Kohler KD2000, KD3250, KD1250, KD800, KD1750 Operating Instructions Manual

Operation

Industrial Generator Sets

Models:

KD800--KD3250

Controller:

APM802

TP-7070 7/18d

W ARNING: This product can expose you

to chemicals, including carbon monoxide
and benzene, which are known to the State
of California to cause cancer and birth
defects or other reproductive harm.
For more information go to
www.P65warnings.ca.gov

Product Identification Information

W ARNING: Breathing diesel engine

exhaust exposes you to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.

S Always start and operate the engine in

a well-ventilated area.

S If in an enclosed area, vent the exhaust

to the outside.

S Do not modify or tamper with the

exhaust system.

S Do not idle the engine except as

necessary.

For more information go to
www.P65warnings.ca.gov/diesel

Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately a fter unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.

Generator Set Identification Numbers

Record the product identification numbers from the
generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the
engine nameplate.

Manufacturer

Model Designation

Serial Number

Alternator Identification

Record the alternator model number from the generator
set nameplate(s).

Alternator Model

Controller Identification

Record the controller description from the generator set
operation manual, spec sheet, or sales invoice. Record
the Controller Serial Number from the controller
nameplate.

Controller Description APM802

Controller Serial Number

Table of Contents

Safety Precautions and Instructions 7.........................................................

Introduction 11...............................................................................

Service Assistance 13.........................................................................

Section 1 Specifications and Features 15......................................................

1.1 Introduction 15...........................................................

1.2 Controller Specifications 15................................................

1.2.1 Controller Specifications 15........................................

1.2.2 Display and Touchscreen 15.......................................

1.3 Controller Features 15....................................................

1.3.1 Connections 17..................................................

1.3.2 Modbus Connections 17...........................................

1.3.3 Optional Keyswitch and Manual Start/Stop Button 18..................

1.4 NFPA Requirements 18...................................................

1.5 Parameter Settings 19....................................................

1.6 Base Module Inputs and Outputs 20........................................

Section 2 Operation 21........................................................................

2.1 Prestart Checklist 21......................................................

2.2 Exercising Generator Set 22...............................................

2.3 Operation in Cold Weather Climates 22.....................................

2.4 Generator Set Operation 23................................................

2.4.1 Start Signal 23...................................................

2.4.2 Stop Signal 23...................................................

2.4.3 Engine Cooldown 23..............................................

2.4.4 Emergency Stop 23...............................................

2.4.5 Idle Mode 23.....................................................

2.5 Controller Operation Modes 24.............................................

2.5.1 Out of Service Mode 24...........................................

2.5.2 Manual Mode 24.................................................

2.5.3 Auto Mode (Standby or System Ready) 25...........................

2.6 Load Shed 26............................................................

2.7 HMI Screen Layout 27....................................................

2.7.1 Home Screen 27.................................................

2.7.2 Top Bar 27.......................................................

2.7.3 Generator View 28................................................

2.7.4 Control Panel 29.................................................

2.7.5 Custom View Button 29...........................................

2.8 Operator Login 30........................................................

2.9 Data Displays 31.........................................................

2.9.1 Generator Mechanical Values 31...................................

2.9.2 Generator Electrical Values 33.....................................

2.9.3 Curve Display 33.................................................

2.9.4 Saved Electrical and Mechanical Data 35............................

2.10 Events 36...............................................................

2.10.1 Faults and Alarms 37.............................................

2.10.2 Resetting an Alarm 39............................................

2.10.3 Resetting a Fault 39..............................................

2.10.4 Consulting Status Messages 40....................................

2.10.5 Full Event Log 41.................................................

2.1 1 Applications 42

2.11.1 Reference 43....................................................

2.11.2 Region Settings 44...............................................

2.11.3 HMI Settings 45..................................................

2.11.4 Restart 47.......................................................

...........................................................

TP-7070 7/18 Table of Contents 3

Table of Contents, continued

2.1 1.5 Display Cleaning 47..............................................

2.11.6 Firmware Update 47..............................................

2.11.7 Screenshot 48...................................................

2.1 1.8 Ladder Tools 49..................................................

2.11.9 Save Parameters 51..............................................

2.11.10 Upload Parameters 51............................................

2.12 Menus 52...............................................................

2.12.1 Menu 1--Settings 54..............................................

2.12.2 Menu 2--Measurements 58........................................

2.12.3 Menu 3--History 61...............................................

2.12.4 Menu 4--Diagnosis 62.............................................

2.12.5 Menus 5 and 6 68................................................

2.12.6 Menu 6.5-Communication 68.......................................

Section 3 Scheduled Maintenance 71..........................................................

3.1 Introduction 71...........................................................

3.2 Service Schedule 74......................................................

3.3 APM802 Controller Maintenance 76.........................................

3.4 Engine Maintenance 76...................................................

3.5 Diesel Fuel Systems 76...................................................

3.5.1 Fuel/Water Separator 77..........................................

3.5.2 Manual Primer Pump 78...........................................

3.5.3 Bleeding Air from Fuel System 79..................................

3.5.4 Restriction Gauge (if equipped) 79..................................

3.6 Lubrication System 80....................................................

3.6.1 Oil Change 80...................................................

3.6.2 Automatic Oil Replenishment System (Optional Kit) 80................

3.6.3 Oil Analysis 81...................................................

3.7 Air Cleaner System 83....................................................

3.7.1 Air Filter Element 83..............................................

3.7.2 Air Cleaner Restrictor Indicator (if equipped) 83......................

3.8 Cooling System 84.......................................................

3.8.1 Coolant System Safety 84.........................................

3.8.2 Coolant Level Check 85...........................................

3.8.3 Cooling System Component Inspection 85...........................

3.8.4 Procedure to Drain Cooling System 85..............................

3.8.5 Procedure to Flush and Clean Cooling System 86....................

3.8.6 Procedure to Refill Cooling System 87..............................

3.8.7 Coolant Analysis 88...............................................

3.8.8 Radiator Maintenance 89..........................................

3.8.9 Radiator Fan Bearing Lubrication (KD2000--KD3250) 90...............

3.8.10 Notched V-Belt Adjustment (KD2000--KD3250) 91....................

3.9 Battery Systems 93.......................................................

3.9.1 Battery Safety 93.................................................

3.9.2 Absorbed Glass Mat (AGM) Battery 94..............................

3.9.3 Clean Battery 94.................................................

3.9.4 Charge Battery 94................................................

3.10 Alternator Maintenance 95.................................................

3.10.1 Alternator Safety 95...............................................

3.10.2 Checking the Installation 96........................................

3.10.3 Checking the Ventilation Circuit 96..................................

3.10.4 Checking the Bearings 96.........................................

3.10.5 Checking the Windings 96.........................................

3.10.6 Voltage Regulator 96..............................................

TP-7070 7/18Table of Contents4

Table of Contents, continued

3.11 Storage Procedure 97.....................................................

3.11.1 Storage Safety 97................................................

3.11.2 Controller 98.....................................................

3.11.3 Lubricating System 98............................................

3.1 1.4 Cooling System 98...............................................

3.1 1.5 Diesel Fuel System 98............................................

3.11.6 Exterior 98.......................................................

3.11.7 Alternator Storage 99.............................................

3.11.8 Battery 99.......................................................

Section 4 Troubleshooting 101.................................................................

4.1 Introduction 101...........................................................

4.2 Generator Set and Controller 101............................................

4.3 Engine 101...............................................................

4.4 Transfer Switch 101........................................................

4.5 General Troubleshooting Chart 102..........................................

Section 5 Accessories 107.....................................................................

5.1 Accessories and Connections 107...........................................

5.2 Accessory Connections 107.................................................

5.3 Input and Output Modules 108..............................................

5.3.1 Analog Input/Output Module 108.....................................

5.3.2 Digital Input/Output Module 109.....................................

5.3.3 Thermocouple Input Module 110.....................................

5.4 Remote Serial Annunciator 1 11..............................................

Appendix A Abbreviations 113................................................................

Appendix B Operating Hour Service Log 115...................................................

TP-7070 7/18 Table of Contents 5

Notes

TP-7070 7/186

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.

This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a
hazard that will cause severe

personal injury, death,orsubstantial
property damage.

WARNING

Warning indicates the presence of a
hazard that can cause severe

personal injury, death, or substantial
property damage.

CAUTION

Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.

NOTICE

Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.

Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.

Accidental Starting

WARNING

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set.
Accidental starting can cause
severe injury or death. Before

working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Shut down the generator set. (2)
Place the controller in Out of Service
mode. (3) Press the emergency stop
button. (4) Disconnect the power to the
battery charger, if equipped.
(5) Remove the battery cables,
negative (--) lead first. Reconnect the
negative (--) lead last when
reconnecting the battery. Follow these
precautions to prevent the starting of
the generator set by the remote
start/stop switch.

Battery

WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.

Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.

WARNING

Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.

Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.

Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid

can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acidsplashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.

Battery acid cleanup. Battery acid
can cause severe injury or death.

Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

7Safety Precautions and InstructionsTP-7070 7/18

Battery gases. Explosion can cause
severe injury or death. Battery gases

can cause an explosion. Do not smoke
or permit flamesor sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.

Battery short circuits. Explosion
can cause severe injury or death.

Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.

Combustible materials. A fire can
cause severe injury or death.

Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.

Servicing the fuel system. A flash
fire can cause severeinjury or death.

Do not smoke or permit flames or
sparks near the fuel injection system,
fuel line, fuel filter, fuel pump, or other
potential sources of spilled fuels or fuel
vapors. Catch fuels in an approved
container when removing the fuel line
or fuel system.

Exhaust System

WARNING

Carbon monoxide.
Can cause severe nausea,
fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:

D Light-headedness, dizziness
D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate
or speak clearly, blurred vision

D Stomachache, vomiting, nausea

If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.

Fuel System

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

Use extreme care when handling,
storing, and using fuels.

Generator set operation. Carbon

Engine Backfire/Flash
Fire

WARNING

Risk of fire.
Can cause severe injury or death.

Do not smoke or permit flames or
sparks near fuels or the fuel system.

Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator

set with the air cleaner removed.

8 Safety Precautions and Instructions TP-7070 7/18

monoxide can cause severe nausea,
fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building unless the exhaust gas is
piped safely outside. Never operate
the generator set where exhaust gas
could accumulate and seep back inside
a potentially occupied building.

The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly

explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Donot operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.

Fuel tanks. Explosive fuel vapors
can cause severe injury or death.

Gasoline and other volatile fuels stored
in day tanks or subbase fuel tanks can
cause an explosion. Store only diesel
fuel in tanks.

Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an

explosion. Use a container to catch fuel
when drainingthe fuel system. Wipe up
spilled fuel after draining the system.

Hazardous Noise

CAUTION

Hazardous noise.
Can cause hearing loss.

Never operate the generator set
without a muffler or with a faulty
exhaust system.

Engine noise. Hazardous noise can
cause hearing loss. Generator sets

not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.

Hazardous Voltage/
Moving Parts

DANGER

Hazardous voltage. Moving parts.
Will cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

WARNING

Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.

If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.

DANGER

Hazardous voltage.
Will cause severe injury or death.

Disconnect all power sources before
opening the enclosure.

Grounding electrical equipment.
Hazardous voltage will cause severe
injury or death. Electrocution is

possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.

Installing the battery charger.
Hazardous voltage will cause severe
injury or death. An ungrounded

battery charger may cause electrical
shock. Connect the battery charger
enclosure to the ground of a permanent
wiring system. As an alternative, install
an equipment grounding conductor
with circuit conductors and connect it to
the equipment grounding terminal or
the lead on the battery charger. Install
the battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.

Connecting the battery and the
battery charger. Hazardous voltage
will cause severe injury or death.

Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).

Short circuits. Hazardous
voltage/current will cause severe
injury or death. Short circuits can

cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.

Engine block heater. Hazardous
voltage will cause severe injury or
death. The engine block heater can

cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.

9Safety Precautions and InstructionsTP-7070 7/18

Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install

a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.

Testing live electrical circuits.
Hazardous voltage or current will
cause severe injury or death. Have

trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry,approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.

(600 volts and under)

Hot Parts

WARNING

Hot coolant and steam.
Can cause severe injury or death.

Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

WARNING

Hot engine and exhaust system.
Can cause severe injury or death.

Do not work on the generator set until
it cools.

Servicing the generator set when it
is operating. Exposed moving parts
will cause severe injury or death.

Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.

Heavy Equipment

WARNING

Unbalanced and elevated weight.
Improper lifting can cause severe
injury or death and equipment
damage.

Do not lift the generator set from the
engine or alternator eyes. Never
stand under a unit being lifted.
Alwaysmaintainasafedistancefrom
the unit being lifted.
See the lifting instructions in the
installation manual that was provided
with the unit.

Servicing the alternator. Hot parts
can cause severe injury or death.

Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.

Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.

The engine and exhaust system
components become extremely hot
during operation.

Notice

NOTICE

Parallel Operation. This product

includes features intended to support
operation in parallel with the utility grid,
but these features have not been
evaluated for compliance with specific
utility interconnection protection
standards or requirements.

NOTICE

Canadian installations only.For

standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

10 Safety Precautions and Instructions TP-7070 7/18

Introduction

This manual provides generator set operation,
maintenance, and basic troubl eshooting instructions. A
separate controller operation manual contains detailed
controller operation information.

Wiring diagram manuals are available separately. Refer
to the engine operation manual for generator set engine
scheduled maintenance information.

Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.

Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
skilled and suitably trained maintenance personnel
familiar with generator set operation and service.

Abbreviations

List of Related Materials

Separate literature contains controller operation
instructions, engine and alternator maintenance, and
accessory information not provided in this manual.
Figure 1 lists the available literature part numbers.

Several engine manufacturers provide engines with
electronic controls. These electronic controls indicate
engine fault codes in addition to the generator set
controller. The engine operation and service literature
provide information for identifying engine fault codes.
For the latest literature part numbers, see the respective
generator set parts catalog.

Literature Description Literature Part No.

APM802 Controller Spec Sheet G6-152

Generator Set Installation Manual TP-5700

Generator Set/Controller Wiring Diagram
Manual

Operation and Maintenance Manual,
KD27V12 Engine

Operation and Maintenance Manual,
KD36V16 Engine

Operation and Maintenance Manual,
KD45V20 Engine

Operation and Maintenance Manual,
KD62V12 Engine

Operation and Maintenance Manual,
KD83V16 Engine

Remote Serial Annunciator III (RSA III) TT-1625

TP-7071

33521029401

33521029701

33521030001

33521030301

33521030601

This publication makes use of numerous abbreviations.
Typically, the word(s) are spelled out along with the
abbreviation in parentheses when shown for the first
time in a section. Appendix A, Abbreviations, also
includes many abbreviation definitions.

Figure 1 Related Literature

11IntroductionTP-7070 7/18

Nameplate Location

Generator sets and their components (engine,
alternator) are identified with decals or nameplates. For
future reference during routine maintenance or to order
service parts, copy the model number, serial number,
and specification number from the generator set
nameplate into the spaces provided in the product
information section on the inside front cover of this
manual.

The generator set nameplate is typically located on the
alternator assembly as shown in Figure 3.

Genset Model

Spec Number

Serial Number

Material Number

Service Duty

Voltage

Alt Model

Insulation

MFG Date

Amps

Phase

RPM

Battery

kW

kVA

PF

Hz

Fuel

1

11811000100--GR1

1. Nameplate location, typical

Figure 3 Generator Set Nameplate Location, Typical

Figure 2 Generator Set Nameplate, Typical

12 Introduction TP-7070 7/18

Service Assistance

For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.

D Visit the Kohler Co. website at KOHLERPower.com.

D Look at the labels and decals on your Kohler product

or review the appropriate literature or documents
included with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside the US and Canada, call the nearest regional

office.

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]

Asia Pacific

Kohler Asia Pacific Headquarters
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

(86) 10 6518 7951
(86) 10 6518 7952

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

13Service AssistanceTP-7070 7/18

Notes

14 Service Assistance TP-7070 7/18

Section 1 Specifications and Features

1.1 Introduction

The spec sheets for each generator set provide model­specific generator and engine information. The
controller spec sheet provides specifications for the
controller. Refer to the respective spec sheet for data
not supplied in this manual. Refer to the generator set
service manual, installation manual, engine operation
manual, and engine service manual for additional
specifications.

1.2 Controller Specifications

1.2.1 Contro ller Specifications

D Power Supply Requirements:

d Nominal voltage: 24 VDC, reverse polarity

protected

d 240 VAC / 60Hz customer-supplied; factory wiring

to basic electrical package available

D Operating Temperature:

-- 4 0 _Cto70_C(--40_F to 158_F)

D Storage Temperature:

-- 4 0 _Cto70_C(--40_F to 158_F)

D Humidity: 5% to 95% non-condensing

D Protection Index:

d IP65 Front

d IP20 Rear

D Standards:

d NFPA 99

d NFPA 110, Level 1

d CSA 282-09

d UL 508

d IEC/EN60068-2-52 (salt spray)

d CE Directive

1.2.2 Display and Touchscreen

1.3 Controller Features

The controller features include a 307 mm (12.1 inch)
touchscreen with backlight and wide viewing angle (140
degrees horizontal and vertical) and terminal blocks for
input and output connections. See Figure 1-1 for an
illustration of the controller front panel and the customer
connection area. Controller features include:

D 12-inch touchscreen with backlight and wide viewing

angle for easy local access to data.

D System settings are password-protected.

D Measurements selectable in metric or English units.

D User language is selectable (English or French).

