TP 7141

Operation
Industrial Generator Set
Models:
KD700-KD4000
KD1250-4, KD2500-4, KD3250-4
Controller:
APM603
TP-7141 11/22c
WARNING: 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
WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth 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 Information
Product identification numbers determine service parts. Record the product identification numbers in the spaces below
immediately after 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: ____________________________________________________________
Controller Identification
Record the controller description from the generator set operation manual, spec sheet, or sales invoice.
Controller Description________________________________________________________
Engine Identification
Record the product identification information from the engine nameplate.
Manufacturer_________________________________________________________________
Model Designation___________________________________________________________
Serial Number_______________________________________________________________
Accessory Number Accessory Description Accessory Number Accessory Description
2 TP-7141 11/22
Table of Contents
Safety Precautions and Instructions ........................................................................................................................................ 7

Introduction .............................................................................................................................................................................. 11
Service Assistance................................................................................................................................................................... 12
Section 1. Controller Specifications and Features ............................................................................................... 13
1.1 Introduction ............................................................................................................................................................ 13
1.2 Controller Specifications......................................................................................................................................... 13
1.3 Controller Features................................................................................................................................................. 13
1.3.1 Switches and Controls ............................................................................................................................. 14
1.3.2 Annunciator LEDs .................................................................................................................................... 14
1.3.3 Touchscreen Display................................................................................................................................ 15
1.3.4 Access Levels .......................................................................................................................................... 17
1.4 Run Relay .............................................................................................................................................................. 17
Section 2. Inputs and Outputs ................................................................................................................................ 19
Section 3. Operation ................................................................................................................................................ 21
3.1 Prestart checklist .................................................................................................................................................... 21
3.2 Generator Set Operation ........................................................................................................................................ 22
3.2.1 Starting and Stopping Functions .............................................................................................................. 22
3.2.2 Start Signal .............................................................................................................................................. 23
3.2.3 Stop Signal............................................................................................................................................... 23
3.2.4 Engine Cooldown ..................................................................................................................................... 24
3.2.5 Emergency Stop ...................................................................................................................................... 25
3.3 Operation in Cold Weather Climates ...................................................................................................................... 26
3.4 Exercising the Generator Set ................................................................................................................................. 27
3.5 Load Bank Operation (Tier 4) ................................................................................................................................. 27
3.6 Warnings and Faults .............................................................................................................................................. 28
3.6.1 Yellow System Warning LED and Fault Messages .................................................................................. 28
3.6.2 Red System Fault Shutdown LED and Fault Messages........................................................................... 28
3.6.3 Fault, Notice, and Status Displays ........................................................................................................... 28
3.6.4 Notifications (Bell icon)............................................................................................................................. 29
3.6.5 EATS Inducement Notifications (Tier 4 Generator Sets) .......................................................................... 30
3.7 Resetting the Controller (Following System Shutdown) ......................................................................................... 31
3.8 Controller Settings .................................................................................................................................................. 31
3.9 Screen Shots .......................................................................................................................................................... 33
3.10 Menu Navigation .................................................................................................................................................... 34
Section 4. Metering Menu and Screens ................................................................................................................. 35
4.1 Metering Screens ................................................................................................................................................... 35
4.1.1 Home ....................................................................................................................................................... 36
4.1.2 Customizing the Home Screens ............................................................................................................... 37
4.1.3 Favorites .................................................................................................................................................. 40
4.2 Electrical................................................................................................................................................................. 42
4.2.1 Metering Screens, Electrical, Generator .................................................................................................. 42
4.2.2 Input Metering .......................................................................................................................................... 44
4.2.3 Output Metering ....................................................................................................................................... 45
4.2.4 Battery Charger........................................................................................................................................ 46
4.3 Engine .................................................................................................................................................................... 46
4.3.1 Overview .................................................................................................................................................. 47
4.3.2 Fuel .......................................................................................................................................................... 49
4.3.3 Temperature ............................................................................................................................................ 50
4.3.4 Pressure................................................................................................................................................... 52
4.3.5 Aftertreatment .......................................................................................................................................... 53
TP-7141 11/22 3
4.4 Operation Records ................................................................................................................................................. 55
4.5 Load Management ................................................................................................................................................. 57
4.5.1 Metering, Load Management Overview Screen ....................................................................................... 59
4.5.2 Metering, Load Management, Status ....................................................................................................... 60
4.5.3 Load Management Setup Details ............................................................................................................. 65
Section 5. Setup Menus and Screens .................................................................................................................... 67
5.1 Setup Menus .......................................................................................................................................................... 67
5.1.1 Changing Settings .................................................................................................................................... 67
5.2 Electrical Setup ...................................................................................................................................................... 68
5.2.1 Generator Electrical Setup ....................................................................................................................... 68
5.2.2 Battery Charger Setup Screens ............................................................................................................... 69
5.2.3 Paralleling Setup ...................................................................................................................................... 69
5.3 Engine Setup.......................................................................................................................................................... 71
5.4 Setup, Communication Screen............................................................................................................................... 73
5.5 Event Configuration................................................................................................................................................ 75
5.5.1 Generator Set Information (Genset Info) .................................................................................................. 79
5.6 Data Log Screens................................................................................................................................................... 80
Section 6. Paralleling ............................................................................................................................................... 83
6.1 Introduction ............................................................................................................................................................ 83
6.2 Metering ................................................................................................................................................................. 85
6.2.1 Paralleling, Metering, Overview ............................................................................................................... 85
6.2.2 Paralleling, Metering Status ..................................................................................................................... 87
6.2.3 Paralleling, Metering, Details ................................................................................................................... 89
6.2.4 Paralleling, Metering, PGEN .................................................................................................................... 91
6.3 Setup ...................................................................................................................................................................... 92
6.3.1 Paralleling, Setup, PGEN ......................................................................................................................... 92
6.3.2 Paralleling, Setup, Protect Relay Screen ................................................................................................. 94
6.4 Generator Management ......................................................................................................................................... 95
6.4.1 Paralleling, Generator Management Status ............................................................................................. 97
6.4.2 Gen Management Modes......................................................................................................................... 98
6.4.3 Gen Management System Status, Generator .......................................................................................... 99
6.4.4
Paralleling, Gen Management, Setup Details ........................................................................................ 101
Section 7. Remote Monitoring Display, Tier 4 Only ............................................................................................ 103
7.1 Home Screen ....................................................................................................................................................... 103
7.2 Menu Screen ........................................................................................................................................................ 104
7.2.1 Overview ................................................................................................................................................ 105
7.2.2 Fuel ........................................................................................................................................................ 106
7.2.3 Temperature .......................................................................................................................................... 107
7.2.4 Pressure................................................................................................................................................. 109
7.2.5 Aftertreatment ........................................................................................................................................ 110
7.2.6 Display Settings ..................................................................................................................................... 112
Section 8. Troubleshooting ................................................................................................................................... 113
8.1 Introduction .......................................................................................................................................................... 113
8.2 Generator Set and Controller ............................................................................................................................... 113
8.3 Engine .................................................................................................................................................................. 113
8.4 Transfer Switch .................................................................................................................................................... 113
8.5 General Troubleshooting Chart ............................................................................................................................ 114
8.6 Controller Display and Voltage Regulation Troubleshooting Chart ....................................................................... 118
Section 9. Accessories .......................................................................................................................................... 119
9.1 Battery Chargers .................................................................................................................................................. 120
9.2 Input/Output (I/O) Modules ................................................................................................................................... 121
9.3 Manual Key Switch............................................................................................................................................... 124
4 TP-7141 11/22
9.4Remote Emergency Stop Kit ................................................................................................................................ 125
9.4.1 Remote emergency stop kit. .................................................................................................................. 125
9.4.2 Lockable Emergency Stop Switch .......................................................................................................... 125
9.5 Remote Serial Annunciator .................................................................................................................................. 126
9.6 Shunt Trip Line Circuit Breaker ............................................................................................................................ 128
Appendix A. Abbreviations ....................................................................................................................................... 129
Appendix B. Engine Data .......................................................................................................................................... 133
Appendix C. Alternator Protection ........................................................................................................................... 153
Appendix D. Operating Hours and Service Log ...................................................................................................... 154
TP-7141 11/22 5
6 TP-7141 11/22
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 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 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) Press the generator set off/reset button to shut do wn
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) 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 Explosion.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well‐ventilated area. Isolate the battery charger from explosive
fumes.
TP-7141 11/22 7
Engine Backfire/Flash Fire
WARNING Risk of fire.

