Kohler KD800 Instruction Manual

Industrial Generator Sets
TP-7070 8/20f
Operation
Models:
KD800- KD4000
Controller:
APM802

WARNING: This product can expose you
to chemicals, including car on monoxide
and enzene, which are known to the State
of California to cause cancer and irth
defects or other reproductive harm.
For more information go to
www.P65warnings.ca.gov
WARNING: Breathing diesel engine
exhaust exposes you to chemicals known to
the State of California to cause cancer and
irth defects or other reproductive harm.
Always start and operate the engine in
a well-ventilated area.
If in an enclosed area, vent the exhaust
to the outside.
Do not modify or tamper with the
exhaust system.
Do not idle the engine except as
necessary.
For more information go to
www.P65warnings.ca.gov/diesel
Product Identification Infor ation
Product identification num ers determine service parts.
Record the product identification num ers in the spaces
elow immediately after unpacking the products so that
the num ers are readily availa le for future reference.
Record field-installed kit num ers after installing the
kits.
Generator Set Identification Nu bers
Record the product identification num ers from the
generator set nameplate(s).
Model Designation
Specification Num er
Serial Num er
Accessory Nu ber Accessory Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Num er
Alternator Identification
Record the alternator model num er 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 Num er from the controller
nameplate.
Controller Description APM802
Controller Serial Num er

Table of Contents
TP-7070 8/20 Ta le of Contents 3
Safety Precautions and Instructions 5. .......................................................
Introduction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Assistance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 Specifications and Features 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Introduction 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Controller Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.1 Controller Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2 Display and Touchscreen 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Controller Features 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.1 Connections 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.2 Mod us Connections 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3.3 Optional Keyswitch and Manual Start/Stop Button 16. . . . . . . . . . . . . . . . .
1.4 NFPA Requirements 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Parameter Settings 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Base Module Inputs and Outputs 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2 Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Prestart Checklist 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Exercising Generator Set 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Operation in Cold Weather Climates 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Generator Set Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Start Signal 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Stop Signal 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Engine Cooldown 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4 Emergency Stop 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.5 Idle Mode 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Controller Operation Modes 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.1 Out of Service Mode 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.2 Manual Mode 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5.3 Auto Mode (Stand y or System Ready) 23. . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Load Shed 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 HMI Screen Layout 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Home Screen 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2 Top Bar 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.3 Generator View 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.4 Control Panel 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.5 Custom View Button 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Operator Login 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 Data Displays 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.1 Generator Mechanical Values 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.2 Generator Electrical Values 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.3 Curve Display 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.4 Saved Electrical and Mechanical Data 33. . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 Events 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.1 Faults and Alarms 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.2 Resetting an Alarm 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.3 Resetting a Fault 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.4 Consulting Status Messages 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10.5 Full Event Log 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11 Applications 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.1 Reference 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.2 Region Settings 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.3 HMI Settings 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.4 Restart 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued
TP-7070 8/20Ta le of Contents4
2.11.5 Display Cleaning 45..............................................
2.11.6 Firmware Update 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.7 Screenshot 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.8 Ladder Tools 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.9 Save Parameters 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.11.10 Upload Parameters 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12 Menus 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.1 Menu 1- Settings 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.2 Menu 2- Measurements 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.3 Menu 3- History 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.4 Menu 4- Diagnosis 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.5 Menus 5 and 6 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.12.6 Menu 6.5-Communication 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3 Troubleshooting 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Introduction 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Generator Set and Controller 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Engine 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Transfer Switch 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 General Trou leshooting Chart 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 Accessories 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Accessories and Connections 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Accessory Connections 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Battery Chargers 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Input and Output Modules 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 Analog Input/Output Module 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Digital Input/Output Module 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Thermocouple Input Module 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Remote Emergency Stop Kit 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.1 Remote Emergency Stop Kit 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5.2 Locka le Emergency Stop Switch 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Remote Serial Annunciator 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A Abbreviations 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B Operating Hour Service Log 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5Safety Precautions and InstructionsTP-7070 8/20
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause odily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents e
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 a hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous
situation which, if not avoided, could
result in minor or moderate injury.
NOTICE
NOTICE is used to address practices
not related to physical injury.
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
pu lication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
Accidental starting.
Can cause severe injury or death.
Disconnect the attery ca les efore
working on the generator set.
Remove the negative (- ) lead first
when disconnecting the attery.
Reconnect the negative (- ) lead last
when reconnecting the attery.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
equipment connected to the set,
disa le 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
utton. (4) Disconnect the power to the
attery charger, if equipped.
(5) Remove the attery ca les,
negative (- ) lead first. Reconnect the
negative (- ) lead last when
reconnecting the attery. Follow these
precautions to prevent the starting of
the generator set y the remote
start/stop switch.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
lindness and urn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the attery in a well-ventilated
area. Isolate the attery charger from
explosive fumes.
WARNING
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause lindness and urn skin.
Always wear splashproof safety
goggles, ru er gloves, and oots
when servicing the attery. Do not
open a sealed attery or mutilate the
attery case. If attery 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
attery after placing the attery in
service, as this may result in hazardous
spattering of attery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 l .) of
icar onate of soda ( aking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
attery acid and continue to add the
neutralizing solution to the spilled
attery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