D Graphic displays show generator set mechanical

values including operating hours, fuel level*, battery
voltage, coolant temperature, oil pressure, and oil

temperature.

D Meter displays provide a visual representation of

generator electrical values including power (kW),
power factor, reactive power (kVAR), frequency,
voltage, and current (amps).

D Two USB ports allow connection of a flash drive,

mouse, or keypad.

D Electrical data, mechanical data, and system settings

can be saved to a flash drive.

D Recording feature allows data collection of key

values.

D Ethernet port allows connection to a PC type

computer and/or Ethernet switch.

D Serial (RS-485) port.

D The controller supports Modbusr RTU and TCP

protocols.

D Real time clock with battery back-up.

D See the controller specification sheet or operation

manual for input and output specifications.

Modbusr is a registered trademark of Schneider Electric.

* Where applicable

D Type: XGA TFT LED LCD

D Screen Size: 305 mm (12 inches)

D Viewing Angle: 140_ horizontal and vertical

D Languages: English, French

Note: Have setup and adjustments of the controller

performed only by an authorized Kohler
distributor. The setup and adjustments are
password protected.

TP-7070 7/18 15Section 1 Specifications and Features

1

2

9

10

11

3

13

4

8

7

5

6

11601000945

Note: Covers have been removed for illustration.

1. APM802 controller human-machine interface (HMI)

2. Emergency stop switch

3. Key switch

4. Manual start/stop button

5. 240 VAC/ 60 Hz power supply connection (required)

6. Terminal block TB10 for accessory connections

7. Wiring harness connection

10. Fault indicator/display button

11. Mode selection switch

12. Generator set electrical values

13. Generator set mechanical data

Figure 1-1 APM802 Controller and Customer Connection Box

Human-Machine Interface (HMI)

8. USB ports, qty. 2 (on the back of the HMI)

9. Controller touchscreen

12

TP-7070 7/1816 Section 1 Specifications and Features

1.3.1 Connectio ns

1.3.2 Modbus Connections

DANGER

Hazardous voltage.
Will cause severe injury or death.

Disconnect all power sources before
opening the enclosure.

Inputs and outputs from the controller base module are
brought out to TB10 in the connection box. See
Figure 1-1 for the terminal block location. Do not
connect directly to the controller base module (except
for the Ethernet 3 connection).

TB10 Terminal Strip for input and output connections.
See the generator set wiring diagram for connections.
Inputs and outputs are factory-set; the default settings
are shown in Figure 1-8.

240 VAC Power Connection. The installer must
connect a 240 VAC power source for the controller
heater. See Figure 1-1 and the wiring diagram for the
240 VAC power connections to TB10.

Mini USB Connectors for connection to a PC for
firmware updates or saving data files. Two USB ports
are located on the back of the controller’s
human-machine interface (HMI). See Figure 1-2. Lift
the hinged panel to access the USB ports.

Use RS-485 cable for Modbus RTU connections.
Belden #9841 or equivalent shielded, twisted-pair cable
is recommended. See Figure 1-3. See the generator
set wiring diagram for the Modbus connection location
on TB10.

The controller also supports Modbus TCP over
Ethernet. Connect to the RJ45 port labeled Ethernet 3
on the controller’s base module.

The controller communicates using Modbusr as a slave
connection with the Modbusr master initiating the
communication. The controller seeks the system and
alternator parameters and diagnostic information then
responds back to the Modbusr master.

Note: Only one Modbusr master can be connected to

the controller. Examples include the remote
serial annunciator and switchgear applications.

RS-485

up to 1220 m (4000 ft.)

Generator Set

Controller

Modbusr Master

Figure 1-3 Modbusr Connections

Ethernet 3 port on the base module can be connected

to a personal computer or network to allow remote
monitoring using VNC.

Additional input and output connections are available
with optional module kits. See Section 5 for accessory
connection details.

1

1. USB Ports

Figure 1-2 USB Ports (back of HMI)

TP-7070 7/18 17Section 1 Specifications and Features

1.3.3 Option al Keyswitch and Manual
Start/Stop Button

Some controllers are equipped with the optional
keyswitch and manual start/stop button shown in
Figure 1-4. See Figure 1-1 for the locations on the
controller assembly.

1.4 NFPA Requirements

In order to meet NFPA 110, Level 1 requirements, the
generator set controller monitors the engine/generator
functions and faults shown below.

Engine functions:

D Overcrank

D Low coolant temperature warning

D High coolant temperature warning

D High coolant temperature shutdown

D Low oil pressure shutdown

D Low oil pressure warning

D Overspeed

D Low fuel level *

D Low coolant level

D EPS supplying load

D High battery voltage

D Low battery voltage

D Air damper indicator

Figure 1-4 Optional Keyswitch and Manual

Start/Stop Button

Keyswitch. The keyswitch disables the mode
pushbutton on the controller touchscreen. The
touchscreen will display the operation mode, but the
mode cannot be changed using the touchscreen if the
controller is equipped with thekeyswitch. The keyswitch
positions are described in Figure 1-5. See Section 2.5
for more information on controller operation modes.

Manual Start/Stop Button. When the keyswitch is in
the Manual position, pressing the Start/Stop button will
start and stop the generator set.

Note: Pressing the manual stop button shuts down the

generator set immediately, without running the
engine cooldown cycle. Running the generator
set without load for 5 minutes before stopping
manually is recommended.

Position Description

Manual Allows generator set start and stop using

the manual pushbutton.

Off Places the generator set in OFF/Out of

Service mode. The generator set will not
start, even if a remote start command is
received or the Start button is pressed.

Auto Automatic operation allows a remote

switch or automatic transfer switch to start
and stop the generator set.

Figure 1-5 Keyswitch Positions

General functions:

D Master switch not in auto

D Battery charger fault *

D Lamp test

D Contacts for local and remote common alarm

D Audible alarm silence switch

D Remote emergency stop

* Function requires optional input sensors or kits.

TP-7070 7/1818 Section 1 Specifications and Features

1.5 Parameter Settings

Controller parameter settings are factory-set and
password-protected. Selected settings are shown in
Figure 1-6. If changes are required, contact your
distributor.

Parameter Setting

Preheat duration* 0s

Air-preheater maximum delay
(at each s tart attempt)*

Number of starting attempts 3

Time between starting attempts 15 s

Fault inhibition time in starting phase 10 s

Auxiliaries start time 5s

Generators starting maximum delay
(Dead Bus synchronizing)

Generator cooling time 300 s

Generator immobilization time 5s

Ventilation time after generator stopped 10 s

* Parameter settings not applicable for KD2000--KD3250

Figure 1-6 Factory Settings

30 s

5s

(5 min.)

TP-7070 7/18 19Section 1 Specifications and Features

1.6 Base Module Inputs and Outputs

The inputs and outputs on the base module are factory set. See Figure 1-7 and Figure 1-8 for base module input and
output factory settings. For optional input/output module settings, see Section 5, Accessories.

Note: Make customer connections to TB10 in the connection box. See the generator set wiring diagram for details.

Inputs Factory Setting

Digital Inputs

Analog Input

Resistive Input

Figure 1-7 APM802 Base Module Input Factory Settings

DI0 Remote Start

DI1 Low Fuel Level Switch

DI2 Breaker Open Status

DI3 Remote Reset

DI4 Aux Shutdown

DI5 High Fuel Level Switch

DI6 Aux Warning

DI7 Low Oil Level

DI8 Battery Charger Fault

DI9 Fuel Leak Alarm

DI10 Idle Mode

DI11 GFCI Tripped

DI12 Remote Speed Adjust Enable

DI13 Key Switch Enable

DI14 Load Shed Enable

DI15 Overcrank Test

DI16 Reserved for Factory Use

DI17 Emergency Stop

AI0--

AI0+

RES0--

RES0+

Remote Speed Adjust
(+/-- 10 VDC)

Ambient Air Temperature

Output Relay

Outputs

Digital Outputs

DO0 Form C Common Fault

DO1 Form C System Ready

DO2 Form C Common Warning

DO3 Form C Reserved for Factory Use

DO4 Form A Horn

DO5 Form A Low Coolant Temp Warning

DO6 Form A Shunt Trip

DO7 Form A Not in Auto

DO8 Form A BCA Excitation

DO9 Form A Generator Running

DO10 Form A EPS supplying Load

DO11 Form A ECU Fault Reset

DO12 Form A Low Oil Pressure

DO13 Form A High Coolant Temp

DO14 Form A Low Coolant Level Fault

DO15 Form A Low Fuel Level

DO16 Form A Start Button Illuminate

DO17 Form A Watchdog

Configuration

Factory Setting

Figure 1-8 APM802 Base Module Output Factory Settings

TP-7070 7/1820 Section 1 Specifications and Features

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.

DANGER

Hazardous voltage. Moving parts.
Will cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering engine.

Air Inlets. Check for clean and unobstructed air inlets.

Exhaust System. Check for exhaust leaks and

blockages. Check the silencer and piping condition and
check for tight exhaust system connections.

Inspect the exhaust system components (exhaust
manifold, exhaust line, flexible exhaust, clamps,
silencer, and outlet pipe) for cracks, leaks, and
corrosion.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace the exhaust clamps
and/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.

Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.

Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.

Coolant Level. Checkthe coolant level according to the
cooling system maintenance information.

Note: Block Heater Damage. The block heater will fail

if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
the system before energizing the block heater.

Drive Belts. Check the belt condition and tension of the
radiator fan, water pump, and battery charging
alternator belt(s) according to the drive belt system
maintenance information.

Enclosure Doors, if equipped. Check that the service
access doors are closed and secured. Leaving the
doors open will create excessive noise.

Controller Check. Touch the controller screen to verify
that it turns on. The controller screen dims automatically
after a period of time with no activity.

Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.

Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near the
generator set.

Radiator. Check that the radiator fins and air
inlets/outlets are clean of leaves, insects, dirt, and other
debris. Use compressed air to clear the obstructed
passages as needed.

Visual Inspection. Walk around the generator set and
look for leaking fluids, loose or dangling wiring, and
loose or missing hardware. Repair as needed before
starting the generator set. This visual inspection should
be routinely done while the unit is running.

TP-7070 7/18 21Section 2 Operation

2.2 Exercising Generator Set

DANGER

Hazardous voltage. Moving parts.
Will cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Operate the generator set under load once each week
for one hour. Perform the exercise in the presence of an
operator when the generator set does not have a n
automatic transfer switch with an exercise option.

During the exercise period apply a minimum of 30% load
based on the nameplate standby rating, unless
otherwise instructed in the engine operation manual.

The operator should perform all of the prestart checks
before starting the manual exercise procedure. Start
the generator set according to the starting procedure in
Section 2.5, Controller Operation. While the generator
set is operating, listen for a smooth-running engine and
visually inspect generator set for fluid or exhaust leaks.

The generator set controller does not provide weekly
scheduled exercise periods. For scheduled exercise
periods, refer to the automatic transfer switch (if
equipped) literature.

2.3 Operation in Cold Weather
Climates

Cold weather operation is generally considered ambient
temperatures below freezing 0C(32F). The following
items are recommended for cold weather starting and/or
operation when the unit is located in an enclosure or
unheated structure. Have a licensed electrician install
240 VAC, 15 amp outlets as needed if not already in the
immediate area.

Refer to the engine operation manual regarding engine
oil viscosity, fuel composition, and coolant mixture
recommendations.

D The engine block heater is generally recommended

for most units when operated below 0C(32F) and
required as part of NFPA 110. Refer to the respective
spec sheet for temperature recommendations in
available options.

D The controller heater is required for operation below

-- 2 0 C(--4F). The controller heater is a standard
feature. Make sure that 240 VAC power for the heater
is connected as shown on the generator set wiring
diagram.

D A battery heater is generally recommended for most

units when operated below 0C(32F). Refer to the
respective spec sheet for model availability.

D An alternator heater to prevent moisture and frost

buildup is available for most generator sets.

TP-7070 7/1822 Section 2 Operation

2.4 Generator Set Operation

2.4.1 Start Signal

2.4.4 Emergency Stop

Use the controller emergency stop switch for immediate
emergency shutdown.

A start signal includes the following:

D Remote start signal via contacts 3 and 4 when the

controller is in AUTO mode. The remote start
contacts may be connected to an ATS (used during a
power outage, exercise period, etc.) or a remote
panel.

D Engine Start signal from the controller. Put the

controller into Manual mode. Then press the Engine
Start button on the screen.

Note: The engine crank cycle is 15 seconds cranking

and 15 seconds rest for 3 cycles.

2.4.2 Stop Signal

A stop signal includes the following:

D Removal of start signal via contacts 3 and 4 when the

controller is in AUTO mode. The remote start
contacts may be connected to an ATS (used during a
power outage, exercise period, etc.) or a remote
panel.

D Engine Stop signal from the controller when it is in

Manual mode. Press the Engine Stop button on the
screen.

D Emergency Stop signal. See Section 2.4.4.

2.4.3 Engine Cooldown

Engine Cooldown runs the generator set with no load to
allow hot engine components time to cool slowly before
the engine is stopped.

When the generator set is running in AUTO mode, an
engine cooldown cycle begins when the remote start
input is deactivated. Also, if stopping due to a remote
stop signal, a cooldown cycle begins. The engine runs
for 5 minutes in the cooldown cycle.

Note: No engine cooldown cycle occurs if the Engine

Stop button is pressed (in manual mode), the
Emergency Stop button is pressed, or if a fault
occurs. The shutdown is immediate. If possible,
run the generator set without load for 5 minutes to
ensure adequate engine cooldown.

The emergency stop switch bypasses the engine
cooldown cycle and immediately shuts down the
generator set.

Note: Use the emergency stop switch(es) for

emergency shutdowns only. Use the controller’s
Manual mode or a remote stop switch for normal
shutdowns.

The controller alarm (fault) button flashes red and the
unit shuts down when the local emergency stop switch is
activated (pressed).

Use the following procedure to reset the generator set
after shutdown by a local or remote emergency stop
switch.

1. Investigate and correct the cause of the
emergency stop.

2. Reset the controller emergency stop switch by
pulling the switch dial outward and/or reset the
remote emergency stop switch (if equipped).

3. Reset the fault on the APM802 controller. See
Section 2.10 for instructions.

4. After resetting all faults using the controller reset
procedure, place the controller into Auto mode or
use Manual mode to restart the generator set. The
generator set will not crank until the reset
procedure completes.

2.4.5 Idle Mode

The generator set controller must be in AUTO mode for
idle mode operation. Idle mode requires a
customer-supplied idle switch connected across
terminals 5 and 6 on terminal block TB10.

When the idle switch on contacts 5 and 6 closes, the
engine runs at low speed (1000 RPM) for 5 minutes.
The engine then ramps up to normal speed and voltage
and continues to run until the idle switch opens. Afterthe
idle switch opens, the engine continues to run through
the cooldown cycle and then shuts down.

TP-7070 7/18 23Section 2 Operation

2.5 Controller Operation Modes

The controller operation includes several types of
starting and stopping functions. Thereare three primary
modes of operation, selected from the controller
touchscreen or the optional keyswitch:

D Auto (Automatic mode)
D Manual
D Out of Service (Off mode)

See Figure 2-1 for the location of the mode selection
switch on the controller touchscreen. See Section 1.3.3
for more information about the optional keyswitch.

Note: To disable the generator set before servicing,

shut down the generator set, place in
Out-of-Service mode, and disconnect the
batteries negative (--) lead first.

2.5.2 Manual Mode

In manual mode, engine start and stop are controlled
manually by the operator using the Engine Start and
Engine Stop buttons on the controller’s touchscreen. If
the controller is equipped with an optional keyswitchand
manual start/stop button, use the start/stop button for
manual operation in the procedures below.

The Emergency Stop button and the optional remote
emergency stop switch will stop the generator set
immediately, with no engine cooldown period.

The three operation modes are briefly described below
and summarized in Figure 2-2.

1

2

1. Alarm (fault) button

2. Mode selection switch

tp7070

Figure 2-1 Controller Mode Selection Switch

2.5.1 Out of Service Mode

Manual start procedure, with optional keyswitch

1. Turn the key to the Manual position. check that the
controller touchscreen shows that the unit is in
MANUAL mode.

2. Check the mechanical parameters (battery
voltage, etc.) and verify that there are no faults.

3. To start the generator set, press the manual
Start/Stop button. The engine speed, voltage, and
frequency will be displayed o n the controller
screen.

Manual start procedure, without optional
keyswitch

1. Press and hold the Manual button on the
controller’s touchscreen until Manual turns green.

2. Release the Manual button. The Engine Start
button appears on the controller touchscreen.

3. Check the mechanical parameters (battery
voltage, etc.) and verify that there are no faults.

4. To start the generator set, press Engine Start on the
controller touchscreen. The engine speed,
voltage, and frequency will be displayed on the
controller screen.

Pressing the Out of Service button on the controller
touchscreen disables the generator set to prevent
starting during generator set maintenance or service.
The generator set remains off and will not respond to a
remote start signal. If the generator set is running,
pressing the Out of Service button immediately shuts off
the generator set, with no engine cooldown.

If a fault causes the generator set to shut down, the
controller automatically enters the Out o f Service mode.

Manual stop procedure

Note: Pressing Engine Stop causes the generator set

engine to stop immediately, without running the
engine cooldown cycle.

The controller must be in Manual mode. Follow these
steps to allow engine cooldown before stopping the
generator set.

TP-7070 7/1824 Section 2 Operation

1. Remove the load from the generator set.

2. Wait five minutes to allow the engine to cool down.

When the start signal is removed, the generator set will
continue to run through the engine cooldown cycle, and
then shut down.