Do not smoke or permit flames or sparks near fuels or the fuel system.
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 f uels in an
approved container when removing the fuel line or 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.
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 recommen ded by the
local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures .
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.
Exhaust System
WARNING Carbon monoxide.

Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. Carbon 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 unles s 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.
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 caus e
death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
• Light-headedness, dizziness
• Physical fatigue, weakness in joints and muscles
• Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
• 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.
8 TP-7141 11/22
Fuel System
WARNING Explosive fuel vapors.

Use extreme care when handling, storing, and using fuels.
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. Do not 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.
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.

Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
DANGER Hazardous voltage. Moving parts.

Operate the generator set only when all guards and electrical enclosures are in place.
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, tra nsfer
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.
TP-7141 11/22 9
Disconnecting the electrical load. Hazardous voltage will cause severe injury or death. Disconnect the generator set from
the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and
heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment
damage.
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.
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 ut ility
electrical system can cause severe injury or death to utility personnel working on power lines.
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.
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).
Welding on the generator set. Can cause severe electrical equipment damage. Before welding on the generator set perform
the following steps: (1) Remove the battery cables, negative (–) lead first. (2) Disconnect all engine electronic control module
(ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the
engine battery-charging alternator connections. (5) Attach the weld ground connection close to the weld location.
Hot Parts
WARNING Hot engine and exhaust system.

Do not work on the generator set until it cools.
10 TP-7141 11/22
Introduction
This manual provides operation instructions for the generator set models listed on the front cover when equipped with the
APM603 controller.
This manual contains generator set operation instructions for readers with user-level or operator-level access to the APM603
controller. Selected accessory information is also included.
Refer to the generator set maintenance manual and the engine operation manual for scheduled maintenance information.
The information (including illustrations) 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 whatsoev er.
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 man ual
with the equipment for future reference.
The equipment service requirements are very important for 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 traine d
maintenance personnel familiar with generator set operation and service.
List of Related Materials
Separate literature contains installation and maintenance information not provided in this manual. Figure 1 lists the available
literature part numbers.
The engine 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.
Literature part numbers are subject to change. For the latest literature part numbers, see the generator set parts list.
Literature Description Literature Part No.
Generator Set Installation Manual, KD Models TP-7153
Generator Set Maintenance Manual, KD Models TP-7143
Generator Set/Controller Wiring Diagram Manuals Original With Updated Digital
8 I/O Module
KD700-KD750 (APM603) NA TP-7262
KD700-KD750 (APM802) NA TP-7263
KD800-KD1000 TP-7144 TP-7252
KD1250A-KD1350 (single starter) TP-7145 TP-7253
KD1250A-KD1350 (redundant starter) TP-7145 TP-7254
KD1250-4 (single starter) TP-7182 TP-7253
KD1250-4 (redundant starter) TP-7187 TP-7254
KD1500-KD1750 (single starter) TP-7146 TP-7255
KD1500-KD1750(redundant starter) TP-7146 TP-7256
KD2000-KD2500(single starter) TP-7147 TP-7257
KD2000-KD2500(redundant starter) TP-7147 TP-7258
KD2800-KD3250 (single starter) TP-7148 TP-7259
KD2800-KD3250 (redundant starter) TP-7148 TP-7260
KD3500-KD4000 TP-7170 TP-7261
Commissioning and Setup Manual, APM603 TP-7131
Communication Protocol Operation Manual, APM603 TP-7151
Service Manual, APM603 Controller TP-7149
TM
SiteTech Software Manual TP-6701
Remote Serial Annunciator III (RSA III) Instructions TT-1625
Figure 1 Related Literature
TP-7141 11/22 11
Abbreviations
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.
SiteTechTM Software
A personal computer and Kohler SiteTech TM software may be required for programming the APM603 controller if the factory
default settings are not appropriate for the application. SiteTech software is also needed for assigning configurable inputs/outputs
and for updating the controller application code. Kohler SiteTech software is available only to Kohler-trained and authorized
distributors and dealers. Contact your local distributor/dealer for assistance.
Service Assistance
For professional advice and conscientious service, please China

contact your nearest Kohler distributor or dealer. North China Regional Office, Beijing
Phone: (86) 10 6518 7950
• Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7951
• Look at the labels and decals on your Kohler product (86) 10 6518 7952
or review the appropriate literature or documents Fax: (86) 10 6518 7955
included with the product.
East China Regional Office, Shanghai
• Call toll free in the US and Canada 1-800-544-2444. Phone: (86) 21 6288 0500
• Outside the US and Canada, call the nearest Fax: (86) 21 6288 0550
regional office. India, Bangladesh, Sri Lanka
Headquarters Europe, Middle East, Africa (EMEA) India Regional Office
Kohler EMEA Headquarters Bangalore, India
Netherlands B.V. Phone: (91) 80 3366208
Kristallaan 1 (91) 80 3366231
4761 ZC Zevenbergen Fax: (91) 80 3315972
The Netherlands Japan, Korea
Phone: (31) 168 331630
Fax: (31) 168 331631 North Asia Regional Office
Tokyo, Japan
Asia Pacific Phone: (813) 3440-4515
Kohler Asia Pacific Headquarters Fax: (813) 3440-2727
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
12 TP-7141 11/22
Section 1. Controller Specifications and Features
1.1 Introduction
The specification sheet for each generator set provides model-specific generator and engine information. The controller
specification sheet provides specifications for this controller. Refer to the respective specification sheet for data not sup plied 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

APM603 Controller
Power source with circuit protection 12 or 24VDC
Power draw 800 mAmps at 12VDC
400 mAmps at 24VDC
Humidity range 5-95% non-condensing
Operating temperature -40° to 70°C (-40° to 158°F)
Storage temperature -40° to 85°C (-40° to 185°F)
1.3 Controller Features

The controller features include the annunciator LED, touchscreen display, USB ports, buttons and controls, and terminal blocks.
See Figure 2 for an illustration of the controller front panel.
USB ports (one USB and one mini-B) Warning and shutdown LEDs
Touchscreen
Alarm Silence/Lamp Test button

Generator master control buttons:
OFF/RESET, AUTO, and RUN
Figure 2 APM603 Controller
TP-7141 11/22 13
Controller Features:
• Large color touchscreen provides:
o Intuitive operation
o System status and metering displays
o Data logging and trending
o Event display and fault reset
• Master control buttons with status LEDs
• Fault LEDs:
o Yellow = Warning
o Red = Shutdown
• Alarm horn and alarm silence button with LED
• USB connector for downloading data files, uploading files, and data logging
• Mini USB connector for controller setup using a PC with SiteTechTM software
The controller features, accessories, and menu displays depend upon the engine electronic control module (ECM) setup and
features.
1.3.1 Switches and Controls
Alarm Horn. The alarm horn alerts the operator or other attendants that a warning or shutdown condition exists.
Alarm (Horn) Silence. The alarm silence button turns off the alarm horn at the operator’s discretion.
Restore alarm horn switches at all locations, including those on remote annunciators, after correcting the fault condition an d
resetting the controller. See Resetting the Controller, in this manual.
Generator Set Master Control (OFF/RESET-AUTO-RUN). These buttons reset the controller fault LEDs and start/stop the
generator set. See the Operation section for additional information.
Note:
If a manual key switch is installed, most button operations are supplanted by the key switch position. The LEDs on the controller
will continue to display the OFF, AUTO, and RUN modes. The OFF/RESET button will reset the controller. See Manual Key
Switch in the Accessories section of this manual for more information.
LED Test. Press and hold the Alarm Silence/Lamp Test button to test the controller indicator LEDs and fault LEDs.
1.3.2 Annunciator LEDs
The controller has red and yellow annunciator fault LEDs that provide visual indication that a warning or shutdown is active. In
addition, each master control button has a status-indicating LED. See Figure 3.
LED/Button LED Color Description

