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Kohler TP-5353 - User Manual

Kohler TP-5353
147 pages
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Industrial Generator Sets
Models:
20-300 kW
TP-5353 8/94c
Service

Table of Contents

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Summary

Safety Precautions and Instructions

Accidental Starting Safety

Warnings and procedures for preventing accidental generator startup.

Battery Safety Precautions

Safety precautions related to battery acid hazards.

Explosion Hazards

Hazards associated with battery gases and sparks, and precautions.

Engine Backfire and Flash Fire Safety

Warnings and precautions regarding fuel and backfire hazards.

Exhaust System Safety

Hazards and precautions related to carbon monoxide from exhaust.

Fuel System Safety

Hazards and precautions related to explosive fuel vapors.

Hazardous Noise Safety

Hazards of noise and precautions to prevent hearing loss.

Hazardous Voltage and Electrical Shock

Warnings about electrical hazards and precautions.

Heavy Equipment Lifting Safety

Warnings about lifting hazards and proper procedures.

Hot Parts Safety

Hazards of hot engine and exhaust components.

Moving Parts Safety

Hazards of moving rotors and rotating parts.

Introduction

Manual Overview

Overview of the manual's content and purpose.

Service Assistance

Obtaining Support

Information on obtaining sales and service support.

Section 1. Specifications

Specifications Introduction

Purpose of the specifications section and references.

Fast-Response II Concepts

Explanation of the generator excitation system design.

Generator Specifications

Component Specifications

Component specifications for the generator.

Generator Adapter and Drive Disc Torque

Generator Adapter to Flywheel Housing Bolt Torque

Torque specifications for generator adapter mounting.

Drive Discs to Flywheel Torque

Torque specifications for drive disc mounting.

Turbocharger Specifications

Specifications for turbocharger axial and radial play.

Engine Prealarm and Shutdown Switch Specifications

Switch Specifications

Specifications for various engine safety switches.

Controller Gauge Sender Specifications

Sender Specifications

Specifications for oil pressure and water temperature senders.

Section 1. Accessories

Remote Annunciator Kit

Description and function of the remote annunciator kit.

Audio;Visual (A;V) Alarm

Description of the audio/visual alarm system.

Ten-Relay Dry Contact Kit

Description of the ten-relay dry contact kit.

Single-Relay Dry Contact Kit

Description of the single-relay dry contact kit.

Common Fault Relay Kit

Description of the common fault relay kit.

Safeguard Breaker

Function and purpose of the safeguard breaker.

Line Circuit Breaker

Function and purpose of the line circuit breaker.

Overvoltage Kit

Function of the overvoltage protection kit.

Run Relay Kit

Function of the run relay kit.

Remote Emergency Stop Kit

Function of the remote emergency stop kit.

Controller Connection Kit

How to connect accessories using the kit.

FASTCHECK Diagnostic Tester

Purpose and function of the FASTCHECK diagnostic tester.

Accessory Connection

How to connect accessories to the controller terminal strip.

Section 2. Operation

Prestart Checklist

Essential checks before starting the generator set.

Exercising the Generator Set

Procedure for running the generator periodically.

16-Light Controller (Level 1) Operation

Features

Details of the indicator lamps and their functions.

Starting Procedures

Procedures for starting the generator set.

Stopping Procedures

Procedures for stopping the generator set.

Resetting Emergency Stop Switches

Procedure to reset emergency stop switches after shutdown.

Fault Shutdowns

Conditions that cause automatic generator set shutdown.

Controller Resetting Procedure

Steps to restart the generator after a fault shutdown.

6-Light Controller (Level 2) Operation

Features

Details of indicator lamps (1-5) and their functions.

Section 4. General Troubleshooting

General Troubleshooting Chart Sheet 1 of 2

Problems, causes, corrective actions, and references for troubleshooting.

General Troubleshooting Chart Sheet 2 of 2

Continues troubleshooting chart with more problems and solutions.

Section 5. Controller Troubleshooting

Microprocessor Controller Description

Description of microprocessor controller components and connections.

Circuit Board Terminal Identification (TB1)

Identification of terminals on the TB1 circuit board.

Fault Shutdowns - Microprocessor Controller

Troubleshooting chart for microprocessor controller fault conditions.

Paralleling Engine Gauge Box Controller Operation

Operation and adjustments for the paralleling gauge box controller.

Speed Switch Adjustments

Adjustments for speed switch crank and overspeed settings.

Manual Controller Operation

Operation sequence for the manual controller.

Engine Safety Shutdown Switches

Function of engine safety shutdown switches.

Section 6. Generator;Controller Troubleshooting

Microprocessor Controller Relay Descriptions

Description of controller and generator relays.

Troubleshooting Microprocessor Controller

Quick reference charts for troubleshooting controller issues.

Checking P1 and P2 Connections

Procedure for checking P1 and P2 connector connections.

Controller Fuses

Possible causes for blown controller fuses.

Engine Will Not Crank Troubleshooting

Troubleshooting flowchart for engine not cranking.