3. To stop the generator set, press Engine Stop on the
controller touchscreen or press the manual
Start/Stop button (if equipped).

Idle Mode

If the generator set is equipped with an idle mode switch
across contacts 5 and 6, the engine can operate in idle

2.5.3 Auto Mode (Standby or System
Ready)

The generator set is waiting for a start signal. The
generator set will start and run when a start signal is
received via a remote start signal or a local start signal.

The generator set will start when it receives a start
signal. If the generator set is not in Auto mode, it will not

mode. When the idle mode switch closes, the engine
runs at low speed (1000 RPM) for 5 minutes and then
ramps up to normal speed and voltage. Idle Mode is
displayed in the status message area on the controller
screen. When the idle mode switch opens, the engine
runs through the cooldown cycle and then shuts down.

The controller must be in Auto mode for idle mode
operation.

start.

Operating Mode Action / Event Operation Notes

Press Auto or place the
optional keyswitch into the
AUTO position (if equipped).

Idle switch on contacts 5
and 6 closes.

Idle switch on contacts 5

AUTO

MANUAL

OUT OF SERVICE

* The E-Stop button overrides the manual engine start/stop buttons and remote start signals. The engine will not start if the E-Stop button is

activated.

and 6 opens.

A warning condition occurs.

A fault condition occurs.

Press Manual or place the
optional keyswitch into the
Manual position (if
equipped).

Press the Engine Start
button or the manual
Start/Stop button (if
equipped).

Press the Engine Stop
button or the manual
Start/Stop button (if
equipped).

Press the Out of Service
button or place the optional
keyswitch into the OFF
position (if equipped).

Generator set shuts down
on a fault.

Responds to remote start/stop
commands from an ATS or
remote start panel. *

Engine runs at 1000 RPM for 5
minutes, then ramps up to normal
speed and voltage. *

Engine runs through the 5 minute
cooldown, then shuts down.

Fault button flashes orange.

Horn may sound, if connected.

Generator set shuts down and
the fault button flashes red. The
mode changes to Out of Service
mode.

Horn may sound, if connected.

Engine can only be started and
stopped using the engine
start/stop buttons on the
touchscreen or the manual
start/stop button (if equipped). *

Starts the engine if there are no
active faults. *

Stops the engine immediately,
with no engine cooldown.

Stops the engine immediately,
with no cooldown.

System is locked and generator
startup is not possible.

Auto is the recommended mode.

Customer-supplied idle switch is required for idle
mode operation. Controller must be in Auto for
idle mode operation.

See Section 2.10 for instructions to view faults
and warnings (alarms).

Engine start/stop is controlled manually by the
operator.

If equipped with the optional keyswitch and
manual Start/Stop button, the engine start and
stop buttons on the controller touchscreen are
disabled. Use the manual Start/Stop button.

Wait 5 minutes after opening the circuit breaker
for engine cooldown before pressing Engine
Stop.

Put the generator set into Out of Service (OFF)
mode and disable the generator set during
maintenance or service.

A fault shutdown automatically puts the
generator into Out of Service Mode. See
Section 2.10 for instructions to view and reset
faults (shutdowns or warnings).

Figure 2-2 Operation Mode Summary

TP-7070 7/18 25Section 2 Operation

2.6 Load Shed

The manual key switch/ load shed module isavailable as
an optional kit.

The load shed function drives outputs to four Form C dry
contacts to remove non-critical loads. If the generator
set load reaches or exceeds the level set in power
threshold #9, loads are shed until the total load drops
below the threshold level.

threshold #9. Load 1 (output #0) is shed first . Additional
outputs are activated every 5 seconds as shown in
Figure 2-3 until the total load drops to the threshold
value or all four non-critical loads are shed. Messages
on the main screen will indicate that load shed outputs 1
through 4 are active.

If all four loads are shed, the generator set will continue
to run if the load remains at or below 100% of the rated
load.

Loads are added again when the total load drops below
the level in threshold #9. Factory-settime delays ensure
that the load is stable before loads are shed or added.
Load 1 is shed first and added last. Load 4 is shed last
and added first.

The load shed level is set in Power Threshold 9 on the
APM802 controller. The factory default setting for
threshold 9 is 90%. The threshold setting can be
changed in Screen 1.2 after logging in with the
operator’s password. See Sections 2.8 and 2.12.1.

Do not connect critical loads to the load shed outputs.
Only connect low-priority loads that can be
disconnected when necessary.

Connection

Controllers with load shed capability are equipped with a
Manual Key Switch/Load Shed digital I/O Module, which
is factory-installed in the first position. Connect up to
four non-critical loads to Load Shed Outputs 1 through 4
on the Manual Key Switch/Load Shed Module. See
Figure 2-4. The load shed outputs are Form C contacts.
Connect to the normally open (NO) or normally closed
(NC) contacts as required for the application.

When the generator set load drops below the level in
threshold 9, the outputs are deactivated one at a time
starting with Load 4 (output #3), reconnecting the loads.
Adjust the loads, if necessary to avoid cyclic adding and
shedding around the threshold #9 level.

MANUAL KEY SWITCH/

LOAD SHED I/O MODULE

Key switch
factory
connections

Load Shed

Power

Threshold *

Load

1 #9 5 seconds 60 seconds O#0

2 #9 5 seconds 45 seconds O#1

3 #9 5 seconds 30 seconds O#2

4 #9 5 seconds 15 seconds O#3

* Default setting = 90%. Power threshold setting can be

changed by the technician.

(Disconnect)

Time Delay

Load Add

(Reconnect)

Time Delay

Displayed

as

Figure 2-3 Load Shed Settings

Operation

The outputs are activated and loads are shed when the
total generator set load reaches the level set in power

Load Shed
Customer
Connections

GM103061

Figure 2-4 Load Shed Output Connections

TP-7070 7/1826 Section 2 Operation

2.7 HMI Screen Layout

2.7.1 Home Screen

The home screen of the APM802 controller’s human-machine interface (HMI) contains status messages, navigation
buttons, data displays, and controls described briefly in the following sections. See Figure 2-5.

1

3

1. Top bar

2. Control Panel

3. Generator view

2

Figure 2-5 Home Screen

2.7.2 Top Bar

The top bar is alwayspresent, it displays system information and status messages, and ithas shortcut buttons for quick
access to other screens.

1 2

9 8 7 6 510

1. Shortcut to operating screen

2. Operating status message

3. Shortcut buttons

4. Date and time display

5. To home screen

6. Alarm indicator and access to events screen

7. For future development

8. To operator login

9. To applications screen

10. Operating sequence display

Figure 2-6 Top B ar

TP-7070 7/18 27Section 2 Operation

3

4

2.7.3 Generator View

The generator view displays engine mechanical data and alternator electrical data. Whenin manual mode, the Engine
Start button also appears. See Figure 2-7.

1

2

1. Engine start appears in Manual mode only

2. Engine and mechanical view

3. Alternator electrical view

Figure 2-7 Generator View

3

TP-7070 7/1828 Section 2 Operation

2.7.4 Control Panel

2.7.5 Custom View Button

The control panel includes the generator set master
switch and other controls. See Figure 2-8.

1

2

4

5

1. Mode selection touch pad

2. Horn silence button appears for alarm or fault

3. Start button in manual mode

4. Voltage and frequency shown when running

5. Touch Menu button for menu access

6. Operator menus (operator login required)

7. User menus

3

6

7

On medium voltage units equipped with thermocouple
modules, touch the custom view button to see alternator
temperature readings from the thermocouple modules.

If no thermocouple modules are installed, 32_F(or0_C)
is displayed for all temperatures. If nothing is connected
to one channel on a thermocouple module, --58_F(or

-- 5 0 _C) is displayed.

1

1. Custom view button

tp7070

Figure 2-9 Custom View Button

Figure 2-8 Control Panel

Figure 2-10 Custom View Temperature Display

TP-7070 7/18 29Section 2 Operation

2.8 Operator Login

Some functions require logging in as an operator.

1. Touch the Operator button. See Figure 2-12.

2. Use the virtual keypad to enter the login (1966).

Note: When logging on as operator 1966, a

password is not required.

When logged in as an Operator, the Modify button
appears on screens where settings can be changed.
See Figure 2-11 for an example.

1

1. Modify button

The operator is automatically logged out after
10 minutes.

3

1. Operator button

2. Virtual keypad

3. Login (1966)

Figure 2-11 Modify Button

1

2

Figure 2-12 Operator Login

TP-7070 7/1830 Section 2 Operation

2.9 Data Displays

2.9.1 Generator Mechanical Values

1

Favorites

2

Overview display

It is possible to display up to 6 mechanical values at the
same time. By default, the following values are
displayed:

D Working hours counter (number of operating hours)

D Fuel level (daily service tank or main tank)

D Starter battery voltage

D Coolant temperature (HT coolant temperature in the

case of a dual circuit engine)

D Oil pressure

D Oil temperature

The display area showing six mechanical values is
called the Favorites page. The content of this page can
be altered at any time. Each mechanical value is
represented by an information bar containing the
information shown in Figure 2-13.

5

4

3

1. Information bar

2. Name/description of the mechanical value

3. A visual display of the value: bar graph, thermometer, meter

4. The numerical value (56_C, 28V, 5.1 bar, etc.)

5. A pictogram

Figure 2-13 Favorites Page

The mechanical values can be scrolled through page by
page. Press the < and > buttons to scroll through the
pages. See Figure 2-14

Favorites page

Favorites

Figure 2-14 Scrolling within the Favorites Page

Page 1/1

TP-7070 7/18 31Section 2 Operation

Detailed View

Pressing any area on an information bar on one of the
mechanical value pages gives access to a detailed view
of the selected mechanical value.

The example below shows a user pressing on the Oil
pressure information bar.

Favorites

Figure 2-15 Information Bar Selection

From an overview display of 6 mechanical values, we
switch to a detailed display of 3 mechanical values.

Three tabs also appear: Fuel, Engine, and Cooling. The
mechanical values are all classed under these three
tabs.

Under each tab, the mechanical values displayed can
be accessed by pressing the < or > buttons in
succession.

Once you zoom into each mechanical value, 2 or 3
additional buttons appear:

Favorites button

The Favorites (+L) button is used to select the 6
mechanical values most useful to the user. See
Figure 2-17.

If the Favorites (+L) button is blue, the mechanical
values appear on the LFavorites page (limited to six
values).

If the Favorites (+L) button is gray, the mechanical
values do not appear in the L Favorites page, but in
another page.

Figure 2-16 Detailed Mechanical Values

1

1. Favorites button

Figure 2-17 Favorites Button in the Detailed View

TP-7070 7/1832 Section 2 Operation

2.9.2 Generator Electrical Values

Overview display

Six electrical values are displayed and shown as
meters. See Figure 2-18.

123

1

4

5

1. Active power, P, in kW

2. Power factor, PF

3. Reactive power, Q, in kvar

4. Frequency, F, in hertz

5. Phase current, I, in amperes

6. Line-to-line voltage, U, in volts

6

Figure 2-18 Electrical Values

Detailed display

Touching any area of a meter gives access to an
expanded view of the selected electrical value. For an
example, see Figure 2-19 and Figure 2-20.

D From an overview display of 6 electrical values, we

switch to a detailed display of 3 electrical values.

1. Curve button

Figure 2-20 Detailed Electrical Values

2.9.3 Curve Display

When you zoom into each mechanical or electrical
value, the Curve button appears. Touch the Curve
button to view the change over a variable period in real
time of one of the 6 electrical values of the overview
display.

Figure 2-21 shows the location of the Curve button. See
Figure 2-22 for an example of a curve display.

1

D The electrical values which are not displayed can be

accessed by pressing the > or < buttons in
succession.

1. Curve button

Figure 2-21 CurveButtonontheDetailedView

Figure 2-19 Electrical Values and Touching on Active

Power

TP-7070 7/18 33Section 2 Operation

1 2 3 4 5 6

On any curve displayed on the screen, inserting a USB
key into the HMI port makes the USB key button appear.
See Figure 2-23. Pressing this button automatically
saves:

D A curve data file (.csv) containing the information

(data points) described in Section 2.9.4.

D An image of the selected window in png format. See

Figure 2-23 for an example showing the battery
window.

1. Choice of recording period (10 minutes, 4 hours, 8 hours,
24 hours)

2. Previous successive press

3. Zoom out

4. Zoom in

5. After successive press

6. Pause the recording or start the recording of the mechanical
value

Figure 2-22 Oil Pressure Curve (example)

Touch the recording period to select the time period:

D 10 minutes: record values every 1 second

D 4 hours: record values every 30 seconds

D 8 hours: record values every 1 minute

D 24 hours: record values every 3 minutes

1

1. Voltage

2. USB button

3. Current

2

3

Figure 2-23 Curve Window (battery data is shown for

this example)

Touch the Back (< ) button to return to the overview
display. See Figure 2-24 for the location of the Back
button.

1

1. Back button

Figure 2-24 Back Button

TP-7070 7/1834 Section 2 Operation

2.9.4 Saved Electrical and Mechanical Data

The recording on a USB stick provides a curve data file
(.csv) containing the information shown in Figure 2-25.

All of this information is saved according to 4 different
time periods:

Depending on the engine type and sensors installed on

D 10 minutes: record values every 1 second

the generator set, some of the 14 mechanical values
may not be used. In that case, 0 will appear in the Excel
table for the value or values concerned.

For electrical values, the voltage input U2 of the
regulation module is present in the Excel table even

D 4 hours: record values every 30 seconds

D 8 hours: record values every 1 minute

D 24 hours: record values every 3 minutes

though this input is not used.

The markers I3.x.x and I5.x.x correspond to the analog
variable numbers (see section 2.12.4).

Mechanical value

Notes

I5.35: U bat #1 Battery voltage 1

I5.36: I bat #1 Battery current 1

I5.10: Engine speed

I5.21: Daily tank fuel level

I5.20: Engine cooling circuit coolant level

I5.15: Fuel temperature

I5.16: Oil temperature

I5.13: Engine cooling circuit coolant temperature

I5.14: Charge air cooling circuit coolant temperature

I5.17: Charge air temperature

I5.24: Oil pressure

I5.25: Low fuel pressure

I5.27: Charge air pressure

I5.115: ECU: Estimated instant fuel consumption

I5.131: ECU: Common rail fuel pressure

I5.110: ECU: Engine speed

I5.138: ECU: ECU voltage supply

I5.139: ECU: Engine running hours (hours)

I5.140: ECU: Engine running hours (seconds)

Electrical value (on generator set side) Notes

I3.1.50: Frequency -- Input1 -- Reg #1 On input U1 of regulation module 1

I3.1.55: U23 Line--to--line voltage -- Input1 -- Reg #1 On input U1 of regulation module 1

I3.1.57: I1 Current -- Input1 -- Reg #1 On input U1 of regulation module 1

I3.1.64: Total active power -- Input1 -- Reg#1 On input U1 of regulation module 1

I3.1.68: Total reactive power -- Input1 -- Reg#1 On input U1 of regulation module 1

I3.1.72: Total cosphi -- Input1 -- Reg #1 On input U1 of regulation module 1

Figure 2-25 Saved Data

TP-7070 7/18 35Section 2 Operation

2.10 Events

The controller displays status, alarm (warning), and fault
(shutdown) messages. See Figure 2-26 for a list of
possible alarms and faults.

Internal
Number

M3.10 Common fault X

M3.16 Common warning X

M3.17 GFCI tripped X

M3.18 Over frequency fault

M3.19 Under frequency fault

M3.20 Over voltage fault (59) X

M3.21 Under voltage fault (27) X

M3.22 Overload active power

M3.24 Reverse active power

M3.25 Overload reactive

M3.26 Reverse reactive power

M3.27 Over current fault (51) X

M3.29 Thermal overload fault X

M3.30 Low cranking voltage X

M3.31 Low controller

M3.42 Genset output greater

M3.43 Load shed 1 active X

M3.44 Load shed 2 active X

M3.45 Load shed 3 active X

M3.46 Load shed 4 active X

M3.63 Idle mode cancelled

M3.66 Alternator winding

M3.67 Alternator winding

M3.68 Alternator bearing

M3.69 Alternator bearing

M3.76 Not in auto warning X

M3.77 Power plant out of

M3.80 Emergency push button

M3.107 Under speed fault X

M3.108 Over speed fault X

M3.109 Speed detection fault X

M3.113 Low engine coolant

M3.116 Engine coolant

Description

(81H)

(81l)

warning (32PH)

fault (32RP)

power warning (32QH)

fault (32RQ)

temperature

than 80% of rated

before idle timeout

temperature warning

temperature fault

temperature warning

temperature fault

service fault

engaged fault

level fault

temperature warning

Alarm

(Warning)

X

X

X

X

X

X

X

X

Fault

(Shutdown)

Internal

Number

M3.117 Engine coolant

M3.124 Low coolant

X

X

X

X

X

X

X

X

X

M3.128 Low oil level warning X

M3.132 Lube (engine) oil

M3.133 Lube (engine) oil

M3.134 Lube (engine) oil

M3.135 Lube (engine) oil

M3.142 Speed detection first

M3.143 Speed detection

M3.153 Low fuel level X

M3.154 Fuel level critically low X

M3.155 High fuel level X

M3.156 Fuel daily tank very

M3.158 Fuel leak alarm X

M3.192 First starter warning X

M3.193 Overcrank X

M3.198 Battery charger fault X

M3.200 Low battery voltage X

M3.201 High battery voltage X

M3.212 APM internal battery

M3.550 Engine CAN bus

M3.553 Regulation module 1

M3.567 APM802 watchdog X

M3.720 Analog sensor fault

M3.721 Analog sensor fault

M3.722 Analog sensor fault

Figure 2-26 Warning and Shutdown Messages

Description

temperature fault

temperature warning

pressure warning

pressure fault

temperature warning

temperature fault

starter warning

second starter warning

high level warning

warning

communication fault

communication fault

input AI #0

input AI #1

input AI #2

Alarm

(Warning)

X

X

X

X

X

X

X

X

X

X

Fault

(Shutdown)

X

X

X

X

X

TP-7070 7/1836 Section 2 Operation

2.10.1 Faults and Alarms

Press the Alarm ( !) button shown in Figure 2-27 to view a
list of generator set events, including status messages,
alarms, and faults.