6 Safety Precautions and Instructions TP-7070 8/20
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 attery at any time, particularly when
it is charging. Do not dispose of a
attery in a fire. To prevent urns and
sparks that could cause an explosion,
avoid touching the attery terminals
with tools or other metal o jects.
Remove all jewelry efore servicing the
equipment. Discharge static electricity
from your ody efore touching
atteries y first touching a grounded
metal surface away from the attery. To
avoid sparks, do not distur the attery
charger connections while the attery
is charging. Always turn the attery
charger off efore disconnecting the
attery connections. Ventilate the
compartments containing atteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause odily injury
and/or equipment damage.
Disconnect the attery efore
generator set installation or
maintenance. Remove all jewelry
efore servicing the equipment. Use
tools with insulated handles. Remove
the negative (- ) lead first when
disconnecting the attery. Reconnect
the negative (- ) lead last when
reconnecting the attery. Never
connect the negative (- ) attery ca le
to the positive (+) connection terminal
of the starter solenoid. Do not test the
attery condition y shorting the
terminals together.
Engine Backfire/Flash
Fire
Risk of fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Co bustible aterials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flamma le and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or near y area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended y the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Servicing the fuel syste . 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.
Exhaust Syste
Carbon onoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must e
leakproof and routinely inspected.
WARNING
Generator set operation. Carbon
onoxide can cause severe nausea,
fainting, or death. Car on monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
reathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
uilding unless the exhaust gas is
piped safely outside. Never operate
the generator set where exhaust gas
could accumulate and seep ack inside
a potentially occupied uilding.
Carbon onoxide sy pto s.
Carbon onoxide can cause severe
nausea, fainting, or death. Car on
monoxide is a poisonous gas present in
exhaust gases. Car on monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Car on
monoxide poisoning symptoms include
ut are not limited to the following:
Light-headedness, dizziness
Physical fatigue, weakness in
joints and muscles
Sleepiness, mental fatigue,
ina ility to concentrate
or speak clearly, lurred vision
Stomachache, vomiting, nausea
If experiencing any of these symptoms
and car on monoxide poisoning is
possi le, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possi ility of car on monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of reathing
fresh air.
Fuel Syste
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
WARNING
The fuel syste . 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
ecause 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 flexi le fuel
lines with rigid lines. Use flexi le
sections to avoid fuel line reakage
caused y vi ration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems efore resuming
generator set operation.

