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Kohler Industrial Generator Set User Manual

Kohler Industrial Generator Set
124 pages
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Industrial Generator Sets
Models:
10-1000 kW
Controller:
APM402/Decision-Makerr 3000
TP-6694 7/18j
Operation

Table of Contents

Questions and Answers:

Kohler Industrial Generator Set Specifications

General IconGeneral
DimensionsVaries by model
WeightVaries by model
Starting MethodElectric
PhaseSingle or Three Phase
Frequency60Hz
Voltage120/240V
Engine TypeDiesel Engine
Cooling SystemLiquid Cooled
WarrantyVaries by model
Noise LevelVaries by model (typically 65-75 dBA at 7 meters)

Summary

Product Identification Information

Generator Set and Component Identification

Record identification numbers from nameplates for service and reference.

Controller and Software Information

Record controller, firmware, and software version details.

Safety Precautions and Instructions

Accidental Starting and Battery Safety

Warnings about accidental startup and battery acid hazards.

Battery Gases, Engine Fire, and Exhaust Safety

Fuel System Safety and Hazardous Conditions

Hazardous Voltage and Moving Parts

Warnings about electrical hazards and moving components.

High Voltage, Backfeed, and Heavy Equipment Safety

High Voltage and Electrical Hazards

Warnings on high voltage testing, charger installation, and electrical connections.

Electrical Backfeed and Testing

Risks of backfeed to utility and testing live circuits.

Heavy Equipment and Hot Parts

Safety regarding lifting, hot components, engine, and exhaust systems.

Section 1 Specifications and Features

Controller Switches, Controls, and Lamps

Details on master control switches, buttons, indicator lamps, and annunciators.

System Fault Warning and Shutdown Lamps

Explains conditions triggering yellow (warning) and red (shutdown) fault lamps.

Digital Display and Overview Menu

Describes the digital display interface and the overview menu structure.

Engine and Generator Metering Menus

Details for monitoring engine parameters and generator output.

Generator Set System and Calibration Menus

User-configurable system settings and calibration procedures.

Voltage Regulator, Digital Inputs, and Outputs Menus

Configuration and review of voltage regulator, digital inputs, and outputs.

1.2.4 Controller Fault Diagnostics

Description of system events, warnings, shutdowns, and their messages.

Factory-Defined Settings List

Voltage Regulator and Adjustment Specifications

Section 2 Operation

Prestart Checklist and Generator Exercising

Essential checks before startup and procedure for generator exercising.

Controller Stopping and Emergency Stop Resetting

Procedures for stopping the generator and resetting the emergency stop.

System Fault Shutdown Lamp with Digital Displays

Details conditions triggering shutdown faults and the red fault lamp.

User-Defined Calibration and Voltage Adjustments

Procedures for calibrating the generator set and adjusting voltage.

2.5 Menu Displays

Menu Summary List

2.6 Monitoring and Programming Setup

2.7 Reviewing Menu Displays

2.7.1 Error Messages

Description of common error messages that may appear on the controller display.

Section 3 Scheduled Maintenance

3.3 Service Schedule

Alternator Bearing Service and Diesel Fuel Systems

Air Cleaner Indicator and Cooling System Maintenance

Cooling System Procedures (Drain, Flush, Refill)

3.10 Battery

Battery Cleaning, Electrolyte Level, and Specific Gravity

Procedures for cleaning, checking electrolyte, and specific gravity.

Section 4 General Troubleshooting

4.1 General Troubleshooting Chart

4.2 Controller Display and Voltage Regulation Troubleshooting Chart

Section 5 Voltage Reconnection

Appendix B Programmer-Defined Settings

Appendix C Voltage Regulator Definitions and Adjustments

Appendix D Alternator Protection

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