D A status message communicates the state of the

generator set (example: appearance of Stop mode).

D An alarm (warning) signals an impending problem

(example: coolant temperature alarm). The alarm
button flashes orange. See Figure 2-28. A warning
(alarm) appears in orange on the screen and does not
cause the generator to shut down.

D A fault shuts down the generator set (example: oil

pressure fault). The alarm button flashes red. See
Figure 2-29. A fault appears in red on the screen and
causes the generator to shut down (instantly or
delayed, depending on the programmed incidence).

D A number on the alarm button indicates the number of

active faults and/or alarms.

There are some exceptions. A specific fault message on
the HMI screen may be processed as an alarm by the
PLC, so there is no engine shutdown.

1

1. Alarm (!) button is orange

2. Stop horn button

2

33508003101

Figure 2-28 Appearance of an Alarm (warning)

1

Press the stop horn button. The horn (if equipped)
turns off and the stop horn button disappears. The alarm
button stops flashing and turns orange.

Press the alarm (!) button. A list of the last three active
alarms that have not been reset is displayed. See
Figure 2-30. Alarms and faults are listed in
chronological order.

1

3 2

1. Alarm (!) button is red

2. Stop horn button

3. Generator set has shut down and is in out of service mode

Figure 2-29 Appearance of a Fault (shutdown)

1. Alarm button

Figure 2-27 Alarm Button

TP-7070 7/18 37Section 2 Operation

1

8

7

6

45

1. Alarm button with number of alarms (press to display list)

2. Pull down tab (press to show full display of additional alarms)

3. Description

4. Internal variable number

3

2

5. Date and time of event

6. Reset button (X)

7. Active (on)

8. Not active (off)

Figure 2-30 Fault and Alarm List (three most recent faults or alarms)

Press the pull--down tab for access to a full screen
display of any other additional alarms. See Figure 2-31.

The 4th alarm in Figure 2-31 shows a fault that is
managed as an alarm.

The full screen brings up the following:

D < Back button on the operating screen

D Drop-down menu A

D Drop-down menu B

D X button (general reset)

D Complete list of active faults and/or faults not reset

1. List of alarms in chronological order

Figure 2-31 Full Screen with Latest Alarms

1

TP-7070 7/1838 Section 2 Operation

2.10.2 Resetting an Alarm

2.10.3 Resetting a Fault

An alarm indicates that a problem has occurred, but the
generator is still able to run. Always correct an alarm
condition before it leads to a fault that will shut down the
generator set. See the Safety Precautions and
Instructions section of this manual before proceeding to
correct an alarm condition. Contact an authorized
distributor or dealer for service, if necessary.

An alarm turns off when the cause of the alarm is
resolved:

D The operator may correct the condition that is causing

the alarm.

D The alarm condition may resolve itself; for example,

the temperature drops, resolving a high temperature
alarm.

After the condition is resolved and the alarm turns off,
RESET the alarm by pressing the X button. See
Figure 2-32.

If the alarm does not appear on the list of the last three
alarms, touch the pull-down tab to display additional
alarms.

1

A fault turns off when the cause of the alarm is resolved
by one of the two following methods:

D The operator has corrected the condition that is

causing the fault.

D The fault condition has resolved itself; for example,

the temperature drops, resolving a high temperature
fault.

Note: The generator set must not be restarted until the

fault condition is identified and corrected.

Always identify and correct the cause of a fault
shutdown before resetting the controller. See the Safety
Precautions and Instructions section of this manual
before proceeding to correct a fault condition. Contact
an authorized distributor or dealer for service, if
necessary.

To reset a fault, first correct the fault condition. The fault
indicator will turn off. Then press the X button next to the
individual fault. See Figure 2-33.

Note that it is also possible to reset a fault from the tab of
the last 3 alarms, if this fault is one of the 3 most recent
alarms.

1. Press the reset alarm button

Figure 2-32 Resetting an Alarm

Emergency Stop Fault

Manually pressing the emergency stop button causes a
fault. After the emergency stop button is unlocked, the
fault indicator will turn off, and it will then be possible to
reset this fault with the X button.

Figure 2-33 Resetting a Fault

TP-7070 7/18 39Section 2 Operation

2.10.4 Consulting Status Messages

D Present/Not present

Reviewing the status messages is possible at any time.

D Open/Close

Depending on the status type, the APM802 will log
different messages:

D Appearance

D Disappearance

D On/Off

D Start/End

After pressing the Alarm (!) button, and if no fault or
alarm is present, select Status messages history in

D Appearance/Disappearance

1. Drop-down menu A (see Figure 2-35)

2. Drop-down menu B (used to select between all, mechanical, or electrical type status messages)

drop-down menu A. See Figure 2-34 and Figure 2-35.

Figure 2-34 Drop--down Menus

1

2

1. The most recent status in the sequence

2. The oldest status in the sequence

Figure 2-35 Drop--down Menu A

12

1. Drop--down list A

2. Drop--down list B

1

2

Figure 2-36 Drop--down Lists A and B

TP-7070 7/1840 Section 2 Operation

2.10.5 Full Event Log

To view all events (status messages, alarms, and faults, active or reset), select Full event log from drop-down list A,
and select All from drop-down list B. See Figure 2-37 for an example of the full event log.

1

2

1. List A, Full event log selected

2. List B, All selected

Figure 2-37 Full Event Log

TP-7070 7/18 41Section 2 Operation

2.11 Applications

Touch the Applications button in the top bar to open the Applications screen. See Figure 2-38. From this screen, you
can access the screens listed in Figure 2-39. Note that access to some screens requires logging on as an operator.

1 234

5

6

9

10

11

1. Reference

7

8

2. Region settings

3. HMI settings

4. Restart

5. Display cleaning

6. Firmware update

7. Screenshot

8. Ladder tools

9. Save parameters

10. Upload parameters

11. Applications button

Figure 2-38 Applications Screen

Number Operator User

1 Reference:

Information on the administrative characteristics of the installation: name of the site, case
reference, software versions, etc.

2 Region settings

Used to set the user language, the date, the time, the mechanical units used, insert a
customer--specific logo

3 HMI settings:

Used to adjust the screen brightness in standby mode, and the calibration of the touch
panel

4 Restart:

Used to reboot the HMI module

5 Display cleaning:

Used to lock the screen for 20 seconds to allow cleaning without adversely affecting
operation

6

Firmware update:

Used for the software update for the HMI module

7 Screenshot:

Used to take a screenshot to capture the installation at a given moment

8 Ladder tools:

Used to view additional equations

9 Save parameters:

Used to save the parameters of the application onto a USB key

10 Upload parameters:

Used to load parameters from a USB key

X X

X X

X X

X

X X

X

X X

X

X X

X X

Figure 2-39 Screens Accessed from the Applications Screen

TP-7070 7/1842 Section 2 Operation

2.11.1 Reference

1

2

1. Modify key (for data modification in Operator mode only)

2. Scroll up or down as needed

Figure 2-40 Reference Screen

Title

Customer reference

Reference

APM identification

Kohler reference

Reference

Genset serial number

Software version

HMI HMI module firmware version

System HMI module OS version

Base module Base module firmware version

System Base module OS version

Regulation module Regulation module firmware version X179

Description and Possible Settings (or selections)

Customer case name (for example: computer center)

Option of assigning a name to the HMI (for example: GS parking number 1)

Commercial case reference (manufacturer’s side)

Generator set serial number associated with the HMI

33508003101

TP-7070 7/18 43Section 2 Operation

2.11.2 Region Settings

1

3

2

1. Select user language

2. Set the date and time

3. Modify

4. Date and time adjustment window
appears after touching the Modify key

Figure 2-41 Region Settings Screen

Title Description and Possible Settings (or selections)

Pressure

Temperature

Customization

Display Selection of the logo at the top left of the screen

Logo Upload an image in JPEG or PNG format (see below)

Selection of the pressure display: bar, PSI

Selection of the temperature display: _C,_F

4

Adding a logo

1. Press the Modify button. An additional Upload key
appears.

2. On a USB key, create a directory called
E:\apm802\ icon and copy the logo* to be inserted
into the main screen of the HMI.

3. Insert the USB key into the appropriate port and
press the Load key.

4. In the window shown in Figure 2-42, press the
central field, select the desired image and confirm.

5. The image appears next to the Upload key (a
Delete key also appears to delete or replace the
image on the screen).

6. Press on Apply. The logo then appears under the
4--position switch.

The Region settings screen can also be accessed by
touching in the date/time area of the top bar.

Figure 2-42 Selecting the Logo Image File

* The ideal image size for the logo is 170 x 100 pixels.

TP-7070 7/1844 Section 2 Operation

2.11.3 HMI Settings

1. Touch the Modify button

2. Slide to adjust the screen brightness during normal operation

3. Slide to adjust brightness during standby operation

Figure 2-43 HMI settings

The sliders on this screen allow adjustment of the
screen brightness during operation and standby. The
two sliders are independent. However, if the brightness
in operation mode is near the brightness in standby
mode, then the setting of the second follows the first, as
shown. Conversely, if the brightness is increased in
standby mode, the brightness during use also
increases.

1

2

3

Title Description and possible settings (or selections)

Standby mode

Time (min)

Delay before activation of screen standby mode: from 10 to 600 minutes

HMI connectivity

HMI type *

Mode of operation [

Display blue background of locked
button (selector 0/1)

]

Remote HMI number [

Addressing mode [

Eth1 IP address [

Eth1 MAC address [

* Several choices available for the parameter

[ These parameters only appear if Remote has been selected
] This parameter only appears if Remote and Display have been selected

Use of HMI connected to the base module: Local, Remote

Use of HMI for remote mode: Full access, Operation, Visualization

When the selector is at 1, the HMI is connected using the access code (see
section 9.4 -- Identification)

Remote HMI number: from 1 to 50 in a complete power plant, but limited to 9
HMIs for a base module

HMI addressing: System, Customer IP, DHCP

Permanent or temporary identification number for the HMI module connected to
another base or to a network (for example: redundant ring)

Unique permanent physical identification number, which is stored in the HMI
module

TP-7070 7/18 45Section 2 Operation

The Home button on the Remote HMI looks different
than the Home button on the local HMI. See
Figure 2-44.

Local HMI Remote HMI

Figure 2-44 Home Buttons

In the case of a Remote HMI in Visualization mode, the
icons in Figure 2-45 show the various displays of key 2.

the search for base modules connected to the ring is in
progress.

At the end of the search, the IP addresses of the
modules connected to the Ethernet ring are shown (see
Figure 2-46). It is also possible to see whether one of the
connected generator sets has a fault (red indicator).

Figure 2-46 IP Address Display

Select the base module to connect to (in the example,
there is only one generator set). A Connect Generator
#1 button also appears.

Figure 2-45 Remote HMI Indication

In the case of a Remote HMI in Operation mode or in Full
access mode, button 2 does not change appearance.

A remote HMI is connected to the Ethernet ring. When
the Home button is pressed, a pop--up window appears;

Press the Connect Generator #1 button. The window
changes as shown in Figure 2-47.

Press the magnifying glass at the top left-hand of the
screen to start a new search to select another module
connected to the Ethernet ring.

Figure 2-47 Selecting a Module from a Remote HMI

TP-7070 7/1846 Section 2 Operation

2.11.4 Restart

2.11.6 Firmware Update

Press the Restart icon to bring the window shown in
Figure 2-48 to the front. Confirm the restart by pressing
OK, or cancel the procedure by pressing Cancel.

This operation will trigger a complete restart of the HMI
module.

Figure 2-48 Restart Window

2.11.5 Display Cleaning

Before wiping the screen, press the Display cleaning
icon. The window shown in Figure 2-49 appears.

Pressing the Firmware update icon carries out an
update of the HMI firmware.

The update requires that a USB key is inserted into the
port provided on the bottom of the HMI. See
Figure 2-50.

1

1. USB Ports

Figure 2-50 USB Port Location on HMI Module

Firmware Update Procedure

1. Tap the selection field area (Figure 2-51) and
select the desired software version.

The entire screen is disabled for 20 seconds, allowing
you to clean the touch panel.

After 20 seconds, the Applications screen appears
again.

Figure 2-49 Display Cleaning Window

2. Press OK to start the software update operation.

Figure 2-51 Firmware Update Screen

At the end of the update, the HMI will automatically
restart.

For this update operation, the USB key must contain the
following type of directory: E:\apm802\update. The
software versions (or firmware) are of the following type:
IHM_APM802_V1_x_x.z208.

TP-7070 7/18 47Section 2 Operation

Note: The HMI firmware version number must match

the firmware version installed in the base module.

2.11.7 Screenshot

Before taking a screenshot, it is necessary to insert a
USB key in the port provided on the bottom of the HMI
module. See Figure 2-50.

Pressing the Screenshot button enables the screenshot
feature. The screenshot icon turns blue when enabled.
Screenshot mode stays enabled until turned off. Return
to the Applications screen and click on the camera
button to turn off the screenshot mode.

The button shown in Figure 2-52, which symbolizes a
camera, then appears at the top right of the screen.

1

Go into the screen to be copied and press the camera
button. The screenshot is automatically saved to the
USB key in the directory “E:\apm802\screenshot.

Note: During the time it takes to create the screenshot,

the camera button remains blue.

Note: The images are in PNG format. It is not possible

to create a partial screenshot.

1. Camera button

Figure 2-52 Camera Button (for screenshots)

TP-7070 7/1848 Section 2 Operation

2.11.8 Ladder Tools

Ladder is a standardized graphic language which is very
similar to a ladder diagram. Implemented in the base
module of the APM802, it is used to define the PLC
functions required for specific functions.

1

Pressing the Ladder tools icon takes you to the screen
shown in Figure 2-53. See Figure 2-38 for the location
of the Ladder tools icon on the applications screen.

2

1. Network access keys

2. Press one of these button to exit the ladder screen

Figure 2-53 Ladder Screen

To exit the Ladder screen, press the Applications button
or the Home button on the top bar.

Generally speaking, there will be at least 2 networks:

D The inputs network (accessed via the Inputs key)

D The outputs network (accessed via the Outputs key).

Depending on the complexity of the application, there
may be an intermediate network.

The Inputs network defines allthe input equations for the
system. These inputs correspond to the physical inputs
for the base module.

The #1 network defines all the intermediate equations
used for the connection between inputs and outputs.

The Outputs network defines all the output equations for
the system. These outputs correspond to the physical
outputs for the base module. See Figure 2-55.

In all networks, press on the contact or the coil to access
more information.

TP-7070 7/18 49Section 2 Operation

1

5

4

1. Input line title

2. Electrical connection

3. Input internal variable

4. Normally closed contact

5. Input variable

2

3

Figure 2-54 Inputs Network

Figure 2-55 Outputs network

TP-7070 7/1850 Section 2 Operation

2.11.9 Save Parameters

2.11.10 Upload Parameters

1. Insert a USB key into the port on the bottom of the
HMI module. See Figure 2-50.

2. Press on the Save Parameters icon; the screen
shown in Figure 2-56. Saving starts automatically.
When it is completed, the screen confirming that
the save operation was performed successfully
appears.

3. Press on OK to close the window.

Figure 2-56 Save Parameters Windows

An authorized service technician can obtain and load
parameter files following the instructions in the
controller service manual.

Parameter files are specific to the individual generator
set, as identified by the generator set serial number. Do
not attempt to load parameters that have been saved
from a different generator set.

On the USB stick, four files are saved in a directory
called case number:

D Parameters (file *****_params.x208)

D Traceability (file *****_apm_info.i208)

D Events (file *****_events.txt)

D Curve data (file *****_curve_data.csv)

where ***** is: 0_gs1_<genset serial number>_.

TP-7070 7/18 51Section 2 Operation

2.12 Menus

Figure 2-57 shows the architecture of the screens accessible from the Menu button.

Menu >

1--Settings 2--Measurements 3 -- History 4--Diagnostic 5--Configuration 6--Hardware

1.2 2.2 3.1 4.1 5.1 6.1

Power thresholds Mechanical A rchiving Variables Application Installation

1.5 2.3 4.2 5.1.1 6.1.1

Timers * Generator electrical Binary inputs General General

1.6 2.6 4.3 5.1.2 6.1.2

Auxiliaries Harmonics Binary outputs Alarms Generator set

1.8 4.4 5.1.3 6.1.3

Parameters Regulation/Protection Status messages Regulator

4.5 5.1.4 6.1.4

* Not used. Regulation Function key Engine sensor

5.1.5 6.1.5

Custom view-­Visualization

5.1.6 6.2

Custom view -­Parameters

5.1.7 6.2.1

Main screen custom
view

5.1.8 6.2.2

Time slots Resistive inputs

5.1.9 6.2.3

Advanced setpoints Analog inputs

5.1.10 6.2.4

Customer messages Analog outputs

5.2 6.3

Generator Extension

5.2.1 6.3.1

Starting CAN#1 inputs/outputs

5.2.2 6.4

Speed Regulation/Protection

5.2.3 6.4.1

Excitation General

5.2.4 6.4.2

Miscellaneous Regulation modules

5.2.5 6.5

Timers Communication

5.3 6.5.1

Regulation Ethernet

5.3.1 6.5.2

Regulation parameters Serial link

5.3.2

Speed regulation PID

5.3.3

Voltage regulation PID

5.3.4

Synchronization PID

Auxiliaries

Base inputs/outputs

Configurable binary
inputs

inputs/outputs

Figure 2-57 Screen Architecture

TP-7070 7/1852 Section 2 Operation

Menu Access

Some menus are view-only and do not allow
modifications. Some menus require the operator
password to view and/or modify. See Figure 2-58 for
menu access information.