7Safety Precautions and InstructionsTP-7070 8/20
Fuel tanks. Explosive fuel vapors
can cause severe injury or death.
Gasoline and other volatile fuels stored
in day tanks or su ase fuel tanks can
cause an explosion. Store only diesel
fuel in tanks.
Draining the fuel syste . 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
spilled fuel after draining the system.
Hazardous Noise
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
CAUTION
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
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
DANGER
Hazardous voltage. Backfeed to
the utility syste .
Can cause property da age,
severe injury, or death.
If the generator set is used for
stand y power, install an automatic
transfer switch to prevent inadvertent
interconnection of stand y and
normal sources of supply.
WARNING
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources efore
opening the enclosure.
DANGER
Grounding electrical equip ent.
Hazardous voltage will cause severe
injury or death. Electrocution is
possi le whenever electricity is
present. Ensure you comply with all
applica le codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit reakers of all power sources
efore servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground ecause these conditions
increase the risk of electrocution.
Installing the battery charger.
Hazardous voltage will cause severe
injury or death. An ungrounded
attery charger may cause electrical
shock. Connect the attery 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 attery charger. Install
the attery charger as prescri ed in the
equipment manual. Install the attery
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 attery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the attery charger and
attery(ies). Have a qualified
electrician install the attery(ies).
Short circuits. Hazardous
voltage/current will cause severe
injury or death. Short circuits can
cause odily injury and/or equipment
damage.Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry efore servicing the
equipment.
Engine block heater. Hazardous
voltage will cause severe injury or
death. The engine lock heater can
cause electrical shock. Remove the
engine lock heater plug from the
electrical outlet efore working on the
lock heater electrical connections.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in stand y power
installations to prevent the connection
of stand y and other sources of power.
Electrical ackfeed 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
pro es and follow the instructions of the
test equipment manufacturer when
performing voltage tests. O serve 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)

8 Safety Precautions and Instructions TP-7070 8/20
Servicing the generator set when it
is operating. Exposed oving parts
will cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the elts and
pulleys when the generator set is
running. Replace guards, screens, and
covers efore operating the generator
set.
Heavy Equip ent
Unbalanced and elevated weight.
I proper lifting can cause severe
injury or death and equip ent
da age.
Do not lift the generator set from the
engine or alternator eyes. Never
stand under a unit eing lifted.
Always maintain a safe distance from
the unit eing lifted.
See the lifting instructions in the
installation manual that was provided
with the unit.
WARNING
Hot Parts
Hot coolant and stea .
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. Fill system
efore starting unit.
WARNING
Hot engine and exhaust syste .
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
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
ecome hot enough to cause severe
urns.
Servicing the exhaust syste . Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components ecome extremely hot
during operation.
Notice
NOTICE
Parallel Operation. This product
includes features intended to support
operation in parallel with the utility grid,
ut these features have not een
evaluated for compliance with specific
utility interconnection protection
standards or requirements.
NOTICE
Canadian installations only. For
stand y service connect the output of
the generator set to a suita ly rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

9IntroductionTP-7070 8/20
Introduction
This manual provides generator set operation,
maintenance, and asic trou leshooting instructions. A
separate controller operation manual contains detailed
controller operation information.
Wiring diagram manuals are availa le separately. Refer
to the engine operation manual for generator set engine
scheduled maintenance information.
Information in this pu lication represents data availa le
at the time of print. Kohler Co. reserves the right to
change this pu lication and the products represented
without notice and without any o ligation or lia ility
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid odily injury. Read and follow the
Safety Precautions and Instructions section at the
eginning 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 prescri ed intervals.
Maintenance work must e performed y appropriately
skilled and suita ly trained maintenance personnel
familiar with generator set operation and service.
Abbreviations
This pu lication makes use of numerous a reviations.
Typically, the word(s) are spelled out along with the
a reviation in parentheses when shown for the first
time in a section. Appendix A, A reviations, also
includes many a reviation definitions.
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 availa le literature part num ers.
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 num ers, see the respective
generator set parts catalog.
Literature Description
Literature Part
No.
APM802 Controller Spec Sheet G6-152
Generator Set Installation Manual,
KD Models TP-7153
Generator Set Maintenance Manual,
KD Models TP-7143
Controller and Generator Set Service Manual TP-7079
Generator Set/Controller Wiring Diagram
Manual
KD800-KD1000 w/APM802 TP-7106
KD1250-KD1750 w/APM802 TP-7071
KD1250-A & KD1350 w/APM802 TP-7117
KD2000-KD2500 w/APM802 TP-7107
KD2800-KD3250 w/APM802 TP-7108
KD3500-KD4000 w/APM802 TP-7169
Engine Operation and Maintenance Manual,
KD27V12 Engine 33521029401
Engine Operation and Maintenance Manual,
KD36V16 Engine 33521029701
Engine Operation and Maintenance Manual,
KD45V20 Engine 33521030001
Engine Operation and Maintenance Manual,
KD62V12 Engine 33521030301
Engine Operation and Maintenance Manual,
KD83V16 Engine 33521030601
Engine Operation and Maintenance Manual,
KD103V20 Engine 33521030901
Remote Serial Annunciator III (RSA III) TT-1625
Figure 1 Related Literature