Alarm (Fault) LED Yellow (Warning) or Yellow LED indicates a fault condition that does not shut down the generator set.
Red (Shutdown) Correct all system warnings as soon as practical.
Red LED indicates that the generator set has shut down because of a fault condition.
The unit will not start until the condition is corrected and the controller is reset.
Off/Reset Button Blue Indicates the generator set is stopped.
Auto Button Blue (System Ready) Indicates the system is in standby mode and detects no faults. The unit is ready to
start by remote command.
Run Button Blue Indicates the generator set is cranking or running from a local command.
Alarm Silence Button Orange Indicates the alarm horn is silenced.
Figure 3 Annunciator LEDs
14 TP-7141 11/22
1.3.3 Touchscreen Display
The touchscreen display provides generator set and engine data, parameter settings, system status, and fault information. Some
values will display zero or N/A (not available) if the generator set is not running.
The main menus are listed below. Within each main menu are multiple submenus as described in the Operation Section.
• Metering
• Setup
• Data Log
• Paralleling (if enabled)
• Active Events (Bell icon)
• Controller Settings
Figure 4 shows the important parts of the touchscreen.
• Two tabs in the upper left corner allow the viewer to toggle between two independent screens.
• The navigation menu on the left side of the screen can be expanded and contracted as shown.
• The bell icon at the upper right indicates active alerts. Touch to view active events and event history.
• The controller settings icon allows access to settings such as display brightness and date/time. This icon al so contains
the link to the logon screen for the different access levels.
• A scroll bar appears on the right side of the screen when there are multiple pages that can be viewed or accessed.
• The boxes on the bottom of the Home screens allow the viewer to move between two screens.
TP-7141 11/22 15
Touch to toggle between two independent screens.
Controller settings
Touch to expand
and contract the
menu.
Date and time

Touch the open square to move Event notification. Touch the
to the other metering screen. bell icon to view active alerts
and event log.
Color Code:
Gray = No Active Faults
Orange = Warning
Red = Shutdown
Expanded
menu
Pencil icon for changing
the metering displays.
See Customizing the
Home Screens.
USB flash drive connected.
Touch arrows to scroll up

and down on screens with
multiple pages.
Figure 4 Screen Features and Functions
16 TP-7141 11/22
1.3.4 Access Levels
Note:
Have setup and adjustments of the controller performed only by an authorized Kohler distributor. The setup and adjustments
are password protected.
Different access levels are used to protect the controller from inadvertent changes that can adversely affect the generator s et
operation. Access levels are described in Figure 5. The current access level is shown in the upper left corner of the screen
when the navigation menu is expanded as shown in Figure 6. The User level is the default level.
Some parameter settings are displayed at the user level but require operator access or higher to change the setting. Password-
controlled access is granted to trained, qualified Kohler distributors and dealers. See the Controller Settings Section for
instructions to log on at the Operator or Distributor access level.
After a set amount of time, the access automatically returns to the User level. The default session time duration is one hour.
The session time can be changed in the Controller Settings menu.
Access Level Password Required Description

User (0) None Can start and stop the generator set. Can navigate through the controller menus and
view, but not change, the settings..
Operator (1) 9879 Allows trained maintenance personnel to adjust selected settings.
Technician (2) Yes Allows trained and authorized Kohler distributors or dealers to adjust controller
settings.
Factory (3) Yes For factory use only.
Figure 5 Access Levels
Figure 6 Access Level Indication

1.4 Run Relay
The run relay is provided as standard equipment with the APM603 controller. The run relay energizes only when the generator
set runs. Use the auxiliary run relay kit to control air intake and radiator louvers, alarms, and/or other signaling devices. Refer to
the generator set wiring diagrams for connections.
TP-7141 11/22 17
18 TP-7141 11/22
Section 2. Inputs and Outputs
The controller is equipped with the standard, dedicated inputs and outputs shown in Figure 7 and Figure 8. These inputs and
outputs are factory set and cannot be adjusted.
Inputs Tier 2 Inputs Tier 4 Input Type
Auxillary Fault (Shutdown) Auxillary Fault (Shutdown)
Auxillary Warning Auxillary Warning
Battery Charger Fault Battery Charger Fault
Breaker Closed Breaker Closed
Breaker Tripped/Open Breaker Tripped/Open
Fuel Leak Alarm Fuel Leak Alarm
High Fuel Level Switch Warning High Fuel Level Switch Warning
Idle Switch Idle Switch Digital Input
Low Fuel Level Switch Low Fuel Level Switch
Low Oil Level Low Oil Level Switch Warning
Remote Emergency Stop Remote Emergency Stop
Remote Reset Remote Reset
Reserved Factory Use Load Bank Fault
Reserved Factory Use Power Supply 1 Fault
Reserved Factory Use Power Supply 2 Fault
Remote Engine Start Remote Engine Start Two-Wire Input
Speed Bias Speed Bias Analog Voltage Input,
Scalable up to +/- 10 VDC
Voltage Bias Voltage Bias
* Only with remote-mounted electrically operated circuit breakers.
Figure 7 Standard Dedicated User Inputs
Outputs Tier 2 Outputs Tier 4 Output Type

Close Breaker Close Breaker
Common Failure Common Failure
EPS Supplying Load EPS Supplying Load
Generator Running Generator Running
Horn Horn
Digital Output
Low Coolant Temperature Low Coolant Temperature
Not In Auto Not In Auto
System Ready System Ready
Trip Breaker/Shunt Trip Trip Breaker/Shunt Trip
Reserved Factory Use Load Bank Control
* Only with remote-mounted electrically operated circuit breakers.
Figure 8 Standard Dedicated User Outputs
An optional Digital Input/Output Module kit is available. The kit provides additional inputs and outputs that are configurable. See
the Accessories section for more information. A personal computer and Kohler SiteTech™ software are required for assigning
input and output functions to the inputs and outputs on the I/O modules. SiteTech is available to Kohler authorized distributors
and dealers.
TP-7141 11/22 19
20 TP-7141 11/22
Section 3. Operation
3.1 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.