1 -- Settings User Operator *

1.2 Power thresholds View Modify *

1.5 Timers (not used) View Modify *

1.6 Auxiliaries View Modify *

1.8 Parameters View Modify *

2 -- Measurements

2.2 Mechanical View View

2.3 Generator electrical View View

2.6 Harmonics View View

3--History

3.1 Archiving View Modify *

4 -- Diagnosis

4.1 Variables Modify Modify

4.2 Binary Inputs View View

4.3 Binary Outputs View View

4.4 Regulation / protection Modify *

4.5 Regulation Modify *

5 -- Configuration

5.1 Application

5.1.1 General View *

5.1.2 Alarms View *

5.1.3 Status Messages View *

5.1.4 Function Key View *

5.1.5 Custom view--Visualization View *

5.1.6 Custom view--Parameters View *

5.1.7 Main screen custom view View *

5.1.8 Time slots View *

5.1.9 Advanced setpoints View *

5.1.10 Customer messages View *

5.2 Generator

5.2.1 Starting View *

5.2.2 Speed View *

5.2.3 Excitation View *

5.2.4 Miscellaneous View *

5.2.5 Timers View *

5.3 Regulation

5.3.1 Regulation parameters View *

5.3.2 Speed regulation PID View *

5.3.3 Voltage regulation PID View *

5.3.4 Synchronization PID View *

5.4 Protection

5.4.1 Low level View *

5.4.4 Grid View *

6 -- Hardware

6.1 Installation

6.1.1 General View *

6.1.2 Generator View *

6.1.3 Regulator View *

6.1.4 Engine Sensor View *

6.1.5 Auxiliaries View *

6.2 Base inputs/outputs

6.2.1 Configurable binary inputs View *

6.2.2 Resistive inputs View *

6.2.3 Analog inputs View *

6.2.4 Analog outputs View *

6.3 Extension inputs/outputs

6.3.1 CAN inputs/outputs View *

6.4 Regulation/ protection

6.4.1 General View *

6.4.2 Regulation modules View *

6.5 Communication

6.5.1 Ethernet [ Modify *[

6.5.2 Serial link Modify *

* Operator password (1966) is required to view and/or modify

settings.

[ Controller must be in Out of Service mode to modify these

settings.

Figure 2-58 Menu Access

TP-7070 7/18 53Section 2 Operation

2.12.1 Menu 1--Settings

Changing Settings

The 1--Settings menu can be accessed via the key with
the same name.

D 1.2 Power Thresholds

D 1.5 Timers (not used)

D 1.6 Auxiliaries

D 1.8 Parameters

Pressing the Modify button brings up text entry fields for
settings that can be changed. See Figure 2-59.

Pressing in the text entry field brings up the
alphanumeric keypad shown in Figure 2-60.

1

1. Modify button

Figure 2-59 Modify Button

1

2

3

1. All CAPS: All letters in upper case

2. Shift: One letter in upper case

3. Displays the numeric keypad

Figure 2-60 Keypad

#

4

4. Returns to the alphabetical keypad

TP-7070 7/1854 Section 2 Operation

Screen 1.2--Power thresholds

The 1.2--Power thresholds screen is used to set up to 10
active power thresholds. Threshold 9 is used for load
shed.

3

4

1

2

1. Threshold reached = green (in this example, thresholds #1 to #4 are reached or exceeded)

2. Thresholds numbered from 1 to 10

3. Setting the threshold in % of the generator power

4. Display of the threshold setting result in kW

5. Entry field for text

Figure 2-61 Power Thresholds Screen

5

TP-7070 7/18 55Section 2 Operation

Screen 1.6--Auxiliaries

The 1.6--Auxiliaries screen is used to set the auxiliary parameters for the generator set fuel warning levels.

Figure 2-62 Auxiliaries screen

Title Description and possible settings (or selections)

Fuel pumps

Low fuel level fault (%) Low fuel level at which the fault is triggered, expressed as a

Low fuel level warning (%) Low fuel level at which the alarm is triggered, expressed as a

High fuel level warning (%) High fuel level at which the alarm is triggered, expressed as

High fuel level fault (%) High fuel level at which the fault is triggered, expressed as a

percentage

percentage

a percentage

percentage

TP-7070 7/1856 Section 2 Operation

Screen 1.8 Parameters

The 1.8--Parameters screen is used to set the engine speed (RPM). The speed can be adjusted by ±10RPM.

Figure 2-63 Parameters Screen

TP-7070 7/18 57Section 2 Operation

2.12.2 Menu 2--Measurements

The 2--Measurements menu can be accessed via the button with the same name. This gives access to the screens
listed below.

D Screen 2.2 -- Mechanical

D Screen 2.3 -- Generator electrical

D Screen 2.6 -- Harmonics

Note: The measurements menus are view-only; no modifications are possible from these menus.

Screen 2.2--Mechanical

The 2.2--Mechanical screen gives an overview of all the mechanical values for the associated generator.

1

1. Separation of the mechanical values into three categories

Figure 2-64 Mechanical Screen

Note: Other values may be displayed depending on the engine selected in the 6.1.2 generator set screen.

TP-7070 7/1858 Section 2 Operation

Screen 2.3--Generator electrical

The 2.3--Generator electrical screen gives a detailed view of all the electrical values for the associated generator (on
generator HMI only).

1

2

3

1. Display for 3 phases

2. Phase sequence indication : Green = Correct; Red = Inverse; Off = Not Activated

3. Active and reactive energy metering

Figure 2-65 Generator Electrical Screen

TP-7070 7/18 59Section 2 Operation

Screen 2.6--Harmonics

The 2.6--Harmonics screen is used to monitor the change in harmonics in real time on the generator set.

1

2

1. Harmonics

2. Line-to-neutral voltage

3. Current

Figure 2-66 Harmonics Screen

3

TP-7070 7/1860 Section 2 Operation

2.12.3 Menu 3--History

The 3--History menu can be accessed via the key with the same name. It gives access to Screen 3.1 -- Archiving.

Screen 3.1-- Archiving

The 3.1--Archiving screen is used to store certain parameters in the controller’s memory.

1. Press the Initialization button next to an item to reset the history to zero. (Operator login required)

Figure 2-67 Archiving Screen

List of archived parameters:

If the Operator is logged in with their access code or if
the User has entered the code 1966 (access limited to

Energy Meters

D Active energy (in MWh)

D Reactive energy (in Mvarh)

ten minutes), then opposite each parameter,on the right
of the screen, an Initialization button appears. See
Figure 2-67.

Each button is used to reset the parameter concerned to

Operating hours

D Total (in hours)

D In override mode (in hours)

zero or to initialize to a given value.

Starter

D Number of starter attempts

1

TP-7070 7/18 61Section 2 Operation

2.12.4 Menu 4--Diagnosis

Screen 4.1--Variables

The 4--Diagnosis menu can be accessed via the key
with the same name. it gives access to the 5 screens
below:

4.1 -- Variables

4.2 -- Binary inputs

4.3 -- Binary outputs

4.4 -- Regulation & Protection

4.5 -- Regulation

The Diagnosis menu may be used for troubleshooting
by factory service support personnel. Active faults and
events can be viewed using the alarm button or the
Event Log. See Section 2.10 for more information.

1

The 4.1--Variables screen is used to read all the system
variables, regardless of whether these are logic or
analog variables.

When the screen is called up, no value is displayed. The
keypad appears automatically at the bottom of the
screen and is used to enter the name of the variable or
variables to be consulted.

When the variable is a logic variable (values 0 or 1), then
the color red or green [0 (off)=red, 1 (on)=green] is
associated with the status of the variable.

See Figure 2-69 for variable identification.

6

5

4

1. Variable title

2. Entry field for a variable name

3. Virtual keypad

4. Type of variable (see Figure 2-69)

5. Color associated with the variable status. 0 = red; 1 = green

6. Value or status of the variable

Figure 2-68 Variables Screen

2

3

TP-7070 7/1862 Section 2 Operation

Typ e Enter on screen keypad Enter on external keypad Complete write access

Logic input variable %I I I0.0.0

Analog input variable %I I I5.21

Internal variable (input or
output)

Logic output variable %Q Q Q0.0.0

Analog output variable %Q Q

%M M

examples

M3.112

M1.0

M1.1

Figure 2-69 Sample Variable Identification

Refer to the example in Figure 2-68 and the variables listed in Figure 2-70. Other variables and events are shown in
Sections 2.9.4 and 2.10.

Title Color Name State or value

%M3.112 Green Low engine coolant warning 1

%I5.21 Fuel level 4

%M1.0 Red Auto mode 0

%M1.1 Green Manual mode 1

%I0.0.0 Red Input #0 (base module) 0

%Q0.0.0 Red Output #0 (base module) 0

Figure 2-70 Sample Variables Shown in Figure 2-68

TP-7070 7/18 63Section 2 Operation

Screen 4.2--Binary inputs

The 4.2--Binary inputs screen is used to get a quick overview of the following logic states:

D Eighteen binary inputs for the base module

D Eight binary inputs for each remote module connected to the base module

1

Red = Not Active (off)
Green = Active (on)

3

1. Input number (DI A#10 to DI A#18 & DI B#19 to DI B#27)

2. Input status indicators: Red = 0 (input inactive); Green = 1 (input active)

3. Extension I/O module inputs appear here, if equipped

Figure 2-71 Binary Inputs Screen

2

TP-7070 7/1864 Section 2 Operation

Screen 4.3--Binary outputs

The 4.3--Binary outputs screen is used to get a quick overview of the following logic states:

D Eighteen base module outputs

D Four outputs for each extension module connected to the base module

1

Red = Not Active (off)
Green = Active (on)

7

6

1. Output number (DO--#0 to DO--#8 &DO--#9 to DO--#16+ WDG *)

2. Output status indicators: Red = 0 (output inactive); Green = 1 (output active)

3. Number of the remote module (only appears if there is a single remote module)

4. Selection of remote module n+1

5. Output status indicators for optional I/O modules: Red = 0 (output inactive); Green = 1 (output active)

6. Selection of remote module n--1

7. Choice of CAN I/O bus (only appears if there is a single CAN bus )

* The output WDG (Watchdog) cannot be used.

2

3

4

5

Figure 2-72 Binary Outputs Screen

Module #0 is reserved for the optional Manual Key
Switch/Load Shed Module. Outputs #0 through #3
represent loads 1 through 4. When the output is

connected. When an output is activated, the indicator
turns green and the load is shed. See Section 2.6 for
more information about the load shed function.

deactivated, the output indicator is red and the load is

TP-7070 7/18 65Section 2 Operation

Screen 4.4--Regulation & protection

The 4.4--Regulation and protection screen is used to read all the internal variables for the regulation and protection
modules.

1

2

3

1. Entry field for a variable name

2. Value or status of the variable

3. Numeric keypad for entering the variable name

Figure 2-73 Regulation and Protection Screen

The process for entering a regulation or protection variable is the same as for the 4.1--Mapping screen.

By default, the diagnostic table for the regulation and protection variables is already completed with the name of the
current variables.

TP-7070 7/1866 Section 2 Operation

Screen 4.5--Regulation

The 4.5--Regulation screen is used to read all of the internal variables for the regulation modules.

1

2

3

1. Entry field for a variable name

2. Value or status of the variable

3. Regulation status

Figure 2-74 Regulation Screen

The virtual numeric keypad appears after the variable entry field has been pressed.

TP-7070 7/18 67Section 2 Operation

2.12.5 Menus 5 and 6

Except for menu 6.5, communication, menus 5 and 6 are view-only menus that can be seen when logged in as an
operator (1966). The view-only menus are not shown in this document.

2.12.6 Menu 6.5-Communication

Screen 6.5.1 - Ethernet

The 6.5.1-Ethernet screen defines the computer addresses for the Ethernet connections for the base module and the

HMI module.

Figure 2-75 Ethernet Screen

The screen is accessible for modification at the operator level, but only for the TCP/IP configuration section.

Group Title Description and Possible Settings

TCP/IP
Settings

Fault Finding Base - Eth3/4 IP address * ] Permanent or temporary identification number for the base module

* IP = Internet Protocol; MAC = Media Access Control.

[ Eth1 = Ethernet port marked 1 at the rear of the HMI module
] Eth3/4 = Ethernet ports marked 3 or 4 on the front of the base module
w DHCP: the DHCP protocol (Dynamic Host Configuration Protocol) allows an APM system to connect to a network, which dynamically

assigns it an IP address

Addressing mode * Choice of address type for the TCP/IP connection: System, Customer

IP, or DHCP.

DNS server IP address of the DNS server. The DNS server is used to make the

connection between an APM802 system and an IP address.

connected to another base or to a mains.

Base - Eth3/4 MAC address * ] Unique permanent physical identification number, which is stored in

the base module.

HMI - Eth1 IP address * [ Permanent or temporary identification number for the HMI module

connected to another base or to a mains.

HMI - Eth1 MAC address * [ Unique permanent physical identification number, which is stored in

the HMI module.

HMI - Eth2 IP address Not used.

w

Figure 2-76 Ethernet Settings

TP-7070 7/1868 Section 2 Operation

Screen 6.5.2-Serial link

The 6.5.2-Serial link screen defines the specifications of the RS485 type serial link available on the base module.

Figure 2-77 Serial Link Screen

The screen is accessible for modification at the operator level. Figure 2-78 shows the range of possible settings and
the factory default settings, which are configured for communication with the RSA III remote serial annunciator.

Group Parameter Description and Possible Settings Factory Settings

Configuration Speed (baud rate) * Communication speed: 9600, 19200, 38400, or

57600

Stop bits 1or2 1

Parity Without, odd, or even Without

Modbus [ Activation (0/1 selector) Set to 1 to activate the slave Modbus function 1 (Modbus slave)

Slave number Choice of sub-system number (address) on the

RS-485 serial network: from 1 to 255 (only appears if
the activation selector is set to 1)

* Baud rate= unit of measurement for the number of symbols transmitted per second
[ Modbus is a communication protocol. It is formed of frames containing the address of the PLC in question, the function to be processed

(read only, write access), the data, and the verification code called the cyclic redundancy check.

19200

1 (must match
connected genset
address on the RSA III)

Figure 2-78 Serial Communication Settings

TP-7070 7/18 69Section 2 Operation

Notes

TP-7070 7/1870 Section 2 Operation

Section 3 Scheduled Maintenance

3.1 Introduction

This section deals with general maintenance of the
generator set and accessories. This section may refer to
other literature for procedures and additional
information.

Refer to Appendix B, Operating Hour Service Log for a
means to document maintenance.

Note: Have maintenance work, including battery

service, performed by appropriately skilled and
suitably trained maintenance personnel familiar
with generator set operation and service.

WARNING

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the
generator set as follows: (1) Shut down the generator set. (2)
Place the controller in Out of Service mode. (3) Press the
emergency stop button. (4) Disconnect the power to the
battery charger, if equipped. (5) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.

WARNING

Hot engine and exhaust system.
Can cause severe injury or death.

Do not work on the generator set until
it cools.

Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The

engine and exhaust system components become extremely
hot during operation.

DANGER

Hazardous voltage. Moving parts.
Will cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Servicing the generator set when it is operating. Exposed
moving parts will cause severe injury or death. Keep

hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.

TP-7070 7/18 71Section 3 Scheduled Maintenance

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

Use extreme care when handling,
storing, and using fuels.

WARNING

Hot coolant and steam.
Can cause severe injury or death.

Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

The fuel system. Explosive fuel vapors can cause severe
injury or death. Vaporized fuels are highly explosive. Use

extreme care when handling and storing fuels. Store fuels in a
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit
flames or sparks to occur near sources of spilled fuel or fuel
vapors. Keep the fuel lines and connections tight and in good
condition. Do not replace flexiblefuel lines with rigid lines. Use
flexible sections to avoid fuel line breakage caused by
vibration. Do not operate the generator set in the presence of
fuel leaks, fuel accumulation, or sparks. Repair fuel systems
before resuming generator set operation.

Draining the fuel system. Explosive fuel vapors can
cause severe injury or death. Spilled fuel can cause an

explosion. Use a container to catch fuel when draining the fuel
system. Wipe up s pilled fuel after draining the system.

WARNING

Hot engine and exhaust system.
Can cause severe injury or death.

Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick
cloth and then slowly turn the cap counterclockwise to
the first stop. Remove the cap after pressure has been
completely released and the engine has cooled. Check
the coolant level at the tank if the generator set has a
coolant recovery tank.

CAUTION

Hot surfaces.

Servicing the alternator. Hot parts can cause severe
injury or death. Avoid touching the alternator field or exciter

armature. When shorted, the alternator field and exciter
armature become hot enough to cause severe burns.

WARNING

Do not work on the generator set until
it cools.

Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The

engine and exhaust system components become extremely
hot during operation.

Risk of fire.
Can cause severe injury or death.

