Format: PDF (Printable Document)
File Language: English
File Pages: 147
File Size: 8.10 MB (Speed Download Link)
Brand: Kohler
Model: 1020-300 kW Industrial Generator Sets
Book No: tp5353
Type of Document: Service Manual
$ 40
These Kohler 1020–300 kW industrial generator sets usually sit in plants, hospitals, data centers, or big commercial buildings, backing up critical loads when the grid drops. This service manual is what I’d keep open when I’m tracking down a no-start, unstable voltage, or a shutdown under load. It walks you through how to confirm whether you’ve got a control issue, a fuel/air problem, or something deeper in the engine or alternator before you start throwing parts at it.
Applications & Use Cases
FAQ
Q: Can I use this manual on a tablet in the field?
A: Yes, it’s practical on a tablet; you can zoom diagrams and search terms instead of flipping through pages.
Q: Is it worth printing sections of this manual?
A: Printing the procedures you use often is handy—keeps greasy hands off your device and lets you mark notes or test values.
Safety Note
Always lock out the generator and verify it cannot start or backfeed before opening panels or disconnecting components.
SUBJECT PAGE SUBJECT PAGE
Safety Precautions and Instructions . . . . . . . I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . i
Section 1. Specifications . . . . . . . . . . . . . . . . . 1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Fast-Response II Concepts . . . . . . . . . . . . . . . 1-1
Short Circuit Performance . . . . . . . . . . . . . . . . . . 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Section 2. Operation . . . . . . . . . . . . . . . . . . . . . 2-1
Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Exercising the Generator Set . . . . . . . . . . . . . . . 2-1
16-Light Controller (Level 1) Operation . . . . . . . 2-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Resetting Emergency Stop Switches . . . . . . . . 2-7
Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Controller Resetting Procedure (Following
Fault Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . 2-9
6-Light Controller (Level 2) Operation . . . . . . . . 2-10
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Resetting Emergency Stop Switches . . . . . . . . 2-14
Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Controller Resetting Procedure (Following
Fault Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Paralleling Engine Gauge Box Controller
Operation (Switchgear) . . . . . . . . . . . . . . . . . . . 2-16
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Manual Controller Operation . . . . . . . . . . . . . . . . 2-18
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Section 3. Scheduled Maintenance . . . . . . . . 3-1
Oil Requirements (30, 80, and100 kW Ford
Powered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Oil Change Procedure (30, 80, and100 kW Ford
Powered) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Turbocharger Service Schedule (30, 80, and
100 kW Ford Powered) . . . . . . . . . . . . . . . . . . . 3-3
Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Section 4. General Troubleshooting . . . . . . . 4-1
General Troubleshooting Chart . . . . . . . . . . . . . . 4-1
Section 5. Controller Troubleshooting . . . . . 5-1
Microprocessor Controller—Description . . . . . . 5-1
Circuit Board Terminal Identification (TB1) . . . 5-3
Fault Shutdowns—Microprocessor
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Paralleling Engine Gauge Box Controller
(Switchgear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Speed Switch Adjustments . . . . . . . . . . . . . . . . . 5-11
Manual Controller . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Engine Safety Shutdown Switches . . . . . . . . . . 5-13
Section 6. Generator/Controller
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Microprocessor Controller . . . . . . . . . . . . . . . . . . 6-1
Relay Descriptions . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting Microprocessor Controller . . . 6-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Will Not Crank . . . . . . . . . . . . . . . . . . . 6-4
Engine Cranks, But Will Not Start . . . . . . . . . 6-5
Controller Instrumentation . . . . . . . . . . . . . . . 6-6
Lamp Circuit Board . . . . . . . . . . . . . . . . . . . . . 6-7
Overcrank Lamp . . . . . . . . . . . . . . . . . . . . . . . 6-8
FASTCHECK Features and Operation . . . . . 6-9
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Manual Controller . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Troubleshooting Manual Controller . . . . . . . . . . 6-15
Section 7. Component Testing and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Generator Troubleshooting . . . . . . . . . . . . . . . . . 7-1
Troubleshooting Generator—No Output
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Troubleshooting Generator—High Output
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Generator Testing . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
No Output On Any Phase . . . . . . . . . . . . . . . . . . 7-4
Overvoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Fluctuating Voltage . . . . . . . . . . . . . . . . . . . . . . . 7-6
LED Circuit Board Test . . . . . . . . . . . . . . . . . . . . . 7-7
SCR Assembly and Photo Transistor Board . . . 7-9
Automatic Voltage Regulator (AVR) Operation
and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
To Test AVR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
SUBJECT PAGE SUBJECT PAGE
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Generator Field . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Exciter Armature . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
End Bracket Removal and Replacement . . . . . . 7-17
Speed Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Air Damper Switch Adjustment . . . . . . . . . . . . . . 7-19
Overspeed/Time Delay Circuit Board . . . . . . . . . 7-20
Overvoltage Circuit Board . . . . . . . . . . . . . . . . . . 7-21
Governor Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-22
Mechanical Governor—Hoof
20-100 kW Ford-Powered Models . . . . . . . . . 7-22
Mechanical Governor—Stanadyne
20-100 kW John Deere-Powered and
20-100 kW Detroit Diesel-Powered
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Mechanical Governor—Nippondenso
125-180 kW John Deere-Powered
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Mechanical Governor—Bosch P
125-180 kW Detroit Diesel-Powered
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Electronic Governor—Barber-Colman
Dyna 2500
20-100 kW Ford-Powered Models . . . . . . . . . 7-26
Electronic Governor—Barber-Colman
Dyna 8000
125-300 kW Detroit Diesel-Powered Models
(Early 20-100 kW John Deere-Powered and
Early 20-100 kW Detroit Diesel-Powered
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Electronic Governor—Barber-Colman
Dyna 2500
125-180 kW John Deere-Powered Models . . 7-29
Electronic Governor—Barber-Colman
Dyna 70025 using Stanadyne D Series
Injection Pump
20-100 kW John Deere-Powered and
20-100 kW Detroit Diesel-Powered Models . 7-31
Section 8. Generator Disassembly/
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Section 9. Generator Reconnection . . . . . . . 9-1
Voltage Reconnection Procedure . . . . . . . . . . . . 9-1
Generator Frequency Change and Adjustment 9-4
Frequency Change . . . . . . . . . . . . . . . . . . . . . . . 9-4
Frequency Adjustment . . . . . . . . . . . . . . . . . . . . 9-4
Appendix A. Glossary of Abbreviations . . . A-1
Appendix B. Common Hardware
Application Guidelines . . . . . . . . . . . . . . . . . . B-1
Appendix C. Common Hardware
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D. General Torque
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