Operate the generator set only when all guards and electrical enclosures are in place.
Note:
Use the procedures in this document after the generator set has been installed according to the instructions in the generator set
Installation Manual.
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.
Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.
Coolant Level. Check the 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.
Diesel Exhaust Fluid (DEF) Tank, if equipped. Ensure that there is an adequate DEF supply; keep the DEF tank full. When filling, watch
that the DEF tank is not overfilled.
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 can interfere with
the cooling air flow and create excessive noise. Check that the enclosure door to the load connection panel is closed and secured. Some
units have a micro switch safety feature that will trip (by shunt trip) the main line circuit breaker if the load connection panel is open.
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.
• Check for corroded or broken 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 unobstructed.
• 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. (diesel models)
Lamp Test. Press and hold the lamp-test button for 1 second to verify all controller LEDs are operational.
Oil Level. Check the 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. Repeat the visual inspection routinely while the unit is running.
TP-7141 11/22 21
3.2 Generator Set Operation
The controller allows operation of the generator set as detailed below.
3.2.1 Starting and Stopping Functions
There are three primary modes of operation, selected by pressing the controller buttons.
Button Description
OFF/RESET Press the OFF/RESET button to stop the generator set immediately, with no engine cooldown.
The generator set remains off and will not respond to a remote start signal.
Press and HOLD the OFF/RESET button for 3 seconds to reset an active fault (shutdown). Be
sure to identify and correct the problem that caused the shutdown before clearing the fault.
AUTO Press AUTO to place the generator set into automatic (standby) mode. The generator set will
respond to remote start and remote stop signals.
RUN Press the RUN button to start the generator set. The generator set runs until the OFF/RESET or
AUTO button is pressed or until a fault condition causes the generator set to shut down.
Figure 9 Controller Button Operation
Notes:
• The alarm horn sounds and the Not-In-Auto Warning display appears whenever the generator set is not in the AUTO
mode.
• The transient start/stop function of the controller prevents accidental cranking of the rotating engine. The generator set
stops and recranks when the OFF/RESET button is momentarily pressed and then the RUN button is pressed.
• The controller provides up to 30 seconds of programmable cyclic cranking and up to 60 seconds rest with up to 6
cycles. The default setting is 15 seconds cranking and 15 seconds rest for 3 cycles. An authorized Kohler distributor or
dealer can make cyclic cranking adjustments using SiteTech™ software.
22 TP-7141 11/22
3.2.1.1 Starting and Stopping Functions, Parallel Operation
The modes of operation for a generator set that is part of a multi-unit paralleled system are shown below. Select the modes by
pressing the controller buttons as shown.
Button Description
OFF/RESET Press the OFF/RESET button to stop the generator set immediately, with no engine cooldown.
The generator set remains off and will not respond to a remote start signal.
Press and hold the OFF/RESET button for 3 seconds to reset an active fault (shutdown). Be sure
to identify and correct the problem that caused the shutdown before clearing the fault.
RUN Press the RUN button to start the generator set. No other generator sets in the system will start.
AUTO Press AUTO to place the generator set into automatic (standby) mode. The generator set will
respond to remote start and remote stop signals.
The generator set will start and run when a start signal is received via a remote start, local auto-
start, or communications-based start.
All generator sets in the system (connected by PGEN paralleling communications and in Standby
Mode by pressing AUTO) will start when any one of the generator sets receives a start signal.
However, any generator set in the system that is not in AUTO mode will not start.
If Generator Management is on, the generator set may shut down after a period of time.
When the start signal is removed, the generator set will shut down with the appropriate engine
cooldown.
AUTO-RUN Press AUTO and RUN together for a system start signal.
All generator sets in the system start and run, close to bus, synchronize, parallel, share load, etc.
Some generator sets may shut down after a period of time (indicated by Generator Management)
but they remain in Standby Mode ready to start and run if needed.
AUTO-OFF Press AUTO and OFF together to remove a system start signal, if AUTO-RUN is active.
All generator sets in the system open their breakers, enter engine cooldown, shut down, and enter
Standby Mode. Closing the remote start contacts has no effect. Generator sets in the system will
enter Standby Mode.
Note:
Pressing AUTO and OFF together stops the generator sets only if there are no other system start
signals present.
3.2.2 Start Signal
When the generator set is in AUTO mode, it can respond to a start signal. A start signal can include any of the following:
• A remote start signal via contacts 3 and 4 (closing a contact between 3 and 4 on terminal block TB -12), typically
received from an automatic transfer switch (ATS) or a remote panel. A closed contact across 3 and 4 takes precedence
over all other start signals. If the generator set is already running, it will keep running and the original source of that
start signal will be ignored.
• System Start (AUTO-START). Press AUTO and RUN simultaneously to send a start signal.
• Communications-based start command from SiteTech™ or a Modbus-based remote panel.
3.2.3 Stop Signal
A stop signal can include any of the following:
• Removal of start signal via contacts 3 and 4 (opening the contact between 3 and 4).
• System Stop (AUTO-OFF). Press AUTO and OFF simultaneously on any controller in the system to send a stop signal
to cancel the system start.
Note:
Pressing AUTO and OFF simultaneously has no effect if the system start is not active or if the system is receiving a
start signal from another source.
• Communications-based stop command from SiteTech™ or a Modbus-based remote panel.
TP-7141 11/22 23
3.2.4 Engine Cooldown
The engine cooldown cycle 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
or a stop signal is received.
The cooldown cycle runs until the cooldown temperature is reached or a predetermined amount of time expires. The cooldown
time and cooldown temperature are adjustable parameters. See the Engine Setup section for more information about the engine
cooldown settings.
Note:
No engine cooldown cycle occurs if the OFF button is pressed or if a fault occurs. The shutdown is immediate. If possible, ru n
the generator set without load for at least 5 minutes to ensure adequate engine cooldown.
3.2.4.1 DEF Injector Cooldown (Tier 4)
NOTICE
Injector damage. Cutting power to the exhaust aftertreatment system can damage the injectors. Rewiring the emergency stop
voids the warranty. If power is cut to the exhaust aftertreatment system during operation or the cooling process, inspect injectors
for damage and replace if needed.
Note:
When the operator presses the OFF button or the emergency stop button, or a shutdown fault occurs, the generator set shuts
down immediately and does not enter low idle cooldown. Only the DEF injector cooldown will continue to function and protect
the injectors from damage.
Tier 4 generator sets (KD1250-4, KD2500-4, and KD3250-4) use low idle cooldown and DEF injector cooldown to prevent
damage to the DEF injectors. When running in AUTO, removal of the start/stop signal initiates a low idle cooldown. The generator
set controller automatically lowers the frequency to low idle during the low idle cooldown until exhaust temperatures reach 220˚C
(428˚F) or for 10 minutes of operation (whichever comes first). Injector cooldown occurs at the same time, and the DEF pump
continues to pump DEF through the injectors even after the engine stops.
Low idle cooldown is the preferred shutdown option for tier 4 generator sets and only occurs when the generator set is running
in AUTO. If the operator starts the generator set by pressing the RUN button, the preferred shut-down method is to switch to
AUTO to allow a low idle cooldown.
In addition to a low idle cooldown, the EATS system utilizes a DEF injector cooldown where the DEF pump continues to pump
DEF through the injectors as the engine aftertreatment system (EATS) cools. The EATS initiates a DEF injector cooldown when
the operator presses the OFF button or the emergency stop button, the generator set receives a remote stop signal, or a
shutdown fault occurs.
24 TP-7141 11/22
3.2.5 Emergency Stop
Note:
Use the emergency stop switch(es) for emergency shutdowns only. Use the generator set OFF/RESET button for normal
shutdowns.
The emergency stop switch shuts down the generator set immediately. The controller fault LED lights and the unit shuts down
without running the engine cooldown cycle.
Use the following procedure to reset the generator set after shutdown by a local or remote emergency stop switch. Refer to the
Controller Resetting procedure to restart the generator set following a fault shutdown.
Procedure to Reset the Generator Set after Emergency Stop
1. Investigate and correct the cause of the emergency stop.
2. Reset the emergency stop switch.
3. Press and hold the generator set OFF/RESET button for 3 seconds.
4. After resetting all faults using the controller reset procedure, press the generator set RUN and/or AUTO button to restart
the generator set. The generator set will not crank until the reset procedure is completed.
3.2.5.1 Emergency Stop (Tier 4)
NOTICE
Injector damage. Cutting power to the exhaust aftertreatment system can damage the injectors. Rewiring the emergency stop
voids the warranty. If power is cut to the exhaust aftertreatment system during operation or the cooling process, inspect injectors
for damage and replace if needed.
When the emergency stop button is pressed, a tier 4 generator set immediately shuts down and the EATS initiates a DEF injector
cooldown where DEF is pumped through the injectors.
The emergency stop switch is factory wired on tier 4 generator sets to keep the EATS powered when the emergency stop button
is pressed. The emergency stop switch will only remove power from the base generator set. Rewiring of the emergency stop
switch will affect the warranty of EATS components. If rewiring the emergency stop switch is necessary, c ontact an authorized
Kohler distributor or dealer.
Note:
Pressing the emergency stop switch cuts power to the heating components of the EATS. If power is not returned, DEF in the
DEF lines, DEF tank, and DEF components can freeze, blocking the DEF flow and causing an inducement (reduction in engine
torque).
TP-7141 11/22 25
3.2.5.2 EATS Electrical Disconnect (Tier 4)
The EATS electrical disconnect is located on the lower electrical box. The EATS electrical disconnect is a manually operated
switch that functions as a stop switch for the EATS. When the EATS electrical disconnect is turned off, power is cut to the FDS
pump and the DEF line heaters.
IMPORTANT! The EATS electrical disconnect should typically be in the ON position even when the generator set is not running.
If needed, the EATS electrical disconnect should only be turned off when the EATS active light is off or in an emergency situation.
If the EATS electrical disconnect is ever turned OFF while the EATS active light is still on, then damage to the DEF injectors is
likely. If the EATS electrical disconnect is turned off, the ECU and the controller report a fault. If power is not returned to the DEF
line heaters in cold weather conditions, DEF lines can freeze and cause blockage.
Lower
electrical box
OFF
EATS electrical
disconnect
ON
Figure 10 EATS Electrical Disconnect
3.3 Operation in Cold Weather Climates
Cold weather operation should be addressed in areas where the ambient temperatures fall 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 120 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 below 0°C (32°F) and required as
part of NFPA 110. Refer to the generator set specification sheet for temperature recommendations in available opti ons.
• A battery heater is generally recommended for most units when operated below 0°C (32°F). Refer to the respective
specification sheet for model availability.
• An alternator heater to prevent moisture and frost buildup is available for some generator sets.
• Heater tape is recommended when the generator set is equipped with a closed crankcase ventilation system and
operated at or below 50% of rated load. Wrap the UL/CSA compliant heater tape around the crankcase
canister/breather system hose that runs from the crankcase to the air intake and use cable ties as needed to secure
the heater tape. If the heater tape is within 152 mm (6 in.) of the exhaust system, use thermal insulation material to
protect the heater tape.
Note:
Tier 4 generator sets (KD1250-4, KD2500-4, KD3250-4) are equipped with DEF line heaters, DEF tank heaters, and DEF
component heaters. These EATS heating components are standard on tier 4 generator sets. To prevent freezing and blocking
of the DEF flow, power should always be supplied to these EATS heaters. Ensure that the EATS electrical disconnect switch is
closed (in the ON position), the emergency stop is released, and that power is provided through the AC power supplies. Refer
to the Engine Aftertreatment System installation and Application manual for electrical requirements and installation details. Refer
to the following subsection on EATS electrical disconnect in this manual for operation instructions.
26 TP-7141 11/22
3.4 Exercising the Generator Set
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 before starting the manual exercise procedure. Start the generator set
according to the starting procedure. 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. If the system is equipped with an automatic
transfer switch (ATS), refer to the ATS literature for information about scheduled exercise periods.
Note:
Tier 4 generator sets (KD1250-4, KD2500-4, KD3250-4) require a minimum exhaust temperature to prevent hydrocarbon buildup
in the catalyst. Tier 4 generator sets use a load bank or the building design to maintain a minimum load. For operation and
requirements, refer to the previous subsection on EATS Electrical Disconnect and the Exhaust Aftertreatment System Installation
and Application Manual.
3.5 Load Bank Operation (Tier 4)
Tier 4 generator sets (KD1250-4, KD2500-4, KD3250-4) require a minimum exhaust temperature to prevent hydrocarbon buildup
on the SCR. To control exhaust temperatures, a minimum load is maintained either through a load bank or the building design.
See the Exhaust Aftertreatment System Installation and Application Manual listed under Related Literature.
• When the hydrocarbon (HC) level reaches the specified limit (default setting is 25%), the APM603 issues a high
hydrocarbon warning that the load needs to increase in order to reduce hydrocarbon buildup.
• At 50% the APM603 will report a critically high warning and command the load bank to turn on. When the APM603
commands the load bank to turn on, the load bank has 2 minutes to be connected to the generator set.
o If after 2 minutes the APM603 does not detect the load bank size as the minimum load, then the generator set will
issue a Load Bank Malfunction Warning.
o If applying the load bank exceeds 90% of the generator set the output rating, the APM603 will not command the
load bank to turn on.
• In paralleling applications, the APM603 will either bring another generator set on line and remove the generator set that
has high hydrocarbon levels off line, or apply the load bank depending on how many generator sets are currently online
and how many generator sets are offline in standby.
o In APM603 paralleling applications, the load bank must be applied to the generator set side of the motorized
breaker.
o See Paralleling section in this manual for addition information on load bank operation in paralleling applications.
• If switchgear is used to manage the hydrocarbon buildup, the switchgear system must keep the hydrocarbon below the
trip points set in the APM603.
TP-7141 11/22 27
3.6 Warnings and Faults
Yellow and red LEDs above the controller’s touchscreen indicate warnings and faults.
An inhibit time or time delay may affect warnings and faults.
Inhibit time: This time delay prevents the fault from triggering immediately when the engine starts. The inhibit time allows the
engine to come up to speed and stabilize before triggering a fault. For example, the low oil pressure fault event typically has an
inhibit time of 10 seconds to allow oil pressure in the engine to build up.
Time Delay. This time delay prevents a fault from triggering immediately when a condition is first detected. This delay prevents
nuisance warnings or shutdowns caused by momentary changes in the signal, which could be false signals or electrical noise.
For example, the overvoltage fault event typically has a time delay of 30 seconds. The overvoltage condition must be detected
for 30 seconds before the fault is triggered.
3.6.1 Yellow System Warning LED and Fault Messages
The yellow WARNING LED turns on and the alarm horn sounds to indicate a warning but does not shut down the generator set.
See the following subsection, Notifications (Bell Icon), for a list of fault and warning events and messages.
Press the Alarm Silence button to silence the alarm horn at the operator’s discretion. If the controller is set up for an NFPA 110
application, press the AUTO button before silencing the alarm horn.
Warnings are automatically cleared from the controller when the condition is corrected.
When a system warning continues, it may lead to a fault and cause a system shutdown.
3.6.2 Red System Fault Shutdown LED and Fault Messages
When a fault condition is detected, the red system FAULT LED turns on, the alarm horn sounds, and the unit shuts down. See
the following subsection, Notifications (Bell Icon), for a list of fault shutdown messages.
Use the Alarm Silence button to silence the alarm horn at the operator’s discretion. If the controller is setup for an NFPA 110
application, press the AUTO button before silencing the alarm horn.
Refer to the subsection Resetting the Controller for information to reset a system shutdown.
3.6.3 Fault, Notice, and Status Displays
New warning or shutdown messages appear in a banner across the top of the screen. See Figure 11. Touch ACKNOWLEDGE
ALL to close the banner. Touch VIEW ACTIVE ALERTS or the Bell icon to see a list of all active faults.
Warnings and shutdowns appear on the Active Alerts screen and become part of the event log. The Event Log also includes
status messages.
• Shutdown messages are written in red and include a red symbol with an X.
• Warning messages are yellow and include a yellow triangle with an ! symbol.
• Status messages are written in white.
Figure 11 Fault Message Banner
28 TP-7141 11/22
3.6.4 Notifications (Bell icon)
The bell icon provides quick access to the Event Log. If the bell appears straight up and down, there are no active warnings or
faults. If the bell is “ringing,” indicated by the bell at an angle with waves, there is at least one active warning or fault . The
breadcrumb bar at the top of the page also changes color if there are active warnings or faults. If there are no active warn ings
or faults, the area is gray. If a warning is active, it is yellow. If a fault is active, it is red.
Touch the Bell icon to review active alerts and the event log. Event details lists the name, severity, and time and date for the
event. Touch View Snapshot to see data captured 7.5 seconds before and after the event. The items displayed in the Snapshot
are factory selected. For example, in Figure 13 the generator power is displayed for each warning and fault.
When a fault is indicated, be sure to identify and correct the cause of the fault before resetting the controller. Contact an
authorized Kohler distributor or dealer for service, if necessary.
When the fault condition has been corrected, press and hold the OFF/RESET button for 3 seconds to clear the fault from the
controller. If the fault occurs again, contact an authorized Kohler distributor or dealer for service. Do not start the generator set
until the condition has been corrected.
Gray = No Active Faults