Servicing the fuel system. A flash fire can cause severe
injury or death. Do not smoke or permit flames or sparks near

the fuel injection system, fuel line, fuel filter, fuel pump, or other
potential sources of spilled fuels or fuel vapors. Catch fuels in
an approved container when removing the fuel line or fuel
system.

Combustible materials. A fire can cause severe injury or
death. If using generator heaters during storage, remove

combustible materials such as covers from contact with the
heater or from areas where heat could potentially cause a fire.

TP-7070 7/1872 Section 3 Scheduled Maintenance

WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.

Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.

WARNING

Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.

Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid
can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety
goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If
battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of
clean water. Seek immediate medical aid in the case of eye
contact. Never add acid to a battery after placing the battery in
service, as this may result in hazardous spattering of battery
acid.

Battery acid cleanup. Battery acid can cause severe
injury or death. Battery acid is electrically conductive and

corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
soda) to a container with4L(1gal.)ofwaterandmixthe
neutralizing solution. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke

or permit flames or sparks to occur near a battery at any time,
particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or

equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the
battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
starter solenoid. Do not test the battery condition by shorting
the terminals together.

TP-7070 7/18 73Section 3 Scheduled Maintenance

3.2 Service Schedule

refer to the Engine Operation Manual or contact an

authorized distributor/dealer. If the schedule is not
Engine maintenance intervals and procedures may vary
for different engine models, types, and applications. For
tasks marked with the symbol

System—Component Visually Inspect Check Change Clean Test Interval

Fuel System

Day tank level X X Weekly

Prefilter(s)

Main Filter(s)

Flexible lines and connections X R Weekly

Fuel level switch X X Weekly

Fuel piping X Yearly

Main tank supply level X Weekly

Tank vents and return lines for obstructions X Yearly

Water in system, remove

Lubrication System

Oil level

Oil analysis

Change oil and oil filter elements

Centrifugal oil filter

Crankcase breather filter(s)

Crankcase breather belt (KD800--KD1000)
and oil separator filter insert

Cooling System

Air cleaner to room/enclosure * X Weekly

Air ducts, louvers X X Yearly

Block heater operation X Weekly

Coolant level

Coolant temperature

Coolant analysis

Coolant, replace

Fan belt(s)

Fan bearing lubrication (KD2000--KD3250) X 500 Hrs.

Flexible hoses and connectors X X Weekly

Louver motors and controls X X X Yearly

Radiator exterior X Yearly

Water pump(s)

Water pump and alternator belts

Exhaust System

Drain condensate trap X Weekly

Excessive back pressure X Yearly

Flexible connector(s) X 6 Months

Hangers and supports X Yearly

Insulation, fire hazards X Quarterly

Leakage X X Weekly

APM802 Controller

Battery ]

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow this

service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
XAction

* Service more frequently if operated in dusty areas.

] Service m ust be performed by an authorized Kohler service representative.

D in the service schedule,

included in the Engine Operation Manual, follow the
service schedule in Section 3.2. Some items in the list
may not apply to all generator sets.

Action

2 Years or 500 Hrs.

2 Years or 1000 Hrs.

See Section 3.6 and

the Engine O/M

Quarterly

2 Years or 1000 Hrs.

D

6 Months

See the Engine O/M

4 Years or 6000 Hrs.

Weekly

Weekly

Weekly

Weekly

D D

D

D D

D D

D
D D

D
D

D D

D

D

D

D

D

D

R Yearly or 500 Hrs.

R 2 Years or 2000 Hrs.

R Every 3 Years

TP-7070 7/1874 Section 3 Scheduled Maintenance

Service Schedule, continued

Action

System—Component Visually Inspect Check Change Clean Test Interval

DC Electrical System

Battery charger operation, charge rate X Monthly

Battery electrolyte level (not necessary with AGM
batteries)

Battery specific gravity, charge state (not necesary with
AGM batteries)

Clean and tighten battery terminals X X Quarterly

Recharge after engine start X Monthly

Remove corrosion, clean and dry battery and rack X X Monthly

Tighten DC electrical connections X 6 Months

AC Electrical System

General Inspection X Weekly
Circuit breakers, fuses[

Safety and alarm operation X X 6 Months

Tighten control and power wiring connections X Yearly
Transfer switch main c ontacts[

Wire abrasions where subject to motion X X Quarterly

Wire-cable insulation breakdown X X 3 Years or 500 Hrs.

Engine and Mounting

General inspection

Air cleaner service

Bolt torque

Lines and hoses

Injector pump, fuel lines, and injectors

Valve clearance

Viscous damper

Turbocharger

Water pump

Remote Control System, etc.

Compartment condition X X Weekly

Remote control X Monthly

Run generator set X Monthly

Alternator

General inspection X Weekly
Bearing condition ] ] ] ]
Exciter ] ] ] ]
Rotor and stator ] ] ]
Voltage regulator ] ] ] ]

Measure and record resistance readings of windings
with insulation tester (Meggerr, with SCR assembly or
rectifier disconnected) ]

Blow dust out of alternator*] ] ]

General Condition of Equipment

Any condition of vibration, leakage, unusual noise,
excessive temperature, damage, or deterioration

Ensure that system is set for automatic operation X Weekly

Interior of equipment room or outdoor weather housing X X Weekly

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow this

service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action.

* Service more frequently if operated in dusty areas.

[ Do not break manufacturer’s seals or internally inspect these devices.
] Alternator service must be performed by an authorized Kohler service representative.

X X R X X Monthly

X X Yearly

D

D

D D

X X X Weekly

X Monthly

X Monthly

Weekly

D D
D D

R 4 Years or 2000 Hrs.

D D D

D

D

D D

2 Years or 3000 Hrs.

3 Years or 500 Hrs.

2000 Hrs.

See the Engine O/M.

]

Yearly

Yearly

Yearly

Yearly

Yearly

2Years

Meggerr is a registered trademark of Biddle Instruments.

TP-7070 7/18 75Section 3 Scheduled Maintenance

3.3 APM802 Controller
Maintenance

The APM802 controller uses two BR2032 internal
batteries in the controller base module and HMI to
preserve the time, date, and generator set events. If
battery power is low, an alarm, M3.212 APM INTERNAL
BATTERY WARNING, appears on the controller. Have
an authorized Kohler service representative service the
controller.

3.4 Engine Maintenance

3.5 Diesel Fuel Systems

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

Use extreme care when handling,
storing, and using fuels.

Regular engine maintenance is essential. Perform
engine maintenance at the intervals specified in the
engine operation and maintenance manuals. Contact
an authorized service distributor/dealer to obtain engine
literature. Refer to the engine operation manual for the
following:

D Engine operation

D Engine maintenance schedules (can vary depending

on engine application)

D Engine maintenance procedures

D Fuel, lubricant, and coolant specifications

The fuel system. Explosive fuel vapors can cause severe
injury or death. Vaporized fuels are highly explosive. Use

extreme care when handling and storing fuels. Store fuels in a
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit
flames or sparks to occur near sources of spilled fuel or fuel
vapors. Keep the fuel lines and connections tight and in good
condition. Do not replace flexiblefuel lines with rigid lines. Use
flexible sections to avoid fuel line breakage caused by
vibration. Do not operate the generator set in the presence of
fuel leaks, fuel accumulation, or sparks. Repair fuel systems
before resuming generator set operation.

Draining the fuel system. Explosive fuel vapors can
cause severe injury or death. Spilled fuel can cause an

explosion. Use a container to catch fuel when draining the fuel
system. Wipe up s pilled fuel after draining the system.

TP-7070 7/1876 Section 3 Scheduled Maintenance

3.5.1 Fuel/Water Separator

Fuel/water separators (fuel prefilters) ensure clean fuel
is delivered to the engine by removing contaminants
and water. Providing clean fuel prevents clogged
injectors and allows the engine to run more efficiently. In
a fuel/water separator, water collects in the lower cavity
of the filter.

1

2

3

4

Periodically, the water must be checked and drained
and the filter must be changed. A sensor on the
fuel/water separator indicates when the collected water
needs to be drained. Refer to the engine operation
manual for scheduled maintenance and procedures.

Draining the water

To drain the water from the fuel/water separator, use the
following procedure:

1. Read and follow the safety precautions in
Section 3.1.

2. Before working on the generator set or connected
equipment, remove the generator set from service.
Refer to the safety precautions for preventing
accidental starts and disabling the generator set.

a. Remove the load from the generator set.

b. Shut down the generator set.

c. Place the generator set controller into

Out-of-Service mode and press the
emergency stop button.

1. Fuel outlet hose

2. Manual primer pump

3. Vent plug (optional restriction
gauge installs here)

4. Fuel inlet hose

5. Filter element

6. Water collection bowl

7. Water-in-fuel sensor

8. Manually operated drain

8

5

6

7

10501000200

Figure 3-1 Fuel/Water Separator

Replacing the filter element

At the interval specified in the service schedule, replace
the fuel/water separator element. Have a suitable
container with the required capacity ready.

1. Read and follow the safety precautions in
Section 3.1.

2. Before working on the generator set or connected
equipment, remove the generator set from service.
Refer to the safety precautions for preventing
accidental starts and disabling the generator set.

a. Remove the load from the generator set.

d. Disconnect the power to the battery charger.

e. Remove the battery cables negative (--) lead

first to disable the generator set.

3. Hold a suitable container beneath the fuel/water
separator.

4. Open the vent plug and the manually operated
drain.

5. See Figure 3-1. Close the drain when fuel (free of
water) flows from the fuel/water separator.

6. Use the manual primer pump to prime the filter until
fuel flows from the vent plug.

7. Close the vent plug.

Note: If the fuel/water separator will not stay primed,

check that the vent plug, drain, filter element,
water collection bowl, and fuel lines are securely
tightened and verify that fuel flow is unobstructed.

b. Shut down the generator set.

c. Place the generator set controller into

Out-of-Service mode and press the
emergency stop button.

d. Disconnect the power to the battery charger.

e. Remove the battery cables negative (--) lead

first to disable the generator set.

3. Make sure engine is off and cool to the touch.

4. If a fuel shut-off valve is present, close the fuel
shut-off valve at the nearest point to the fuel/water
separator inlet or at the fuel tank.

5. Disconnect the fuel-in-water sensor.

6. Open the vent plug on the mounting head. See
Figure 3-1.

TP-7070 7/18 77Section 3 Scheduled Maintenance

7. Remove the water drain plug (or push up the drain
valve) and allow water and fuel to flow into a
suitable container.

Note: Depending upon the location of the fuel

valve, a considerable amount of fuel may
drain out.

8. Remove the separator’s element from the
mounting head by twisting in a counterclockwise
direction.

9. Remove the bowl from the fuel/water separator
element. Wipe the excess fuel from the bowl and
the O--ring. Do not discard the bowl or O--ring.

10. Inspect the components for wear or damage.
Replace parts as necessary.

11. Lubricate the O--ring with clean diesel fuel and
replace it in the bowl.

12. Install the bowl onto a new fuel/water separator
filter element.

13. Lubricate the bowl/element assembly with clean
fuel. Install the bowl/element onto the filter
mounting head.

14. Replace the water drain plug (if removed).

3.5.2 Manual Primer Pump

The manual primer pump, located on the fuel/water
separator, allows the operator to pump fuel through the
fuel system without cranking the engine. Prime the fuel
system under the following conditions:

D Before starting the engine for the first time

D After running out of fuel and adding fuel to the tank

D After fuel system maintenance such as changing the

fuel filter, draining the fuel/water separator, or
replacing a fuel system component

The manual primer pump is actuated by pressing down
on the primer pump.

1

2

1. Manual primer pump

2. Vent plug

10501000200

15. Connect the fuel-in-water sensor.

16. Open the fuel shut-off valve.

17. Use the manual primer pump to prime the filter until
fuel flows from the vent plug.

18. Close the vent plug.

Note: If the fuel/water separator will not stay primed,

check that the vent plug, drain, filter element,
water collection bowl, and fuel lines are securely
tightened and verify that fuel flow is unobstructed.

Figure 3-2 Manual Primer Pump

To bleed air from the fuel system, see Section 3.5.3.

TP-7070 7/1878 Section 3 Scheduled Maintenance

3.5.3 Bleeding Air from Fuel System

Trapped air in the fuel system causes difficult starting
and/or erratic engine operation. The fuel system uses
an automatic bleed line which allows fuel and air to flow
back to the tank. To bleed the fuel line, crank the engine
and allow the fuel to circulate through the system for
approximately 5 minutes. After an initial rough start, the
fuel line should be bled.

Refer to the safety precautions for preventing
accidental starts and disabling the generator set.

a. Remove the load from the generator set.

b. Shut down the generator set.

c. Place the generator set controller into

Out-of-Service mode and press the
emergency stop button.

3.5.4 Restriction Gauge (if equipped)

The fuel/water restriction gauge mounts to the fuel water
separator head in the vent plug port. This gauge helps
determine the filter element change interval for the
fuel/water separator and allows visual monitoring of the
filter condition.

The restriction gauge monitors fuel flow and
continuously displays restriction readings indicated as
vacuum. Increased restriction indicates a clogged
fuel/water separator element.

As the filter getsdirty, a yellow plunger moves toward the
red service area on the indicator. To reset the indicator,
simply press the button on the top. See Figure 3-3.

1

2

1. Reset button

2. Restriction gauge

d. Disconnect the power to the battery charger.

e. Remove the battery cables negative (--) lead

first to disable the generator set.

3. If a fuel shut-off valve is present, close the fuel
shut-off valve at the nearest point to the fuel/water
separator inlet or at the fuel tank.

4. Coat the the threads and O-ring with motor oil
before installation.

Note: Do not use thread tapes. Loose particles

could work their way into the fuel system.

5. Thread the restriction gauge into the vent plug port
on the fuel/water separator. See Figure 3-4. Use a
16 mm wrench to install or remove the restriction
gauge (do not tighten by hand).

6. Open the fuel shut-off valve when the installation is
complete.

1

2

Figure 3-3 Restriction gauge

To install the restriction gauge, use the following
instructions.

1. Read and follow the safety precautions at the
beginning of the section.

2. Before working on the generator set or connected
equipment, remove the generator set from service.

TP-7070 7/18 79Section 3 Scheduled Maintenance

1. Manual primer pump

2. Vent plug

10501000200

Figure 3-4 Vent Plug Port

3.6 Lubrication System

3.6.1 Oil Change

The engine oil change interval varies for different
engines, applications, and oil type. Identify the following
for your application and then refer to the Engine
Operation and Maintenance Manual for oil change
intervals and oil specifications.

D Engine model. See the engine nameplate or the

generator set specification sheet to identify the
engine.

3.6.2 Automatic Oil Replenishment
System (Optional Kit)

6

5

4

3

2

1

7

D Engine oil type (category 1, 2, 3). See the engine

Operation Manual for definitions.

D Generator set engine type (fuel-optimized or

emission-optimized). Generator set models with a -F
in the model designation are fuel-optimized.

D Generator set application (standby, prime, or

continuous).

Note: Change both the oil filters and centrifugal oil filter

(if applicable) during the oil change.

8

10404000145-KA

1. Shutoff valve

2. Regulator supply line
(inlet port)

3. Shutoff valve

4. Oil level regulator

9

5. Sight glass

6. Bracket

7. Vent line

8. Oil pan

9. Engine supply line

Figure 3-5 Automatic Oil Replenishment System

The oil replenishment system typically works with an oil
reservoir to maintain a constant oil level in the engine
crankcase. As the oil level in the crankcase drops, the
valve inside the oil level regulator opens to supply fresh
oil from the oil reservoir.

Note: The pressure-equalizing vent line between the oil

regulator and the engine prevents positive or
negative crankcase pressure.

Adjusting the oil level regulator position

The oil level regulator can be adjusted by changing the
positioning of the regulator on the mounting bracket.
Use the following procedure:

Note: If the oil level regulator runs continuously, lower

the oil level regulator position approximately
10 mm (3/8 in.) on the bracket to prevent the
excess use of oil.

1. Start the engine and allow the oil level to stabilize.

2. Check the oil level on the dipstick. If the oil level is
low, adjust the regulator higher on the bracket to
allow more oil into the crankcase. If the oil level is
above the full line on the regulator,drain the excess
oil out of the crankcase and move the regulator
down on the bracket.

3. Repeat until desired running oil level is achieved.

TP-7070 7/1880 Section 3 Scheduled Maintenance

3.6.3 Oil Analysis

Sampling Point

The engine oil analysis interval varies for different
engines, applications, and oil types. Refer to the Engine
Operation and Maintenance Manual for oil analysis
intervals.

Follow the procedures and recommendations in this
section to ensure that samples provide a good
representation of the engine oil condition. Always use
the same procedure for oil sampling to allow reliable
comparisons.

In extreme conditions, perform the oil analysis more
frequently. For example:

D In extreme climates

D When the generator set is subject to repeated starts

D When the engine is running for a long time on low load

D If there is high sulphur content in the fuel (from 0.5 to

1.5% by weight)

Some signs that the o il is no longer carrying out its
function may include:

D Unusually large deposits or precipitations on the

inside of the engine and its components such as
filters, centrifuges or separators, in particular when
compared with the previous analysis

D Unusual discoloration of components

As a precaution, also send a bottle containing a new oil
sample which will serve as a reference point for the
analysis of the used oil.

Sampling is carried out at a representative point in the
system, preferably just after the machine is shut down.

D Always sample at the designated sampling point(s).

See the engine Operation Manual for the
recommended sampling point.

D Failing this, sample via the dipstick well with a syringe

and flexible hose.

D As a last resort, sample directly from the sump drain

point after draining the dirty fluid at the bottom of the
sump.

