Kohler Industrial Generator Sets Model 20 - 300 Kw Factory Service Manual

US $12.95

Richmond, Michigan, United States
Jan 30th

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Hello and Thank You For Looking! This is a complete Factory Service Manual for the Kohler Industrial Generator Sets Models 20 - 300 kW on a CD. This CD is filled with very well detailed easy to read diagrams, schematics, specifications and pictures. (147 pages & 8.1MG) This manual covers the below listed Generators. NOTICE* The photo depicted is a generalization of the entire series of manuals. Each individual CD is printed with the information specific to that piece of equipment. Hello and Thank You For Looking! This is a complete Service Manual for the Kohler Marine Generators Parts List and Complete Breakdown on a CD. This CD is filled with very well detailed easy to read diagrams, schematics, specifications and pictures. This manual covers the below listed Generators. This is a Parts List with the Illustrated Parts Breakdown. There is no service information on this manual NOTICE* The photo depicted is a generalization of the entire series of manuals. Each individual CD is printed with the information specific to that piece of equipment. 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 Proredure (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13-5353 8/94 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 We re-stock and have new manuals arriving on a regular basis. If you don’t see what you’re looking for please email us with your request! We strive for 100% Customer Satisfaction! If you have any problem with your CD whatsoever please contact us so that we may promptly remedy the problem! Be Sure To Click “SEE OTHER ITEMS” For Many More Of Our Manuals! FREE SHIPPING (within Continental U.S., Alaska, Hawaii, Puerto Rico, Guam U.S. Virgin Islands and American Samoa Only) All Orders Shipped Via USPS 1st Class Mail (estimated 2-3 day delivery) CANADA and Other International Orders O.K.. Email Seller For Shipping Rates or Use “Get Rates” Under Shipping Tab. All International Orders Shipped Via USPS 1st Class International Mail. Orders Are Shipped The Same Day Payment Is Made And Cleared. (Monday - Friday Before 2:30 PM EST) Orders Received After 2:30 PM EST And On Saturday Will Be Shipped The Following Business Day. Orders Received On Holidays Will Be Shipped The Following Business Day. Thank You For Looking! FREE! 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Condition:	Brand New: A new, unread, unused book in perfect condition with no missing or damaged pages. See the seller’s listing for full details. ...	Brand	Kohler
Model	20-300 kW