10 Introduction TP-7070 8/20
Na eplate 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 num er, serial num er,
and specification num er 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 assem ly as shown in Figure 3.
Service Duty
Voltage
Alt Model
Insulation
MFG Date
Amps
Phase
RPM
Battery
Fuel
kW
kVA
Hz
Genset Model
Spec Num er
Serial Num er
Material Num er
PF
Figure 2 Generator Set Nameplate, Typical
1
11811000100- GR1
1. Nameplate location, typical
Figure 3 Generator Set Nameplate Location, Typical

11Service AssistanceTP-7070 8/20
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distri utor or dealer.
Visit the Kohler Co. we site at KOHLERPower.com.
Look at the la els and decals on your Kohler product
or review the appropriate literature or documents
included with the product.
Call toll free in the US and Canada 1-800-544-2444.
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 Zeven ergen
The Netherlands
Phone: [phone]
Fax: [phone]
Asia Pacific
Kohler Asia Pacific Headquarters
Singapore, Repu lic 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]

12 Service Assistance TP-7070 8/20
Notes

TP-7070 8/20 13Section 1 Specifications and Features
Section 1 Specifications and Features
1.1 Introduction
The spec sheets for each generator set provide model-
specific 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 Controller Specifications
Power Supply Requirements:
Nominal voltage: 24 VDC, reverse polarity
protected
240 VAC /60Hz customer-supplied; factory wiring
to asic electrical package availa le
Operating Temperature:
- 40C to 70C (- 40F to 158F)
Storage Temperature:
- 40C to 70C (- 40F to 158F)
Humidity: 5% to 95% non-condensing
Protection Index:
IP65 Front
IP20 Rear
Standards:
NFPA 99
NFPA 110, Level 1
CSA 282-09
UL 508
IEC/EN60068-2-52 (salt spray)
CE Directive
1.2.2 Display and Touchscreen
Type: XGA TFT LED LCD
Screen Size: 305 mm (12 inches)
Viewing Angle: 140horizontal and vertical
Languages: English, French
Note: Have setup and adjustments of the controller
performed only y an authorized Kohler
distri utor. The setup and adjustments are
password protected.
1.3 Controller Features
The controller features include a 307 mm (12.1 inch)
touchscreen with acklight and wide viewing angle (140
degrees horizontal and vertical) and terminal locks 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:
12-inch touchscreen with acklight and wide viewing
angle for easy local access to data.
System settings are password-protected.
Measurements selecta le in metric or English units.
User language is selecta le (English or French).
Graphic displays show generator set mechanical
values including operating hours, fuel level*, attery
voltage, coolant temperature, oil pressure, and oil
temperature.
Meter displays provide a visual representation of
generator electrical values including power (kW),
power factor, reactive power (kVAR), frequency,
voltage, and current (amps).
Two USB ports allow connection of a flash drive,
mouse, or keypad.
Electrical data, mechanical data, and system settings
can e saved to a flash drive.
Recording feature allows data collection of key
values.
Ethernet port allows connection to a PC type
computer and/or Ethernet switch.
Serial (RS-485) port.
The controller supports Mod usRTU and TCP
protocols.
Real time clock with attery ack-up.
See the controller specification sheet or operation
manual for input and output specifications.
Mod usis a registered trademark of Schneider Electric.
* Where applica le