Preparation of Sampling Point

In order to avoid contaminating the sample:

D Carefully clean the sampling point and the sampling

equipment before each sample is taken and before
opening the system.

D If possible, avoid environmental disturbances when

taking the sample (wind, dust, rain,...).

The laboratory-supplied bottle should be filled to 3/4 full.
In the absence of a laboratory-supplied bottle, make
sure there is a minimum amount of 125 ml (4.3 oz.).

Use an appropriately labeled and cleaned bottle. Some
important points to note during sampling are:

D Oil brand and type

D Sampling date

D Equipment type and serial number

D Operating hours since commissioning (startup)

D Operating hours since oil change

D Sampling type: during draining or during a sampling

D If oil was added (topped up) since the last oil change,

indicate how many liters (quarts) were added.

D Interventions carried out

TP-7070 7/18 81Section 3 Scheduled Maintenance

Sampling Methods

Recommended Tests

Method 1: Sampling with a Syringe

1. Read and follow the safety precautions in
Section 3.1.

2. Connect a flexible hose to the syringe.

3. Insert the other end of the hose into the dipstick
well, taking care not to reach the bottom of the
sump.

4. Draw the oil into the syringe until it is completely
filled..

5. Once the syringe is full, remove the hose, empty
the syringe into the bottle and seal it as soon as
possible.

6. If necessary, repeat the operation until the bottle is
3/4 full.

7. Close the bottle by tightly screwing the cap and
check the information on the label.

Method 2: Sampling at the Drainage Point

This method can be used by adapting the periodic
draining of the oil sump.

1. Read and follow the safety precautions in
Section 3.1.

2. Place a basin under the drain point.

3. Open the drain point.

4. Allow a little oil to flow out before collecting the
sample.

5. Fill the bottle tightly to 3/4 full.

6. Close the bottle by tightly screwing the cap and
check the information on the label.

7. Close the drain point.

8. Top up the engine oil if necessary.

The recommended tests for the analysis are shown in
Figure 3-6 and Figure 3-7.

Spectrometric Analysis (wear) Units

Iron (Fe) DIN 51399-1:2012-5 mg/kg

Chromium (Cr) DIN 51399-1:2012-5 mg/kg

Tin (Sn) DIN 51399-1:2012-5 mg/kg

Aluminum (Al) DIN 51399-1:2012-5 mg/kg

Nickel (Ni) DIN 51399-1:2012-5 mg/kg

Copper (Cu) DIN 51399-1:2012-5 mg/kg

Lead (Pb) DIN 51399-1:2012-5 mg/kg

Molybdenum (Mo) DIN 51399-1:2012-5 mg/kg

PQ Index

Impurities

Silicon (Si) DIN 51399-1:2012-5 mg/kg

Potassium (K) DIN 51399-1:2012-5 mg/kg

Sodium (Na) DIN 51399-1:2012-5 mg/kg

Water DIN 51,451 %

Glycol DIN 51375-1 %

Vegetable oil DIN 51639-4:2010-02 %

Diesel fuel DIN 51375-1 %

Biodiesel DIN 51375-1 %

Soot DIN 51452 %

Figure 3-6 Oil Spectrometric Analysis

Physical parameters Units

Viscosity at 40_C DIN 51562 mm2/s

Viscosity at 100_C DIN 51562 mm2/s

Viscosity Index (VI) calc.

Oxidation DIN 51451, DIN 51453 A/cm

Nitration DIN 51451, DIN 51453 A/cm

Salvation DIN 51451, DIN 51453 A/cm

Dirt moving capability %

TBN (total base number) DIN ISO 3771 mgKOH/g

TAN (total acid number) DIN E N 12634-1999-02 mgKOH/g

pH

Additives

Calcium (Ca) DIN 51399-1:2012-5 mg/kg

Magnesium (Mg) DIN 51399-1:2012-5 mg/kg

Boron (B) DIN 51399-1:2012-5 mg/kg

Zinc (Zn) DIN 51399-1:2012-5 mg/kg

Phosphorous (P) DIN 51399-1:2012-5 mg/kg

Barium (Ba) DIN 51399-1:2012-5 mg/kg

Molybdenum (Mo) DIN 51399-1:2012-5 mg/kg

Sulphur (S) DIN 51399-1:2012-5 mg/kg

Figure 3-7 Oil Physical Parameters

TP-7070 7/1882 Section 3 Scheduled Maintenance

3.7 Air Cleaner System

4. For heavy-duty filters:

The air cleaner requires periodic maintenance. See the
maintenance schedule. A dusty environment or
conditions may require the use of a heavy duty air filter
and/or more frequent maintenance.

3.7.1 Air Filter Element

Follow this procedure to replace the air filter element for
standard-duty and heavy-duty air filters.

1. Read and follow the safety precautions at the
beginning of the section.

2. Before working on the generator set or connected
equipment, remove the generator set from service.
Refer to the safety precautions for preventing
accidental starts and disabling the generator set.

a. Remove the load from the generator set.

b. Shut down the generator set.

c. Place the generator set controller into

Out-of-Service mode and press the
emergency stop button.

d. Disconnect the power to the battery charger.

a. Release the cover clips (KD2000--KD2500) or

remove the wingnut (KD2800--KD3250) and
remove the cover. See Figure 3-9.

b. Remove the filter element.

c. Clean the internal components with a damp

cloth.

d. Install the new element.

e. Replace the cover. For models

KD2000--KD2500, point the dust ejector on the
cover downward. See Figure 3-9.

1

1. Filter element

2. Cover

3. Dust ejector

Figure 3-9 Heavy-Duty Air Filter

(KD2000--KD2500 shown)

2

3

e. Remove the battery cables negative (--) lead

first to disable the generator set.

3. For standard-duty filters:

a. Loosen the filter clamp and remove the filter

element from the air intake elbow.

b. Replace the filter and tighten the filter clamp.

1. Filter element

2. Clamp

3. Air intake elbow

Figure 3-8 Standard Air Filter

3.7.2 Air Cleaner Restrictor Indicator (if
equipped)

The air cleaner restriction gauge mounted on the air
cleaner(s) helps determine the air cleaner change
interval.

The air cleaner restriction gauge monitors air flow and
continuously displays restriction readings indicated as

1

2

3

vacuum (see Figure 3-10). Increased restriction
indicates a clogged air cleaner element.

As maximum allowable restriction is reached, the gauge
window turns red indicating the air cleaner element
needs replacement. To reset the gauge, push the gauge
top down and release.

1

3

1. Push down to reset 2. Display 3. Gauge window

10
15
19
22
25

2

273113

TP-7070 7/18 83Section 3 Scheduled Maintenance

Figure 3-10 Restriction Indicators (styles vary)

3.8 Cooling System

KD series generator sets in the range of 800--2500 kW
use two-slab radiators with a multi--core construction
and expansion tanks. The multi-core construction
allows the isolation of cooling circuits and improves the
serviceability of the product.

KD series generator sets in the range of 2800 kW and
above use a two-slab, single core radiator construction.

Note: Engine damage. Bleed the air from the cooling

system to prevent overheating and subsequent
engine damage.

Note: Block heater damage. The block heater will fail if

the energized heater element is not immersed in
coolant. Fill the cooling system before turning on
the block heater. Run the engine until it is warm,
and refill the radiator to purge the air from the
system before energizing the block heater.

3.8.1 Coolant System Safety

WARNING

DANGER

Hazardous voltage. Moving parts.
Will cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Servicing the generator set when it is operating. Exposed
moving parts will cause severe injury or death. Keep

hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.

WARNING

Accidental starting.
Can cause severe injury or death.

Hot coolant and steam.
Can cause severe injury or death.

Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick
cloth and then slowly turn the cap counterclockwise to
the first stop. Remove the cap after pressure has been
completely released and the engine has cooled. Check
the coolant level at the tank if the generator set has a
coolant recovery tank.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the
generator set as follows: (1) Shut down the generator set. (2)
Place the controller in Out of Service mode. (3) Press the
emergency stop button. (4) Disconnect the power to the
battery charger, if equipped. (5) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.

TP-7070 7/1884 Section 3 Scheduled Maintenance

3.8.2 Coolant Level Check

Check the coolant level in the coolant expansion tank.
Maintain the coolant level between the high and low
marks on the radiator sight glass.

3.8.3 Cooling System Component
Inspection

To prevent generator set shutdown or damage caused
by overheating:

D Keep the cooling air inlets clean and unobstructed.

3.8.4 Procedure to Drain Cooling
System

For optimum protection, drain, flush, and refill the
cooling system at the intervals listed in the service
schedule.

Note: Dispose of all waste materials (oil, fuel, coolant,

filters, and gaskets) in an environmentally safe
manner.

1. Read and follow the safety precautions in
Sections 3.1 and 3.8.1.

D Inspect the radiator’s exterior for obstructions.

Remove dirt and foreign material using a soft brush or
cloth to avoid damaging the radiator fins.

D Check the hoses and connections for leaks. Replace

any cracked, frayed, or spongy hoses.

D Check the condition and tension of the radiator fan

and water pump belt(s). Follow the belt tension
procedure in this manual and/or the engine operation
manual.

D Check thepressure cap seal and replace a cracked or

deteriorated cap. Remove dirt and other debris from
the pressure cap and filler neck. The pressure cap
raises the boiling point of the coolant, enabling higher
operating temperatures. Replace a leaking pressure
cap with one rated for the same p ressure. The
pressure cap rating usually appears on the pressure
cap.

2. Allow the engine to cool.

3. Deenergize the block heater, if equipped.

4. Remove the pressure cap to allow the entire
system to drain and prevent air pockets from
restricting coolant flow through the engine block.

5. Open the radiator and/or engine block coolant
drain valve(s) and allow the system to drain.

Note: The drain valve(s) are typically located

along the bottom of the skid. See
Figure 3-11.Models KD2000--KD3250 have
two drains, one for each coolant circuit, on
the skid plus a drain valve for each coolant
tube. See Figure 3-12.

TP-7070 7/18 85Section 3 Scheduled Maintenance

1

1. Radiator drain valve (typical)

Figure 3-11 Radiator Drain Valve, Typical

KD800--KD1750

3.8.5 Procedure to Flush and Clean
Cooling System

Use the instructions in the engine operation manual
when available to flush and clean the cooling system.
Otherwise, use the following procedure and the cooling
system cleaner manufacturer’s instructions.

1. Flush the cooling system with clean water.

2. If the inside of the radiator still has mineral
deposits, use a radiator cleaner to remove the

2

remaining deposits following the manufacturer’s
instructions.

1

1. Drain valve for high and low temperature cooling circuits

2. Drain valve for hoses

Figure 3-12 Radiator Drain Valves, KD2000--KD3250

6. On models KD2000--KD3250, use the engine
drainage ports to drain coolant from the high
temperature and low temperature water pumps
and the oil cooler. See Figure 3-13.

2

1

3. Drain, clean, and flush the coolant expansion tank.

1. Water pump port, low temperature

2. Oil cooler port

3. Water pump port, high temperature

Figure 3-13 Engine Drainage Ports,

KD2000--KD2500 Shown

7. If the inside of the radiator has mineral deposits or
the used coolant contains dirt or grease, refer to
Section 3.8.5, Procedure to Flush and Clean the
Cooling System. If the cooling system does not
have mineral deposits, go to Section 3.8.6,
Procedure to Refill the Cooling System.

3

TP-7070 7/1886 Section 3 Scheduled Maintenance

3.8.6 Procedure to Refill Cooling
System

6. Leave the radiator cap off and run for 5 minutes
with no load.

See the generator set spec sheet for coolant capacity.

Note: Do not add coolant to a hot engine. Adding

coolant to a hot engine can cause the cylinder
block or cylinder head to crack. Wait until the
engine has cooled.

1. Remove the pressure cap.

2. Close the radiator and/or engine block coolant
drain valve(s) and tighten the cooling system hose
clamps.

3. Fill the cooling system with the recommended
coolant/antifreeze mixture based on the engine
manufacturer’s recommendation.

4. Fill the coolant expansion tank to the middle of the
sight glass.

5. For models KD2000-- KD3250, use the manual
engine venting ports to bleed trapped air from the
system. Refer to the engine operation manual for
the venting locations on the water pumps,
thermostat housing, and engine block. See
Figure 3-14.

7. Stop the engine and allow it to cool.

8. Check and repair any coolant leaks.

9. Add coolant to bring the coolant level to just below
the overflow tube opening of the filler neck.

10. Replace the pressure cap.

11. Operate generator set until the thermostat opens
when the upper cooling system hose warms.

12. Maintain the coolant level in the coolant expansion
tank between the high and low marks.

Air pockets often form in the engine water jacket
when the coolant system is refilled. Check the
coolant level in the coolant expansion tank after
each generator set operation and add coolant as
necessary until the coolant level stabilizes. Then
check the coolant at the interval specified in the
service schedule.

13. Reenergize the block heater, if equipped.

Note: To open the venting ports, thread the venting

tool into the port.

1

1. Manual engine venting ports, typical

Figure 3-14 Engine Coolant Venting or Bleeding,

KD2000--KD3250

TP-7070 7/18 87Section 3 Scheduled Maintenance

3.8.7 Coolan t Analysis

The coolant analysis interval varies for different
engines, applications, and oil types. Refer to the Engine
Operation and Maintenance Manual for coolant analysis
intervals.

Follow the procedures and recommendations in this
section to ensure that samples provide a good
representation of the coolant condition. Always use the
same procedure for coolant sampling to allow reliable
comparisons.

D If there are no other accessible coolant venting/

bleeding ports or drain valves, then take the sample
through the radiator coolant drain valve after draining
the dirty fluid at the bottom of the radiator.

Preparation of Sampling Point

In order to avoid contaminating the sample:

D The sampling point and the sampling equipment

must be meticulously cleaned before each sample is
taken and before opening the system.

Regular analysis of the coolant will allow you to prevent
engine problems well before they present themselves,
improve equipment performance, and reduce costly
repairs.

The test can detect:

D Cavitation corrosion

D Chemical distribution

D Leakage of combustion gases

D Contamination

D Electrical earthing (grounding) problems

In extreme conditions, perform the analysis more
frequently. For example:

D In extreme climates

D When the generator set is subject to repeated starts

D When the engine often runs for a long time on low

load

Some signs that the coolant is no longer carrying out its
function may include:

D Engine overheating

D Color alteration

D Deposits present

D If possible, avoid environmental disturbances when

taking the sample (wind, dust, rain,...).

The laboratory supplied bottle should be filled to 3/4 full.
In the absence of a laboratory supplied bottle, make
sure there is a minimum amount of 250 ml (8.5 oz.).

Use an appropriately labelled and cleaned bottle. Some
important points to note during sampling are:

D Brand and type

D Date of sampling

D Type of equipment and serial number

D Operating hours since commissioning

D Operating hours since last draining

D Type of Sampling: during draining or during a

sampling

D Any coolant top ups. If this is the case, indicate how

many liters (quarts) were added.

D Interventions carried out.

The recommended tests for the coolant analysis are as
follows:

D pH

D Spectrometric analysis (Phosphorus, Zinc, Calcium,

etc.)

Sampling Point

Sampling is carried out at a representative point in the
system, preferably just after the machine is shut down.

D On KD2000--KD3250 models, take the sample

through the engine venting/bleeding ports, or through
the coolant hose drain ports.

D Additives

D Percentage of coolant/water

D Physicochemical analysis (reserve alkalinity, density,

etc.)

D Conductivity.

TP-7070 7/1888 Section 3 Scheduled Maintenance

Sampling Method

3.8.8 Radiator Mainten ance

1. Read and follow the safety precautions in
Sections 3.1 and 3.8.1.

2. Place a basin under the drain point.

3. Turnthe cap on the expansion tank to the first notch
to release the pressure, then remove it completely.

4. Open the drain point.

5. Allow about one liter (1 qt.) of liquid to flow out
before collecting the sample

6. Collect about 1 liter (1 qt.) of liquid.

7. Close the bottle by tightly screwing the cap and
check the information on the label.

8. Close the drain point.

9. Top up the engine coolant if necessary.

10. Put the expansion tank cap in place and close.

Use the following list for radiator maintenance:

D Periodically check for leakage from the core or tank

connections.

D Inspect the liquid level at regular intervals using the

top tank sight glass.

D Test antifreeze before cold weather periods.

D If the unit is on stand-by for long periods of time,

check the interior of the top tank through the fill neck
for signs of scale or rust every one to three months. If
necessary, the radiator should be cleaned, flushed,
and treated.

D Dirt and debris can be removed from the core face

with compressed air, steam, or water, if required. If
water is used, slowly increase the pressure and stand
at least 0.9 m (3 feet) away from the core. Keep the
water stream parallel with the fins in order to avoid
damaging them.

Note: Ensure that fins and tubes are not damaged from

rough brushing or excessive jet pressure of the
steam, air, or water.

D Clean fan blades once per year. Use a stiff brush or an

air nozzle for loose dirt and a nonflammable solvent
with brush for solid deposits. Care must be taken not
to damage the fan blades as a resulting
out-of--balance condition might cause vibration and
damage to fan bearings or motor bearings.

TP-7070 7/18 89Section 3 Scheduled Maintenance

3.8.9 Radiator Fan Bearing Lubrication
(KD2000--KD3250)

Note: The following content on fan bearing lubrication

does not apply to models KD800--KD1750.

The system should be checked periodically (depending
on usage) to prevent equipment damage or failure.

d Check and maintain correct tension of fan belts.
d Check for frame imbalance, bearing wear, or loose

drive components.

d Check and maintain alignment of sheaves by

adjusting their location on fan shaft and idler shaft.