Orange = Active Warning(s)
Red = Shutdown
Figure 12 Notifications (Active Alerts and Event Log)
TP-7141 11/22 29
Figure 13 Event Details and Snapshot
Event Log:
This menu allows the user to review up to 10,000 entries of generator set system events including shutdowns, warnings, notices,
and status events with date and time stamp.
A message is sent each time there is a change in a monitored engine condition (i.e. fault becomes active, fault is cleared). Upon
broadcast of this message, the controller will request another message that contains the following information for each fault:
• SPN (Suspect Parameter Number) is a 3-to-5 digit code that represents an engine component. Refer to the engine Operation
Manual for a list of SPN codes.
• FMI (Failure Mode Indicator) is a two-digit code that represents the type of fault that occurred (i.e. short circuit, value is
high).
For generator events, see the Event Configuration section. For a list of engine events and FMI codes, see the Engine Data
Appendix.
3.6.5 EATS Inducement Notifications (Tier 4 Generator Sets)
For tier 4 generator sets (KD1250-4, KD2500-4, KD3250-4), engine aftertreatment system (EATS) warnings and shutdown faults,
when active, appear at the top of the page. If the icons are not visible, there are no active DEF warnings or faults. These icons
indicate low DEF fluid, poor DEF quality, poor SCR conversion, or component failure. If action is not taken, a reduction in engine
torque occurs. Orange icons indicate warnings, and red icons indicate shutdown faults. See Figure 14. For details about system
inducements, refer to the Engine Aftertreatment System Installation and Application manual listed under Related Literature.
Red icons = Shutdown