TP-7070 8/2014 Section 1 Specifications and Features
1. APM802 controller human-machine interface (HMI)
2. Emergency stop switch
3. Key switch
4. Manual start/stop utton
5. 240 VAC / 60 Hz power supply connection (required)
6. Terminal lock TB10 for accessory connections
7. Wiring harness connection
8. USB ports, qty. 2 (on the ack of the HMI)
9. Controller touchscreen
10. Fault indicator/display utton
11. Mode selection switch
12. Generator set electrical values
13. Generator set mechanical data
19
12
10
13
7
11
2
11601000945
Note: Covers have een removed for illustration.
6
5
8
Hu an-Machine Interface (HMI)
3
4
Figure 1-1 APM802 Controller and Customer Connection Box

TP-7070 8/20 15Section 1 Specifications and Features
1.3.1 Connections
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources efore
opening the enclosure.
DANGER
Inputs and outputs from the controller ase module are
rought out to TB10 in the connection ox. See
Figure 1-1 for the terminal lock location. Do not
connect directly to the controller ase module (except
for the Ethernet 3 connection).
TB10 Ter inal 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 ack of the controller’s
human-machine interface (HMI). See Figure 1-2. Lift
the hinged panel to access the USB ports.
Ethernet 3 port on the ase module can e connected
to a personal computer or network to allow remote
monitoring using VNC.
Additional input and output connections are availa le
with optional module kits. See Section 4 for accessory
connection details.
1. USB Ports
1
Figure 1-2 USB Ports ( ack of HMI)
1.3.2 Modbus Connections
Use RS-485 ca le for Mod us RTU connections.
Belden #9841 or equivalent shielded, twisted-pair ca le
is recommended. See Figure 1-3. See the generator
set wiring diagram for the Mod us connection location
on TB10.
The controller also supports Mod us TCP over
Ethernet. Connect to the RJ45 port la eled Ethernet 3
on the controller’s ase module.
The controller communicates using Mod usas a slave
connection with the Mod usmaster initiating the
communication. The controller seeks the system and
alternator parameters and diagnostic information then
responds ack to the Mod usmaster.
Note: Only one Mod usmaster can e connected to
the controller. Examples include the remote
serial annunciator and switchgear applications.
Generator Set
Controller Mod usMaster
RS-485
up to 1220 m (4000 ft.)
Figure 1-3 Mod usConnections

TP-7070 8/2016 Section 1 Specifications and Features
1.3.3 Optional Keyswitch and Manual
Start/Stop Button
Some controllers are equipped with the optional
keyswitch and manual start/stop utton shown in
Figure 1-4. See Figure 1-1 for the locations on the
controller assem ly.
Figure 1-4 Optional Keyswitch and Manual
Start/Stop Button
Keyswitch. The keyswitch disa les the mode
push utton on the controller touchscreen. The
touchscreen will display the operation mode, ut the
mode cannot e changed using the touchscreen if the
controller is equipped with the keyswitch. The
keyswitch positions are descri ed 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 utton will
start and stop the generator set.
Note: Pressing the manual stop utton shuts down the
generator set immediately, without running the
engine cooldown cycle. Running the generator
set without load for 5 minutes efore stopping
manually is recommended.
Position Description
Manual Allows generator set start and stop using
the manual push utton.
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 utton 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
1.4 NFPA Require ents
In order to meet NFPA 110, Level 1 requirements, the
generator set controller monitors the engine/generator
functions and faults shown elow.
Engine functions:
Overcrank
Low coolant temperature warning
High coolant temperature warning
High coolant temperature shutdown
Low oil pressure shutdown
Low oil pressure warning
Overspeed
Low fuel level *
Low coolant level
EPS supplying load
High attery voltage
Low attery voltage
Air damper indicator
General functions:
Master switch not in auto
Battery charger fault *
Contacts for local and remote common alarm
Audi le alarm silence switch
Remote emergency stop
* Function requires optional input sensors or kits.