Lubricate the bearings through the remote grease
fittings every 500 hours.

Use lithium grease with EP additive, conforming to
NLGI 2 consistency, suitable for --28_C to +121_C
(--20_F to +250_F). Re-lubrication should be
discontinued when clean grease has purged through
the seal, regardless of the quantity added. Approximate
quantities are listed in Figure 3-15.

Shaft Size Amount -- ml (Oz.)

1--1/8in.to1--1/4in. 3.0 (.10)

1--3/8 in. to 1--7/16 in. 6.5 (.22)

1--1/2 in. to 1-- 11/16 in. 9.5 (.32)

1--3/4in.to2in. 14.8 (.50)

2 in. to 2--3/16 in. 16.3 (.55)

2--1/4in.to2--1/2in. 19.2 (.65)

2--11/16 in. to 3 in. 25.1 (.85)

3--3/16 in. to 3--1/2 in. 37.0 (1.25)

3--15/16 in. to 4 in. 74.0 (2.50)

4--7/16 in. to 4--1/2 in. 91.7 (3.10)

4--15/16 in. to 5 in. 140.5 (4.75)

a. Remove the load from the generator set.

b. Shut down the generator set.

c. Place the generator set controller into

Out-of-Service mode and press the
emergency stop button.

d. Disconnect the power to the battery charger.

e. Remove the battery cables, negative (--) lead

first, to disable the generator set.

3. To grease the bearings, inject grease at the
remotely located grease fittings located on the
left-hand side of the radiator. See Figure 3-16.
Grease slowly to prevent over-greasing the
bearings.

4. Remove any excess grease.

5. Reconnect the generator set engine starting
battery(ies), negative (--) lead last and return the
generator set to service.

Figure 3-15 Grease Quantity

1. Read and follow the safety precautions at the
beginning of the section.

2. Before working on the generator set or connected
equipment, remove the generator set from service.
Refer to the safety precautions for preventing
accidental starts and disabling the generator set.

1

1. Grease fittings

Figure 3-16 Fan Bearings Grease Fittings

10301001101

TP-7070 7/1890 Section 3 Scheduled Maintenance

3.8.10 Notched V-Belt Adjustment
(KD2000--KD3250)

For models KD2000--KD3250, use the following
procedure to adjust the tension on the six notched
V-belts which turn the fan pulley.

Note: The following content on fan bearing adjustment

does not apply to models KD800--KD1750.On
models KD800-- KD1000, the fan belt tension is
self-tensioning and maintenance-free. On
Models KD1250--KD1750 , the tensioner is
located on the engine. Refer to the engine
operation manual to adjust the tension.

1. Read and follow the safety precautions at the
beginning of the section.

2. Before working on the generator set or connected
equipment, remove the generator set from service.
Refer to the safety precautions for preventing
accidental starts and disabling the generator set.

a. Remove the load from the generator set.

b. Shut down the generator set.

c. Place the generator set controller into

Out-of-Service mode and press the
emergency stop button.

1

1. Rear face panel

10301001101

Figure 3-17 Fan Guard

4. Check the fan belt tension and adjust, if necessary.
Set the tension by using either a sonic tension
meter or by setting the belt deflection. See
Figure 3-19.

Note: For either method, measure only a single

belt. Do not overlap multiple belts in the
measurement.

a. To adjust the tension with an sonic tension

meter, use the following procedure:

d. Disconnect the power to the battery charger.

e. Remove the battery cables negative (--) lead

first to disable the generator set.

3. Remove the fan guard rear face panel. Inspect the
fan drive belt and replace if it is damaged or worn.
See Figure 3-17.

(1) Check the tension at the front and rear belt

of the fan pulley to understand alignment
characteristics. See Figure 3-18. Use a
sonic tension meter and compare the
reading to the frequency setting in
Figure 3-19.

(2) If a large deviation exists between the two

belts, then the pulleys may be misaligned.

1

1. Tension measurement location

2. Access panel

2

Figure 3-18 Tension Measurement Location

TP-7070 7/18 91Section 3 Scheduled Maintenance

b. To check the fan belt tension using belt

deflection, use the following procedure:

(1) Measure the belt span (center line of pulley

#1 to center line of pulley #2).

(2) Use the measurement to determine the

middle of the belt.

(3) Press on the V--Belt at the middle point and

measure the deflection from its original
position.

(4) For the maximum deflection, refer to

Figure 3-19.

Engine to Fan Sheave (Driver to Driver)

KD2000 to KD2500

Frequency (Hz) Deflection

New Belt 78.4--81.2 81--86 N @ 9 mm

Used

Belt

New Belt 62.7--64.9 89--95 N @ 12 mm

Used

Belt

72.6--75.6 70--75 N @ 9 mm

KD2800 to KD3250

Frequency (Hz) Deflection

58.1–60.5 77--83 N @ 12 mm

(18--19 lbs @ 0.4 in.)

(16--17 lbs. @ 0.4 in.)

(20--21 lbs @ 0.5 in.)

(17--19 lbs. @ 0.5 in.)

Note: Tension chart is only applicable for models

KD2000--KD3250.

1

3

4

5

1. Fan pulley

2. 3/4” undercarriage bolt locations

3. Lead screw

4. Tensioner pulley

5. Engine pulley

2

10301001101

Figure 3-20 Tension Adjustment, KD2000--KD3250

6. Make the necessary adjustments until belt tension
falls into the range listed in Figure 3-19.

7. Check the pulley alignment on the fan shaft for
angularity.

Figure 3-19 Belt Tension and Deflection

5. Before making adjustments to the tension, loosen
the four 3/4” undercarriage bolts. Then, adjust the
tensioner pulley along the tensioner slots via the
lead screw. See Figure 3-20.

8. Adjust the fan sheaves and tensioner sheaves to
eliminate or reduce the pulley angularity.

9. Tighten the 3/4” undercarriage bolts.

10. Reinstall the belt guards using the original
hardware.

11. Reconnect the generator set engine starting
battery(ies), negative (--) lead last and return the
generator set to service.

12. Test run the generator set for a few minutes and
listen for belt noise (squeal) indicating a slipping
belt. Stop the generator set.

If the belt slips after the belt tension procedure, clean the
pulley surfaces and repeat the belt tension procedure. If
slippage continues, replace the fan belt.

TP-7070 7/1892 Section 3 Scheduled Maintenance

3.9 Battery Systems

Refer to this section for general battery information and
maintenance. All generator set models use a negative
ground with a 24-volt engine electrical system. Consult
the generator set nameplate for the engine electrical
system voltage. Consult the generator set spec sheet for
battery capacity recommendations for replacement
purposes. The wiring diagrams provide battery
connection information. See Figure 3-21 for typical
battery connections, including multiple battery
configurations.

4321

12 34

KW-272000-B

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

3. To positive (+) terminal on second starter solenoid.

4. To ground (--) terminal on or near second starter motor.

WARNING

Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.

Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid
can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety
goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If
battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of
clean water. Seek immediate medical aid in the case of eye
contact. Never add acid to a battery after placing the battery in
service, as this may result in hazardous spattering of battery
acid.

Battery acid cleanup. Battery acid can cause severe
injury or death. Battery acid is electrically conductive and

corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
soda) to a container with4L(1gal.)ofwaterandmixthe
neutralizing solution. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.

Figure 3-21 24-Volt Electrical System, Dual Starter

Motors, Typical Battery Connections

3.9.1 Battery Safety

WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.

Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.

Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke

or permit flames or sparks to occur near a battery at any time,
particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
away from the battery. To avoid sparks, do not disturb the
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.

TP-7070 7/18 93Section 3 Scheduled Maintenance

Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or

equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the
battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
starter solenoid. Do not test the battery condition by shorting
the terminals together.

3.9.2 Absorbed Glass Mat (AGM)
Battery

Absorbed Glass Mat (AGM) type batteries do not
require electrolyte level inspection or specific gravity
check.

AGM batteries use the same general maintenance
instructions for battery cleaning and charging as shown
in Sections 3.9.3 and 3.9.4. For specific maintenance
instructions, refer to the battery manufacturer’s
instructions.

Note: Ensure that the battery charger is compatible with

AGM type batteries before charging.

3.9.3 Clean Battery

Clean the battery and cables and tighten the battery
terminals according to the service schedule
recommendations. Clean the battery by wiping it with a

damp cloth. Keep the electrical connections dry and
tight.

If corrosion exists, disconnect the cables from the
battery and remove the corrosion with a wire brush.
Clean the battery and cables with a solution of baking
soda and water. Do not allow the cleaning solution to
enter battery cells. Flush the battery and cables with
clean water and wipe the battery with a dry cloth.

After reconnecting the battery cables, coat the terminals
with petroleum jelly, silicon grease, or other
nonconductive grease.

3.9.4 Charge Battery

Use a battery charger to maintain a fully charged battery
when the generator set is used in a standby application.
The engine battery-charging alternator charges the
battery while the generator set is running. Refer to the
battery charger operation manual for installation,
operation, and service procedures.

Note: If the battery is an AGM type, ensure that the

battery charger is compatible with AGM type
batteries before charging.

Note: If the generator set is in a temporary prime power

application in which the generator set has periods
of inactivity, the controller circuitry may drain the
battery. If there is no power source for a battery
charger, disconnect the battery from the
generator set.

TP-7070 7/1894 Section 3 Scheduled Maintenance

3.10 Alternator Maintenance

This section covers alternator maintenance for several
different types of alternators and voltage regulators.
Refer to the instructions that correspond to the relevant
alternator models.

D Refer to the generator set specification sheet for

alternator models.

D Have an authorized distributor/dealer perform

service.

3.10.1 Alternator Safety

Grounding electrical equipment. Hazardous voltage will
cause severe injury or death. Electrocution is possible

whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set and related equipment and electrical circuits.
Turn off the main circuit breakers of all power sources before
servicing the equipment. Never contact electrical leads or
appliances when standing in water or on wet ground because
these conditions increase the risk of electrocution.

Short circuits. Hazardous voltage/current will cause
severe injury or death. Short circuits can cause bodily injury

and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.

WARNING

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the
generator set as follows: (1) Shut down the generator set. (2)
Place the controller in Out of Service mode. (3) Press the
emergency stop button. (4) Disconnect the power to the
battery charger, if equipped. (5) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.

Testing live electrical circuits. Hazardous voltage or
current will cause severe injury or death. Have trained and

qualified personnel take diagnostic measurements of live
circuits. Use adequately rated test equipment with electrically
insulated probes and follow the instructions of the test
equipment manufacturer when performing voltage tests.
Observe the following precautions when performing voltage
tests: (1) Remove all jewelry. (2) Stand on a dry, approved
electrically insulated mat. (3) Do not touch the enclosure or
components inside the enclosure. (4) Be prepared for the
system to operate automatically.

(600 volts and under)

CAUTION

Hot surfaces.

Servicing the alternator. Hot parts can cause severe
injury or death. Avoid touching the alternator field or exciter

armature. When shorted, the alternator field and exciter
armature become hot enough to cause severe burns.

DANGER

Hazardous voltage. Moving parts.
Will cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Servicing the generator set when it is operating. Exposed
moving parts will cause severe injury or death. Keep

hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.

TP-7070 7/18 95Section 3 Scheduled Maintenance

3.10.2 Checking the Installation

5. If your system is equipped with filters:

1. Check the operation at regular intervals (no
abnormal noise or vibration).

2. Check the tightness of all nuts and bolts. Pay
particular attention to the electrical connections.

3.10.3 Checking the Ventilation Circuit

1. Read and follow the safety precautions at the
beginning of the section.

2. Before working on the generator set or connected
equipment, remove the generator set from service.
Refer to the safety precautions for preventing
accidental starts and disabling the generator set.

a. Remove the load from the generator set.

b. Shut down the generator set.

c. Place the generator set controller into

Out-of-Service mode and press the
emergency stop button.

d. Disconnect the power to the battery charger.

a. Remove the grid and remove the filter.

b. Clean the filter with low pressure compressed

air or replace if it is clogged. See Figure 3-22.

1

2

3

1. Air inlet

2. Filter

3. Support

Figure 3-22 Ventilation of alternator

3.10.4 Checking the Bearings

Have an authorized distributor/dealer perform service.

e. Remove the battery cables negative (--) lead

first to disable the generator set.

3. Ensure that air flow is not reduced by partial
blocking of the air inlet and discharge grids by mud,
fiber, grease, etc.

4. Check for corrosion or abrasion on the air outlet
grids .

3.10.5 Checking the Windings

Have an authorized distributor/dealer perform service.

3.10.6 Voltage Regulator

To make adjustments to the voltage regulator settings,
contact an authorized Kohler distributor. Have an
authorized distributor/dealer perform service.

Note: For models that use the DER2 voltage regulator,

the potentiometers (VOLT, STAB, Hz, AMP.) are
disabled.

TP-7070 7/1896 Section 3 Scheduled Maintenance

3.11 Storage Procedure

Perform the following storage procedure before taking a
generator set out of service for three months or longer.
Follow the engine manufacturer’s recommendations, if
available, for fuel system and internal engine
component storage.

DANGER

Hazardous voltage. Moving parts.
Will cause severe injury or death.

3.11.1 Storage Safety

WARNING

Accidental starting.
Can cause severe injury or death.

Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the

generator set or equipment connected to the set, disable the
generator set as follows: (1) Shut down the generator set. (2)
Place the controller in Out of Service mode. (3) Press the
emergency stop button. (4) Disconnect the power to the
battery charger, if equipped. (5) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.

Operate the generator set only when
all guards and electrical enclosures
areinplace.

Servicing the generator set when it is operating. Exposed
moving parts will cause severe injury or death. Keep

hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.

WARNING

Risk of fire.
Can cause severe injury or death.

Combustible materials. A fire can cause severe injury or
death. If using generator heaters during storage, remove

combustible materials such as covers from contact with the
heater or from areas where heat could potentially cause a fire.

WARNING

WARNING

Hot engine and exhaust system.
Can cause severe injury or death.

Do not work on the generator set until
it cools.

Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The

engine and exhaust system components become extremely
hot during operation.

TP-7070 7/18 97Section 3 Scheduled Maintenance

Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.

Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.

3.11.2 Controller

3.11.5 Diesel Fuel System

If the generator set is stored in a location where the
temperature drops below --20_C(--4_F), connect power
to the controller heater.

3.11.3 Lubricating System

Prepare the engine lubricating system for storage as
follows:

1. Run the generator set for a minimum of 30 minutes
to bring it to normal operating temperature.

2. Stop the generator set.

3. With the engine still warm, drain the oil from the
crankcase.

4. Remove and replace the oil filter.

5. Refill the crankcase with oil suited to the climate.

6. Run the generator set for two minutes to distribute
the clean oil.

7. Stop the generator set.

Prepare the fuel system for storage as follows:

1. Fill the fuel tank.

2. Condition the fuel system with compatible
additives to control microbial growth.

3. Change the fuel filter/separator and bleed the fuel
system. See the engine owner’s manual.

3.11.6 Exterior

1. Clean the exterior surface of the generator set.

2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.

3. To prevent impurities from entering the air intake
and to allow moisture to escape from the engine,
secure a cloth over the air intake.

4. Mask electrical connections.

5. Spread a light film of oil over unpainted metallic
surfaces to inhibit rust and corrosion.

8. Check the oil level and adjust, if needed.

3.11.4 Cooling System

Prepare the cooling system for storage as follows:

1. Check the coolant freeze protection using a
coolant tester.

2. Add or replace coolant as necessary to ensure
adequate freezing protection. Use the guidelines
included in the engine operation manual.

3. Run the generator set for 30 minutes to redistribute
added coolant.

TP-7070 7/1898 Section 3 Scheduled Maintenance

3.11.7 Alternator Storage

3.11.8 Battery

WARNING

Risk of fire.
Can cause severe injury or death.

Combustible materials. A fire can cause severe injury or
death. If using generator heaters during storage, remove

combustible materials such as covers from contact with the
heater or from areas where heat could potentially cause a fire.

Humidity, moisture, and dust can damage the alternator
during storage. Store the generator set in a clean, dry
area and protect the alternator from inclement weather.
Keep room temperatures relatively constant to prevent
condensation on the windings. Cover ventilation and
other entry points to prevent damage by rodents, birds,
and insects.

For medium voltage generator sets (larger than 600
volts), store the units with the generator heater

operational and check periodically throughout the
storage period to confirm operation. To eliminate the
formation of condensation in the alternator winding,
maintain an AC alternator temperature above the
ambient dew point.

Before returning the alternator to service, have an
authorized service distributor/dealer, perform the
following alternator service:

D Clean the ventilation circuit.

D Blow dust off the windings.

WARNING

Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.

Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.

Perform battery storage after all other storage
procedures.

1. Confirm that the generator set is stopped.

2. Disconnect the battery(ies), negative (--) lead first.

3. Clean the battery. Refer to Section 3.9.3 for the
battery cleaning procedure.

4. Place the battery in a cool, dry location.

5. Connect the battery to abattery charger or charge it
monthly with a trickle battery charger. Refer to the
battery charger manufacturer’srecommendations.

Maintain a full charge to extend battery life.

Note: If the battery is an absorbed glass mat

(AGM) type, ensure that the battery charger
is compatible with AGM type batteries
before charging.

D Check the rotor and stator winding insulation.

D Check the rotor and stator winding resistance and

continuity.

D On units with regreasable bearings, grease the

bearings and rotate the shaft to distribute grease on
the bearings.

TP-7070 7/18 99Section 3 Scheduled Maintenance

Notes

TP-7070 7/18100 Section 3 Scheduled Maintenance