Format: PDF (Printable Document)
File Language: English
File Pages: 139
File Size: 24.94 MB (Speed Download Link)
Brand: Kohler
Model: Fast Response2, Dec-3 Microcomputer & Overspeed Relay Controllers
Book No: tp5262
Type of Document: Service Manual
$ 40
When these Kohler generator controls are running a hospital, data center, or plant, they have to pick up load instantly and stay online. This manual is what I keep nearby when the Fast Response2, DEC-3 microcomputer, or overspeed relay starts acting up. It walks you through how to trace control faults logically—so instead of just throwing parts at a no-start or nuisance overspeed trip, you can confirm exactly which board, sensor, or wiring run is at fault before you replace anything.
Applications & Use Cases
FAQ
Q: Can I use this manual on a tablet at the generator site?
A: Yes, it’s practical on a tablet; you can zoom diagrams and keep it open while probing terminals and checking readings.
Q: Is it worth printing parts of this manual?
A: Many techs print the key diagnostic and wiring pages so they can mark notes, trace circuits, and keep them in a job folder.
Safety Note
Always lock out the generator and verify no live voltage before opening panels or disconnecting controller wiring.
SUBJECT PAGE
Introduction …………………………… i
Service Assistance …………………….. i
Safety Precautions …………………….. i
Section 1. Fast Response II Concepts ……. l-l
General……………………………..l- 1
System …………………………… ..l- 1
Short Circuit Performance …………….. l-3
Section 2. Operation ………………….. 2-1
Prestart Checklist ……………………. 2-1
Relay Controller Operation …………….. 2-1
Testing …………………………. ..2- 2
Starting ………………………… ..2- 2
Stopping ……………………….. ..2- 2
Fault Shutdowns …………………… 2-3
Resetting – Fault Shutdowns ………… 2-3
Voltage Adjustment ………………… 2-3
Dee-3 Microcomputer Controller
Operation ……………………….. ..2- 4
Lamps …………………………. ..2- 4
Switches and Alarms ……………….. 2-5
Meters and Fuses ………………….. 2-5
“Local” Starting ……………………. 2-6
“Auto” Starting …………………….. 2-6
Stopping …………………………. 2-6
Emergency Stopping ……………….. 2-6
Fault Shutdowns …………………… 2-6
Resetting …………………………. 2-7
Section 3. Controller Troubleshooting …… 3-1
Overspeed Relay Controller ……………. 3-1
Description ……………………….. 3-l
Sequence of Operation ……………… 3-2
Fault Shutdowns …………………… 3-2
Relay Descriptions …………………. 3-4
Troubleshooting …………………… .3-5
Dee-3 Controller …………………….. 3-9
Description ……………………….. 3-9
Fault Shutdowns ………………….. 3-17
Relay Descriptions ………………… 3-18
Troubleshooting …………………… 3-19
Speed Sensor Test ………………… 3-30
Fast Check Features and Operation ….. 3-30
Section 4. Generator Troubleshooting …… 4-l
Generator Conditions ………………… .4-l
No Output On Any Phase ……………… 4-3
Overvoltage ………………………… 4-3
Standard FR Activator ……………… .4-3
Split FR Activator ………………….. 4-4
Fluctuating Voltage …………………… 4-4
Component Testing ………………….. 4-4
LED Circuit Board Test ……………… 4-4
FR Activator ………………………… 4-5
Standard FR Activator ………………. 4-8
Split FR Activator ………………….. 4-9
SUBJECT PAGE
AVR (Voltage Regulator) Operation
and Adjustment (AVR Circuit Board
A-255670 Only) ……………………. 4-12
To Test AVR (All Sets) ……………… 4-13
Stator …………………………. ..4-14
Generator Field …………………… 4-15
Exciter Armature ………………….. 4-17
Photo Transistor Board …………….. 4-18
End Bracket Removal and
Replacement ……………………. 4-20
Section 5. Generator Reconnection and
Frequency Adjustment ……………….. 5-l
Generator Reconnection ………………. 5-l
Overspeed Relay Controller/Dee-3
Controller…………………………..5- 1
Generator Frequency Adjustment ………. 5-4
Section 6. Generator Disassembly/
Reassembly …………………………. 6-l
Disassembly ………………………… 6-l
Reassembly ………………………. ..6- 5
Section 7. Governor Adjustment ………… 7-l
Mechanical Governor Adjustments-
Diesel Engines ……………………… 7-1
Frequency Adjustment ………………. 7-1
Mechanical Governor Adjustments-
Gas/Gasoline ………………………. 7-l
Speed…………………………….7- 2
Sensitivity ………………………… 7-2
Bosch Electronic Governor
Adjustments-Diesel and Gas/
Gasoline ………………………… ..7- 3
Stability and Gain Adjustments ……….. 7-3
Barber-Colman Electronic Governor
Adjustments ……………………….. 7-4
Speed and Gain Adjustments ………… 7-4
Section 8. Accessories ………………… 8-1
Remote Annunciator Kit (Decision
Monitor) …………………………. ..8- 1
Audio-Visual (AV) Alarm Kit ……………. 8-1
Safeguard Breaker Kit ………………… 8-l
Line Circuit Breaker Kit ……………….. 8-2
Emergency Stop Kit ………………….. 8-2
Overvoltage Kit ……………………… 8-3
Isolated Alarm Contact Kit
(12 and 24 Volts) ……………………. 8-3
Function …………………………… 8-3
Mounting ………………………… ..8- 3
Relay Contact Rating ………………… 8-3
Connection Requirements ……………. 8-3
Accessory Connection ……………….. 8-5
Section 9. Wiring Diagrams …………….. 9-l
Generator Output Table ………………. 10-l
Electrical Formulas ………………….. 10-2