Orange icons = Warning
Engine emission
system malfunction
indicator
DEF Indicator alert
Figure 14 EATS Inducement Icons
30 TP-7141 11/22
3.7 Resetting the Controller (Following System Shutdown)
Use the following procedure to restart the generator set after a system shutdown. This procedure includes the resetting of the
optional remote annunciator.
Refer to the Emergency Stop Section to reset the generator set after an emergency stop.
1. Disconnect the generator set load using the line circuit breaker or automatic transfer switch.
2. Correct the cause of the fault shutdown or warning. See the Safety Precautions and Instructions section of this manual
before proceeding.
3. Reset the fault by pressing and holding the OFF/RESET button for 3 seconds.
4. Start the generator set by pressing the RUN button.
5. When equipped, the remote annunciator alarm horn sounds. Press the ALARM SILENCE/LAMP TEST button to stop
the alarm horn. The alarm silenced LED turns on if the alarm is silenced.
6. Allow the generator set to run long enough to verify that the fault condition has been corrected.
7. Press the generator set OFF/RESET button to stop the generator set.
8. Press the generator set AUTO button.
9. Silence the controller alarm horn by pressing the ALARM SILENCE button.
10. Reconnect the generator set load via the line circuit breaker or automatic transfer switch.
11. When equipped, the remote annunciator alarm horn sounds. Press the ALARM SILENCE/LAMP TEST button to stop
the alarm horn. The alarm silence LED turns on if the alarm is silenced.
3.8 Controller Settings

Touch the down arrow icon at the upper right corner of the screen to access the controller settings.
• Display Brightness
Adjusts the brightness of the controller’s touchscreen display. Touch the sun icons at either end of the bar to increase
or decrease the brightness of the display.
• LED Brightness
Adjusts the brightness of the Warning and Fault LEDs above the display. Touch the sun icons at either end of the bar
to increase or decrease the brightness of the LEDs.
• Date/Time
Set the date, time, and time zone at the controller’s location. The date and time are displayed on the Home screens
and are used in the event log and for data logging.
• Language.
For future development. At this time, English is the only available option.
• Controller Session Login Timeout
Controls the session time for access levels above the user level. The access level returns to the lowest (user) level
after the session timeout to prevent unauthorized access after an operator or service technician has finished working.
• Access Level
This is where an operator or technician can log into the controller using an Operator or Technician password. The
Operator and Technician level passwords allow access to view and change settings that are not available at the default
user level. See the Access Levels Section for more information.
TP-7141 11/22 31
Figure 15 Controller Settings and Access Levels
32 TP-7141 11/22
3.9 Screen Shots
It is possible to save screen shots showing the controller display. Screen shots showing the controller display can be saved to
a flash drive. The screens shots are saved as .png files, which can be viewed using a photo viewer on your PC.
Refer to the Controller Features Section for the locations of the USB port and the Alarm Silence/Lamp Test bu tton on the
controller, if necessary.
Procedure to Create Screen Shot Files

1. Insert a flash drive into the USB port on the front of the APM603 controller.
2. Check for the flash drive symbol near the top of the screen, which shows that the controller recogniz es the flash drive.
3. Navigate to the desired screen and press the Alarm Silence/Lamp Test button once.
4. Wait at least 5 seconds to allow the png file to be saved to the flash drive. If the flash drive has an LED indicator, wait
for the LED to stop flickering.
5. If multiple screen shots are needed, repeat steps 2 and 3 for each screen.
6. Remove the flash drive from the controller and insert it into a USB port on your PC. Open the files to verify that the
screen shots were saved correctly.
Flash Drive Symbol
Figure 16 Flash Drive Symbol
TP-7141 11/22 33
3.10 Menu Navigation
The APM603 controller provides menus and submenus that display controller settings, generator set status, and paralleling
information. The following list shows the locations of the menus and submenus on the controller.
• Metering
o Favorites
o Electrical
• Generator
• Inputs
• Outputs
• Battery Charger (N/A for KD models)
o Engine
- Overview (Tier 4 only)
- Fuel (Tier 4 only)
- Temperature (Tier 4 only)
- Pressures (Tier 4 only)
- Aftertreatment (Tier 4 only)
o Op Records
o Load Management
• Overview
• Status
o System
o Load
• Setup Details
• Setup
o Electrical
• Generator
• Battery Charger (N/A for KD models)
• Paralleling
o Engine
o Communications
o Event Config
o Genset Info
• Data Log
• Paralleling (only appears if paralleling screens are enabled under Setup>Electrical>Paralleling)
o Metering
• Overview
• Status
• Details GEN 1-4
• Details GEN 5-8
• PGEN
o Setup
• PGEN
• Protect Relay
o Gen Management
• Overview
• Status
o System
o Generator
• Setup Details
34 TP-7141 11/22
Section 4. Metering Menu and Screens
4.1 Metering Screens

The metering screens allow the user to view generator set status and operation records. The home screens display frequently -
viewed parameters including generator set voltage, frequency, current and power, as well as engine data such as RPM and oil
pressure. The home screens can be modified to display your choice of up to 16 system parameters using four different display
formats.
The Favorites screen provides another way to display your choice of data. Separate favorites screens can be set up for each
access level: user, operator, and technician.
The metering screens are designed for viewing only. Settings cannot be changed through the metering screens.
The metering screens display:
• Favorites
• Electrical, including generator set, inputs, outputs, and battery charger
• Engine
• Operation records
• Load Management
Figure 17 Metering Menu, Expanded
TP-7141 11/22 35
4.1.1 Home
At startup, the controller displays the home screen shown in Figure 18. Two home screens showing up to 16 different generator
set values can be displayed. Touch the square buttons at the bottom of the screen to move between the two home screen
displays.
Touch the open square to move to the other

home screen.
Figure 18 Home Screens
36 TP-7141 11/22
The parameters shown below are displayed on the home screens by default. Follow the instructions in the next section to
change the parameters displayed. Up to 16 system parameters can be selected for display on the two Home screens.
Default Parameters
Average Voltage L to L
Frequency
Battery Voltage
Oil Pressure
Total Real Power
Speed
Coolant Temperature
Fuel Level
Voltage L1-N
Voltage L2-N
Voltage L3-N
Total Power Factor
Current L1
Current L2
Current L3
Runtime Hours
Figure 19 Default Parameters Shown on the Home Screens
4.1.2 Customizing the Home Screens

The displayed values and the gauge styles for the Home screens can be changed as desired.
To add a gauge, there must be at least one empty space available on the screen. It may be necessary to remove a gauge to
create an empty space. When any gauge is removed, the remaining gauges shift to fill the vacated space, and the new open
space will appear at the end of the second screen. To change the order of the gauges, it is necessary to remove the gauges
using the trash can icon and then replace them in the desired order.
Choose up to 16 values from the following categories:
• Electrical – Generator
• Electrical – Inputs
• Electrical – Outputs
• Electrical – Battery Charger 1 (no battery charger data is available for KD models)
• Engine
• Engine – Overview (Tier 4 only)
• Engine – Fuel (Tier 4 only)
• Engine – Temperature (Tier 4 only)
• Engine – Pressures (Tier 4 only)
• Engine – Aftertreatment (Tier 4 only)
• Operation Records
• Load Management
• Paralleling
Full gauge, half gauge, vertical gauge, or tile (text only) styles are available.
TP-7141 11/22 37
Procedure to Remove Gauges from the Home Screens
Refer to Figure 20 during this procedure.

