.3.5 Controller Resetting After a Fault Shutdown

2.4.1 Generator Set Starting

2.4.2 Generator Set Stopping

2.4.3 Fault Shutdowns

2.4.4 Controller Resetting After a Fault Shutdown

Section 3 Scheduled Maintenance

Safety Precautions for Maintenance

Groups general safety warnings relevant to maintenance tasks.

3.3 Service Schedule

Service Schedule, continued

3.5 Diesel Fuel Systems

3.6 Gas Fuel Systems

3.7 Cooling System

Hot Coolant and Steam Warning

Warns of severe injury from hot coolant and steam.

3.10 Battery

Battery Safety Warnings

Groups warnings related to battery acid, explosion, and sulfuric acid.

Battery Gases

Battery Short Circuits

Battery Electrolyte Hazards

Battery Acid Cleanup

3.10.3 Specific Gravity Check

3.11 Detroit Diesel Engine Control Systems

3.11.2 DDEC Engine Diagnostics

Explains how to access and interpret DDEC engine diagnostic codes.

3.12 Engine Control Systems

3.13 Storage Procedure

Section 4 Troubleshooting

Troubleshooting Information

Provides guidance for diagnosing and correcting common generator problems.

Troubleshooting Chart

Controller Issues

Lists common controller-related symptoms, causes, and recommended actions.

Cooling System Issues

Lists common cooling system symptoms, causes, and recommended actions.

Electrical System (DC circuits) Issues

Lists common DC electrical system symptoms, causes, and recommended actions.

Engine and Fuel System Troubleshooting

Engine Issues

Lists common engine-related symptoms, causes, and recommended actions.

Fuel System Issues

Lists common fuel system symptoms, causes, and recommended actions.

Alternator and Lubrication System Troubleshooting

Alternator Issues

Lists common alternator symptoms, causes, and recommended actions.

Section 5 Generator Set Reconnection

Safety Precautions for Reconnection

Groups safety warnings related to generator set reconnection.

Section 6 Accessories

6.1.11 Remote Emergency Stop Kit (DEC 3+)

6.1.12 Remote Serial Annunciator (DEC 3+)

Figure 6-18 System Monitoring LEDs and Functions

6.3 Communication Module Kit and Gauge Driver Circuit Board

Kohler 20-300 kW Specifications

General IconGeneral
BrandKohler
Model20-300 kW
CategoryPortable Generator
LanguageEnglish

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