TP-7070 8/20 17Section 1 Specifications and Features
1.5 Para eter Settings
Controller parameter settings are factory-set and
password-protected. Selected settings are shown in
Figure 1-6. If changes are required, contact your
distri utor.
Para eter Setting
Preheat duration* 0 s
Air-preheater maximum delay
(at each start attempt)*
30 s
Num er of starting attempts 3
Time etween starting attempts 15 s
Fault inhi ition time in starting phase 10 s
Auxiliaries start time 5 s
Generators starting maximum delay
(Dead Bus synchronizing)
5 s
Generator cooling time 300 s
(5 min.)
Generator immo ilization time 5 s
Ventilation time after generator stopped 10 s
* Parameter settings not applica le for KD2000- KD4000
Figure 1-6 Factory Settings

TP-7070 8/2018 Section 1 Specifications and Features
1.6 Base Module Inputs and Outputs
The inputs and outputs on the ase module are factory set. See Figure 1-7 and Figure 1-8 for ase module input and
output factory settings. For optional input/output module settings, see Section 4, Accessories.
Note: Make customer connections to TB10 in the connection ox. See the generator set wiring diagram for details.
Inputs Factory Setting
Digital Inputs 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 Ena le
DI13 Key Switch Ena le
DI14 Load Shed Ena le
DI15 Overcrank Test
DI16 Reserved for Factory Use
DI17 Emergency Stop
Analog Input AI0- Remote Speed Adjust
(+/- 10 VDC)
AI0+
Resistive Input RES0- Am ient Air Temperature
RES0+
Figure 1-7 APM802 Base Module Input Factory Settings
Outputs
Output Relay
Configuration Factory Setting
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
Figure 1-8 APM802 Base Module Output Factory Settings

TP-7070 8/20 19Section 2 Operation
Section 2 Operation
2.1 Prestart Checklist
To ensure continued satisfactory operation, perform the
following checks or inspections efore 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.
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
DANGER
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering engine.
Air Inlets. Check for clean and uno structed air inlets.
Battery. Check for tight attery connections. Consult
the attery manufacturer’s instructions regarding
attery care and maintenance.
Coolant Level. Check the coolant level according to
the cooling system maintenance information.
Note: Block Heater Da age. The lock heater will fail
if the energized heater element is not immersed
in coolant. Fill the cooling system efore turning
on the lock heater. Run the engine until it is
warm, and refill the radiator to purge the air from
the system efore energizing the lock heater.
Drive Belts. Check the elt condition and tension of the
radiator fan, water pump, and attery charging
alternator elt(s) according to the drive elt 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.
Exhaust Syste . Check for exhaust leaks and
lockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, exhaust line, flexi le exhaust, clamps,
silencer, and outlet pipe) for cracks, leaks, and
corrosion.
Check for corroded or roken metal parts and replace
them as needed.
Check for loose, corroded, or missing clamps and
hangers. Tighten or replace the exhaust clamps
and/or hangers as needed.
Check that the exhaust outlet is uno structed.
Visually inspect for exhaust leaks (blowby). Check
for car on or soot residue on exhaust components.
Car on 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.
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 o structions that could
lock the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or de ris on or near the
generator set.
Radiator. Check that the radiator fins and air
inlets/outlets are clean of leaves, insects, dirt, and other
de ris. Use compressed air to clear the o structed
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 efore
starting the generator set. This visual inspection should
e routinely done while the unit is running.

TP-7070 8/2020 Section 2 Operation
2.2 Exercising Generator Set
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
DANGER
Operate the generator set under load periodically. Refer
to the engine operation manual for the exercise intervals
and load recommendations. Perform the exercise in the
presence of an operator when the generator set does
not have an automatic transfer switch with an exercise
option.
The operator should perform all of the prestart checks
efore 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
Cli ates
Cold weather operation is generally considered am ient
temperatures elow 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.
The engine block heater is generally recommended
for most units when operated elow 0°C (32°F) and
required as part of NFPA 110. Refer to the respective
spec sheet for temperature recommendations in
availa le options.
The controller heater is required for operation elow
- 20°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.
Abattery heater is generally recommended for most
units when operated elow 0°C (32°F). Refer to the
respective spec sheet for model availa ility.
An alternator heater to prevent moisture and frost
uildup is availa le for most generator sets.