1. Touch the pencil icon.
2. Touch the trash can icon. Trash cans will then appear on each tile.
3. Touch the trash can for the gauge (or gauges) to be removed.
4. Touch the green check mark. Notice that the last position is now empty.
The numbers below correspond to the numbered steps in the Procedure to Remove Gauges from the Home Screen.
1 3
2 4
Figure 20 Removing Gauges from the Home Screen
38 TP-7141 11/22
Procedure to Add New Gauges to the Home Screen
Refer to Figure 21 during the following procedure.

1. Touch the pencil icon.
2. Touch the + icon.
3. Select the category for the parameter to be displayed.
4. Touch the parameter.
5. Four gauge styles will appear. Touch to choose the style.
6. The new gauge is added. Notice that the newly added gauge appears in the last open space.
Note:
A maximum of 16 values can be displayed. One or more blank tiles must be available before gauges can be added.
The numbers below correspond to the numbered steps in the Procedure to Add New Gauges to the Home Screen.
1 4
2 5
3 6
Figure 21 Adding Gauges to the Home Screen
TP-7141 11/22 39
4.1.3 Favorites
The Favorites screen allows the user, operator, and technician to view selected parameters from different categories on one
screen.
Procedure to View Favorites

1. Touch Metering or the gauge symbol.
2. Touch Favorites or the star symbol.
3. Favorite parameters are displayed.
The numbers below correspond to the numbered steps in the Procedure to View Favorites.
1 3
Figure 22 Metering, Favorites

A user can select the parameters to display in the Favorites screen. A different set of favorites can be selected for each access
level. The operator and technician can select different favorites than the user. There is no limit to the number of favorites that
can be selected. See Figure 23 for instructions to select parameters from nine different categories:
• Electrical – Generator
• Electrical – Inputs
• Electrical – Outputs
• Engine
• Operation Records
• Load Management
• Paralleling
Note:
The parameters are listed on the Favorites screen in the order selected.
40 TP-7141 11/22
Procedure to Select Favorites
First, go to the Favorites screen as described in Figure 22.
1. Touch the Star icon in the upper right corner of the screen.
2. Touch the category.
3. Touch the stars for one or more parameters to be included in the Favorites display. The selected stars turn solid
white.
4. Touch the left arrow symbol to close the selection box. Repeat steps 2 and 3 for other categories.
5. Observe that the selected parameters are now displayed in the order they were selected.
The numbers below correspond to the numbered steps in the Procedure to Select Favorites.
1 4
2 5
Figure 23 Selecting Favorites
TP-7141 11/22 41
4.2 Electrical
4.2.1 Metering Screens, Electrical, Generator
The Generator Metering screens display generator set electrical information such as output voltage, frequency, current, and
other electrical data listed in Figure 25. The metering screens display information only. Parameter settings cannot be changed
from the metering screens.
Procedure to View Generator Electrical Metering Screens

1. In the navigation panel on the left side of the screen, touch Metering or the gauge symbol.
2. Touch Electrical or the sine wave symbol.
3. Touch Generator or the generator symbol.
4. Touch the arrows on the right side of the screen to scroll through the electrical metering screens.
The numbers below correspond to the numbered steps in the Procedure to View Generator Electrical Metering Screens.
1 3
2 4
Figure 24 Electrical Metering Screen
42 TP-7141 11/22
The generator metering screen displays the values shown below.
Parameter Units
Frequency Hz
Average Voltage L-L V
Average Voltage L-N V
Three Phase Average Current kA
Total Real Power kW
Total Reactive Power kVAR
Total Apparent Power kVA
Total Power Factor
Battery Voltage * V
Controller RTC Battery Voltage V
Voltage L1-L2 V
Voltage L2-L3 V
Voltage L3-L1 V
Voltage L1-N V
Voltage L2-N V
Voltage L3-N V
Current L1 A or kA
Current L2 A or kA
Current L3 A or kA
Real Power L1 kW
Real Power L2 kW
Real Power L3 kW
Reactive Power L1 kVAR
Apparent Power L1 kVA
Voltage Phase Angle L1-L2 Degrees
Voltage Phase Angle L1-L3 Degrees
* On units with redundant starters, battery voltage is
displayed for two batteries.
Figure 25 Generator Metering Data
TP-7141 11/22 43
4.2.2 Input Metering
Input status is displayed on the Metering, Electrical, Inputs screen.
The standard, dedicated inputs are listed in the previous section Inputs and Outputs. Optional input/output modules are avail able.
I/O Module 0 inputs and outputs are factory set. I/O Module 1 outputs are also factory set. I/O Module 1 inputs and I/O Module
2 inputs and outputs are configurable.
A personal computer and Kohler SiteTech™ software are required to assign input functions to the inputs on the I/O modules.
SiteTech is available to Kohler authorized distributors and dealers.
Procedure to View Input Status

3. Touch Inputs or the i/o symbol with the bold i.
4. Touch the up and down arrows on the right side of the screen to view the inputs.
The numbers below correspond to the numbered steps in the Procedure to View Input and Output Status.
1 3
2 4
Figure 26 Inputs Metering Screen
Parameter Values Parameter Values

E-Stop Local Yes/No Key Switch Auto On/Off
E-Stop Remote Yes/No Key Switch Run On/Off
Battery Charger Fault True/False Remote Start On/Off
Breaker Closed Yes/No OFF Button On/Off
Breaker Tripped/Open Yes/No RUN Button On/Off
Coolant Temperature °F or C AUTO Button On/Off
Idle Mode Start On/Off Speed Bias V
Fuel Level % Voltage Bias V
Fuel Leak Alarm On/Off I/O Module 0 Digital Inputs 0-7 On/Off
Low Fuel Level Switch True/False I/O Module 1 Digital Inputs 0-7 On/Off
Ground Fault Relay On/Off I/O Module 2 Digital Inputs 0-7 On/Off
Figure 27 Inputs Included in the Inputs Metering Screen
44 TP-7141 11/22
4.2.3 Output Metering
The Electrical Metering screen for outputs displays the status of the outputs.
The standard, dedicated outputs are listed in Section 2. Optional I/O Modules are available.
A personal computer and Kohler SiteTech™ software are required to assign output functions to the programmable outputs on
the I/O module. SiteTech is available to Kohler authorized distributors and dealers.
Procedure to View Output Status

3. Touch outputs or the i/o symbol with the bold letter o.
4. Touch the up and down arrows on the right side of the screen to view the outputs.
The numbers below correspond to the numbered steps in the Procedure to View Output Status.
1 3
2 4
Figure 28 Outputs Metering Screen
Output Units/Value
Run/Generator Running On/Off
BCA Excitation On/Off
Horn On/Off
Common Failure/Fault On/Off
Common Warning On/Off
High Coolant Temperature On/Off
Close Breaker On/Off
Trip Breaker On/Off
Alternator Excitation %
I/O Module 0 Digital Outputs0-7 On/Off
Figure 29 Outputs Displayed in the Outputs Metering Screen
TP-7141 11/22 45
4.2.4 Battery Charger
The electrical metering screens for battery chargers are not applicable for model KD generator sets.
4.3 Engine
The Engine Metering screen displays the engine data shown in Figure 31.
Procedure to View the Engine Metering Screen
2. Touch Engine or the engine symbol.
3. Observe the engine data shown on the screen.
The numbers below correspond to the numbered steps in the Procedure to View the Engine Metering Screen.
1 3
Tier 4 Engine Metering Screen

