Kohler KG50 User Manual

Models:
10-1000 kW
Controller:
APM402/Decision-Maker
®
3000
Industrial Generator Set
TP 6694 6/22n
Operation

Kohler KG50 Specifications

General

Brand	Kohler
Model	KG50
Category	Portable Generator
Language	English

Summary

Safety Precautions and Instructions

Accidental Starting

Details hazards and procedures related to accidental generator set starting.

Battery

Safety precautions and hazards associated with handling generator set batteries.

Engine Backfire/Flash Fire

Exhaust System

Fuel System

Hazardous Voltage/Moving Parts

Hot Parts

Section 1. Specifications and Features

1.2 Controller Features

Description of the various features of the generator set controller.

1.2.1 Switches and Controls

1.2.2 Annunciator Lamps

1.2.3 Digital Display

1.2.4 Controller Fault Diagnostics

1.2.8 Communication Ports

1.3 Controller Logic Specifications

1.3.1 Status Event and Fault Specifications

Lists status events and faults with their ranges and time delays.

1.3.2 Voltage Regulator and Calibration Specifications

1.3.3 Voltage Regulator Adjustments

Section 2. Operation

2.1 Prestart Checklist

Essential checks to perform before starting the generator set.

2.2 Exercising Generator Set

2.4 Controller Operation

Details the various starting and stopping functions of the controller.

2.4.1 Starting

2.4.2 Stopping (User Stopping and Fault Shutdown)

2.4.3 Emergency Stop Switch Resetting

2.4.4 System Status Lamps

2.4.5 System Fault Warning Lamp with Digital Displays

2.4.6 System Fault Shutdown Lamp with Digital Displays

2.4.7 Status and Notice Digital Displays

2.4.8 Controller Resetting (Following System Shutdown or Warning)

2.4.9 Powering up the Engine Control Module (ECM)

2.5 Menu Displays

2.6 Monitoring and Programming Setup

2.7 Reviewing Menu Displays

2.7.1 Error Messages

Lists and explains various error messages displayed by the controller.

2.7.3 Engine Metering

2.7.4 Generator Metering (and Calibration)

Displays generator output data and provides calibration procedures.

2.7.8 GenSet Calibration

Procedure for calibrating the controller and generator set.

2.7.9 Voltage Regulator

Details voltage regulator adjustment and settings.

Section 3. Scheduled Maintenance

3.2 Engine Service

3.3 Service Schedule

3.5 Diesel Fuel Systems

3.5.1 Bleeding Air from Fuel System

Procedure for bleeding air from the diesel fuel system.

3.6 Gaseous Fuel Systems

3.6.3 Natural Gas and LPG Conversion

3.6.4 Fuel System Changeover Kits (Dual Fuel)

3.6.5 Fuel Conversion Connections

KG80–KG125, KG80R–KG125R Dual Fuel Operation

3.9 Cooling System

3.9.1 Coolant Level Check

3.9.3 Procedure to Drain Cooling System

3.9.4 Procedure to Flush and Clean Cooling System

3.9.5 Procedure to Refill Cooling System

3.10 Battery

3.10.2 Electrolyte Level Inspection

3.10.3 Specific Gravity Check

3.10.4 Charge Battery

3.11 Storage Procedure

3.11.7 Battery

Section 4. General Troubleshooting

4.1 General Troubleshooting Chart

A chart to diagnose and correct common generator set problems.

4.2 Controller Display and Voltage Regulation Troubleshooting Chart

Section 5. Voltage Reconnection

5.2 Voltage Reconnection Procedure

5.3 Voltage Reconnection Procedure

6.1.2 Battery Charger Kit with Alarm Option

6.1.4 Four-Input/Fifteen-Output Module

6.1.6 Two-Input/Five-Output Module

6.1.8 Low Fuel (Level/Pressure) Switch

6.1.11 Remote Emergency Stop Kit

6.1.12 Remote emergency stop kit.

6.1.13 Lockable Emergency Stop Switch

6.1.14 Remote Reset Feature

6.1.15 Remote Serial Annunciator

6.2 Accessory Connections

Appendix B. Programmer-Defined Settings

Appendix C. Voltage Regulator Definitions and Adjustments

Appendix D. Alternator Protection

Appendix E. Controller Displays from the Engine ECM