Kohler KG100

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TP-6694 6/22 129

Figure 59 300 kW and Larger Pilot-Excited, Permanent Magnet 4M/5M/7M/10M Alternators, ADV-5875AB-4

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Table of Contents3
Safety Precautions and Instructions7
Introduction13
Service Assistance15
Specifications and Features17
Introduction17
Controller Features17
Switches and Controls18
Annunciator Lamps19
Digital Display21
Controller Fault Diagnostics28
Digital Display Circuit Board and Connections30
Main Logic Circuit Board31
Terminal Jumper32
Communication Ports33
Fuses33
Controller Logic Specifications34
Status Event and Fault Specifications35
Voltage Regulator and Calibration Specifications41
Voltage Regulator Adjustments41
Operation43
Prestart Checklist43
Exercising Generator Set44
Operations in Cold Weather Climates44
Controller Operation44
Starting45
Stopping (User Stopping and Fault Shutdown)46
Emergency Stop Switch Resetting46
System Status Lamps46
System Fault Warning Lamp with Digital Displays46
System Fault Shutdown Lamp with Digital Displays48
Status and Notice Digital Displays52
Controller Resetting (Following System Shutdown or Warning)54
Powering up the Engine Control Module (ECM)55
Menu Displays57
Monitoring and Programming Setup59
PC Communications59
Modbus® Communications60
Reviewing Menu Displays60
Error Messages62
Overview63
Engine Metering64
Generator Metering (and Calibration)64
Genset Information67
Genset Run Time67
Genset System67
Genset Calibration68
Voltage Regulator70
Digital Inputs71
Digital Outputs72
Analog Inputs75
Battery Charger 1 and 276
Event Log77
Volt Select77
Scheduled Maintenance79
Alternator Service79
Engine Service79
Service Schedule80
Alternator Bearing Service82
Kw Models82
300-1000 Kw Models with 4M/5M/7M Single-Bearing Alternator82
Diesel Fuel Systems82
Bleeding Air from Fuel System82
Gaseous Fuel Systems83
Gaseous Fuel System Concept (Single Fuel)84
LPG Liquid Withdrawal Fuel System Concept84
Natural Gas and LPG Conversion84
Fuel System Changeover Kits (Dual Fuel)85
Fuel Conversion Connections86
Crankcase Ventilation (CCV) Heater Kit GM78171-KP1103
Air Cleaner Restriction Indicator (if Equipped)103
Cooling System104
Coolant Level Check104
Cooling System Component Inspection104
Procedure to Drain Cooling System105
Procedure to Flush and Clean Cooling System105
Procedure to Refill Cooling System105
Battery106
Clean the Battery108
Electrolyte Level Inspection108
Specific Gravity Check109
Charge Battery110
Storage Procedure110
Lubrication System111
Cooling System111
Diesel Fuel System Storage111
Gaseous Fuel System Storage111
Exterior112
Alternator112
Battery113
General Troubleshooting115
General Troubleshooting Chart116
Controller Display and Voltage Regulation Troubleshooting Chart121
Voltage Reconnection123
Introduction123
Voltage Reconnection Procedure124
Voltage Reconnection Procedure125
Accessories131
Accessories and Connections131
Battery Chargers132
Battery Charger Kit with Alarm Option132
Common Fault/Failure (32A) Relay134
Four-Input/Fifteen-Output Module135
Gas Fuel Valve Kit139
Two-Input/Five-Output Module140
Manual Key Switch141
Low Fuel (Level/Pressure) Switch142
Manual Speed Adjust (Engine RPM Menu)143
Prime Power Switch Kit143
Remote Emergency Stop Kit144
Remote Emergency Stop Kit145
Lockable Emergency Stop Switch145
Remote Reset Feature146
Remote Serial Annunciator147
Run Relay Kit149
Shunt-Trip Line Circuit Breaker150
Accessory Connections151
Appendix A. Abbreviations157
Appendix B. Programmer-Defined Settings161
Appendix C. Voltage Regulator Definitions and Adjustments167
Appendix D. Alternator Protection171
Appendix E. Controller Displays from the Engine ECM173

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