Engine Cranks, But Will Not Start Troubleshooting

Troubleshooting flowchart for engine cranking but not starting.

Controller Instrumentation Troubleshooting

Troubleshooting steps for controller instrumentation issues.

Lamp Circuit Board Troubleshooting

Troubleshooting steps for the lamp circuit board.

Overcrank Lamp Troubleshooting

Troubleshooting flowchart for the overcrank lamp flashing.

FASTCHECK Features and Operation

Features and operational guide for the FASTCHECK simulator.

FASTCHECK Tester Operation

How to operate the FASTCHECK tester.

Overcrank Testing

Testing the controller's overcrank and speed sensor capabilities.

Controller Speed Sensor Circuitry Check

Procedure to check the controller's response to speed sensor signals.

Generator Condition Indicator Terminals (TB1)

Identification of generator condition indicator terminals.

Generator Condition Indicator Terminals (Continued)

Continuation of generator condition indicator terminal identification.

Manual Controller Safety Precautions

Safety precautions for manual controller operation.

Manual Controller Troubleshooting

Troubleshooting flowchart for manual controller issues.

Manual Controller Troubleshooting (Continued)

Continues the troubleshooting flowchart for manual controllers.

Manual Controller Troubleshooting (Continued)

Continues the troubleshooting flowchart for manual controllers.

Manual Controller Troubleshooting (Continued)

Continues the troubleshooting flowchart for manual controllers.

Section 7. Component Testing and Adjustment

Generator Troubleshooting Flowchart

Flowchart for troubleshooting generator output voltage issues.

Troubleshooting Generator - No Output Voltage

Troubleshooting steps for generator with no output voltage.

Troubleshooting Generator - High Output Voltage

Troubleshooting steps for generator with high output voltage.

Generator Testing Overview

General procedures for testing generator output conditions.

No Output On Any Phase Troubleshooting

Steps to troubleshoot generator with no output on any phase.

Components to Test for Output Conditions

Table of components to test for different generator output conditions.

Overvoltage Troubleshooting

Troubleshooting steps for overvoltage conditions.

Fluctuating Voltage Troubleshooting

Troubleshooting steps for fluctuating voltage conditions.

LED Circuit Board Test

Procedure for testing the LED circuit board.

SCR Assembly and Photo Transistor Board Test

Testing procedures for SCR assembly and photo transistor board.

Automatic Voltage Regulator (AVR) Operation and Adjustment

Operation and adjustment procedures for the AVR.

Automatic Voltage Regulator (AVR) Test

Step-by-step guide to test the Automatic Voltage Regulator.

Stator Testing

Procedures for checking stator windings and connections.

Generator Field Testing

Procedures for testing generator field continuity and voltage.

Exciter Armature Testing

Procedures for testing exciter armature continuity and voltage.

End Bracket Removal and Replacement

Procedure for removing and replacing the generator end bracket.

Speed Sensor Test

Procedure to determine if the speed sensor is emitting a signal.

Air Damper Switch Adjustment

Procedure for adjusting the air damper switch.

Overspeed;Time Delay Circuit Board Testing

Testing the overspeed and time delay circuit board functions.

Overvoltage Circuit Board Testing

Testing the overvoltage protection circuit board.

Governor Adjustment - Mechanical Governors

Governor adjustments for various mechanical governor types.

Governor Adjustment - Electronic Governors

Governor adjustments for electronic governor systems.

Governor Calibration

Procedures for calibrating mechanical and electronic governors.

Governor Calibration for Paralleling Generator Sets

Calibration procedure for paralleling generator sets.

Droop Adjustment

Procedure for adjusting droop settings.

Section 8. Generator Disassembly;Reassembly

Disassembly Preparation

Steps to perform before disassembling the generator set.

Generator Components Identification

Illustration and list of typical generator components.

Generator Components Identification (Typical)

Illustration and list of typical generator components.

Generator Disassembly Steps

Steps for disassembling the generator set.

Generator Reassembly Steps

Procedures for reassembling the generator set.

Section 9. Generator Reconnection

Voltage Reconnection Procedure

Procedure for reconnecting generator stator leads for different voltages.

Generator Reconnection Diagrams

Diagrams illustrating different generator winding reconnections.

Generator Frequency Change and Adjustment

Procedure to change frequency and adjust generator speed.

Appendix A. Glossary of Abbreviations

Abbreviations Glossary

List of abbreviations used in the manual.

Appendix B. Common Hardware Application Guidelines

Hardware Application Guidelines

Guidelines for applying common hardware types.

Appendix C. Common Hardware Identification

Screws;Bolts;Studs Identification

Guide for identifying common screw, bolt, and stud types.

Nuts;Washers Identification

Guide for identifying common nut and washer types.

Appendix D. General Torque Specifications

Torque Specifications

General torque specifications for fasteners.

Kohler TP-5353 Specifications

General IconGeneral
BrandKohler
ModelTP-5353
CategoryIndustrial Equipment
LanguageEnglish