Kohler KG180 - User Manual

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Models:

10-1000 kW

Controller:

APM402/Decision-Maker

3000

Industrial Generator Set

TP 6694 2/25p

Operation

Main Page

Product Identification Information2
Table of Contents3
Safety Precautions and Instructions7
Accidental Starting7
Exhaust System9
Fuel System10
Hot Parts12
Introduction15
List of Related Materials16
Service Assistance17
Section 1. Specifications and Features19
Introduction19
Controller Features19
Switches and Controls20
Annunciator Lamps21
Digital Display23
Controller Fault Diagnostics29
Digital Display Circuit Board and Connections31
Main Logic Circuit Board32
Terminal Jumper33
Communication Ports34
Fuses34
Controller Logic Specifications35
Status Event and Fault Specifications36
Voltage Regulator and Calibration Specifications42
Voltage Regulator Adjustments42
Section 2. Operation43
Prestart Checklist43
Exercising Generator Set44
Operations in Cold Weather Climates44
Controller Operation45
Starting45
Stopping (User Stopping and Fault Shutdown)46
Emergency Stop Switch Resetting46
System Status Lamps47
System Fault Warning Lamp with Digital Displays47
System Fault Shutdown Lamp with Digital Displays49
Status and Notice Digital Displays52
Controller Resetting (Following System Shutdown or Warning)54
Powering up the Engine Control Module (ECM)54
Menu Displays57
Monitoring and Programming Setup59
PC Communications59
Modbus® Communications60
Reviewing Menu Displays60
Error Messages62
Overview63
Engine Metering64
Generator Metering (and Calibration)65
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
Section 3. 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-KP1105
Air Cleaner Restriction Indicator (if Equipped)105
Cooling System106
Coolant Level Check106
Cooling System Component Inspection106
Procedure to Drain Cooling System107
Procedure to Flush and Clean Cooling System107
Procedure to Refill Cooling System107
Battery108
Clean Battery110
Electrolyte Level Inspection110
Specific Gravity Check111
Charge Battery112
Storage Procedure112
Lubrication System113
Cooling System113
Diesel Fuel System Storage113
Gaseous Fuel System Storage113
Exterior114
Alternator114
Battery115
Section 4. General Troubleshooting117
General Troubleshooting Chart118
Controller Display and Voltage Regulation Troubleshooting Chart123
Section 5. Voltage Reconnection125
Introduction125
Voltage Reconnection Procedure126
Voltage Reconnection Procedure127
Section 6. Accessories133
Accessories and Connections133
Battery Chargers134
Battery Charger Kit with Alarm Option134
Common Fault/Failure (32A) Relay135
Four-Input/Fifteen-Output Module136
Gas Fuel Valve Kit140
Two-Input/Five-Output Module140
Manual Key Switch141
Low Fuel (Level/Pressure) Switch142
Manual Speed Adjust (Engine RPM Menu)142
Prime Power Switch Kit143
Remote Emergency Stop Kit144
Lockable Emergency Stop Switch144
Remote Reset Feature145
Remote Serial Annunciator146
Run Relay Kit148
Shunt-Trip Line Circuit Breaker149
Accessory Connections150
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

Brand	Kohler
Model	KG180
Category	Portable Generator
Language	English

Kohler KG180 - User Manual

Table of Contents

Kohler KG180 Specifications

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