2
Figure 30 Metering, Engine
46 TP-7141 11/22
Tier 2 Generator Models Tier 4 Generator Models
Item Units Item Units
Engine Speed RPM Frequency Hz
Oil Pressure PSI Coolant Temp °F or °C
Oil Temperature °F or °C Oil Pressure PSI or kPa
Coolant Temperature °F or °C Engine Speed RPM
Crankcase Pressure PSI/kPa DEF Level %
Intake Manifold Pressure PSI Fuel Level %
Intake Manifold Temperature °F or °C
Intercooler Coolant Temperature
°F or °C
(K175 engines only)
Ambient Temperature °F or °C
ECU Runtime Hours Hours
Fuel Pressure PSI/kPa
Common Rail Fuel Pressure PSI/kPa
Fuel Temperature °F or °C
Fuel Consumption Rate Gallons/hour
Figure 31 Engine Metering Data
4.3.1 Overview
The Overview Metering screen displays the overview data shown in Figure 33.
Note:
This menu is only available on Tier 4 generator sets.
Procedure to View the Engine Overview Metering Screen
3. Touch Overview.
4. Observe the data shown on the screen.
The numbers below correspond to the numbered steps in the Procedure to View the Engine Overview Metering Screen.
1 3
2 4
Figure 32 Metering, Engine Overview
TP-7141 11/22 47
Tier 4 Generator Sets
Item Units
Engine Speed RPM
Oil Pressure PSI or kPa
Coolant Temp °F or °C
Fuel Level %
Run Time Hours Hours
SCR System State ScrSytemStates
DEF Level %
SCR HC Level %
SCR Temperature °F or °C
Coolant Level
Aftercooler Coolant Level
ECU Battery Voltage V
ECU Keyswitch Voltage V
SCR Operator Inducement
Severity Level
Engine Derate Is Active Yes/No
NOx Control Torque Limit %
Engine Operating State EngOperatingStates
Figure 33 Engine Overview
48 TP-7141 11/22
4.3.2 Fuel
The Fuel Metering screen displays the fuel data shown in Figure 35.
Note:
Procedure to View the Engine Fuel Metering Screen
3. Touch Fuel.
The numbers below correspond to the numbered steps in the Procedure to View the Engine Fuel Metering Screen.
1 3
2 4
Figure 34 Metering, Engine Fuel

Tier 4 Generator Sets
Item Units
Fuel Level %
Total Fuel Used liters
Fuel Consumption Rate L/Hr
Fuel Temperature ˚F or ˚C
Fuel Pressure PSI or kPa
Common Rail Fuel Pressure Bar
Common Rail 2 Fuel Pressure Bar
Water In Fuel Yes/No
Figure 35 Fuel Metering Data
TP-7141 11/22 49
4.3.3 Temperature
The Temperature Metering screen displays the Temperature data shown in Figure 37.
Note:
Procedure to View the Engine Temperature Metering Screen
3. Touch Temperature.
The numbers below correspond to the numbered steps in the Procedure to View the Temperature Metering Screen.
1 3
2 4
Figure 36 Metering, Engine Temperature
50 TP-7141 11/22
Item Unit
Coolant Temperature °F or °C
Oil Temperature °F or °C
DEF Temperature °F or °C
Fuel Temperature °F or °C
Intake Manifold Temperature °F or °C
Ambient Temperature °F or °C
Auxiliary Coolant Temperatue °F or °C
ECU Temperature °F or °C
Turbo 1 Turbine Intake Temperature °F or °C
Turbo 2 Turbine Intake Temperature °F or °C
Turbo 1 Compressor Intake Temperature °F or °C
Exhaust Gas Port 1 Temperature °F or °C
Figure 37 Engine Temperature Metering Data
TP-7141 11/22 51
4.3.4 Pressure
The Pressure Metering screen displays the pressure data shown in.
Note:
Procedure to View the Engine Pressure Metering Screen
3. Touch Pressure.
The numbers below correspond to the numbered steps in the Procedure to View the Pressure Metering Screen.
1 3
2 4
Figure 38 Metering, Engine Pressure

Item Unit
Oil Pressure PSI or kPa
Fuel Pressure PSI or kPa
Crankcase Pressure PSI or kPa
Barometric Pressure PSI or kPa
Intake Manifold Pressure PSI or kPa
DEF Doser Absolute Pressure PSI or kPa
Common Rail Fuel Pressure Bar
Common Rail 2 Fuel Pressure Bar
Figure 39 Engine Pressure Metering Data
52 TP-7141 11/22
4.3.5 Aftertreatment
The Aftertreatment Metering screen displays the aftertreatment data shown in Figure 41.
Note:
Procedure to View the Engine Aftertreatment Metering Screen
3. Touch Aftertreatment.
The numbers below correspond to the numbered steps in the Procedure to View the Engine Aftertreatment Metering
Screen.
1 3
2 4
Figure 40 Metering, Engine Aftertreatment
TP-7141 11/22 53
Item Units
SCR System State ScrSytemStates
DEF Level %
DEF Temperature °F or °C
DEF Concentration %
DEF Consumption L/Hr
SCR HC Level %
DEF Doser Absolute Pressure PSI or kPa
DEF Doser Pump Speed RPM
DEF Doser Pump Command %
Engine Derate Is Active Yes/No
NOx Control Torque Limit %
SCR Operator Inducement Severity Level
SCR Defrost Complete Yes/No
DEF Defrost Complete Yes/No
DEF Level Inducement State AftertreatmentInducementState
System Failure Inducement State AftertreatmentInducementState
DEF Level Time To Next Inducement Min
System Failure Time To Next Inducement Min
SCR Exhaust Gas Mass Flow kg/Hr
DEF Line Heater 1 On/Off
DEF Line Heater 2 On/Off
Aftertreatment 1 Intake NOx ppm
Aftertreatment 1 Outlet NOx ppm
Aftertreatment 1 Outlet NH3 ppm
Figure 41 Aftertreatment Metering Data
54 TP-7141 11/22
4.4 Operation Records
The Op Records screen displays generator set operation records such as engine run time, last start date, and other information
shown in Figure 43.
To reset the maintenance records after performing scheduled oil changes and other maintenance tasks, log in as Technician.
The password is required.
Procedure to View Operation Records

2. Touch Op Records or the notepad symbol.
3. Touch the up and down arrows on the right side of the screen to scroll through the generator set operation records.
The numbers below correspond to the numbered steps in the Procedure to View Operation Records.
1 3
Figure 42 Metering Screen, Operation (Op) Records
TP-7141 11/22 55
Parameter Units
Total Run Time Hours Hours
Total Loaded Hours Hours
Total Unloaded Hours Hours
Total kW Hours kWh
Controller Hours Hours
Controller Run Time Hours Hours
ECU Run Time Hours Hours
Number of Starts
Number of Crank Attempts
Last Crank Duration Seconds
Last Start Run Time Duration Hours
Last Start Time of Day
Last Start Date (Day)
Last Start Date (Month)
Last Start Date (Year)
Last Stop Time of Day
Last Stop Date (Day)
Last Stop Date (Month)
Last Stop Date (Year)
Total Run Time Since Maintenance Hours
Loaded Hours Since Maintenance Hours
Unloaded Hours Since Maintenance Hours
kW Hours Since Maintenance kWh
Reset Maintenance Records * Yes/No *
* The Technician password is required to reset maintenance records.
Figure 43 Operation Records
56 TP-7141 11/22
4.5 Load Management
Load management allows a generator set to support load which may occasionally exceed the rated capacity of the generator
set.
Note:
Life safety and critical loads should never be connected to a device that is managed as a priority through load management.
Load management should only be used on loads that can be turned on and off as required to allo w the generator system to
operate reliably for life safety and critical loads that are always connected.
In single-generator set applications, load management may shed unimportant but highly demanding loads when the generator
set is overloaded, preventing a power outage caused by the generator set going offline.
In paralleling systems, load management permits the bus to stay at rated voltage and frequency while an additional generator
set is synchronizing to it. It ensures the total load on the bus does not exceed the total capacity of the generators online at a
given moment. Load management may shed lower priority loads in the event that a generator fails or the system is waiting for a
generator to synchronize and close to the bus.
The load management function in the generator set controller supports up to 16 load control priorities. In a single -generator set
application, the system will be limited to 16 (8 for each D8IOM) load control priorities for KD models. In paralleling systems, the
full 16 load control priorities can be used. These priorities generate internal notices for the add and shed conditions. The internal
notices are generated any time a load is add or shed, but they will only operate a load control relay if they are co nfigured to a
digital output.
Optional I/O modules are required for load management connections.
• For KD models, one or two digital input/output modules (DIOMs) are required, providing up to 8 or 16 outputs (4 per
original DIOM or 8 per updated D8IOM) to be accessed and configured to control up to 16 loads (each load priority can
interrupt several devices) from a single generator.
• For non-KD Models, the optional 4 input / 15 output relay module is required, providing up to 14 RDO outputs to be
accessed and configured to control up to 14 loads (each load priority can interrupt several devices) from a single
generator.
In paralleling applications, up to 16 load priorities can be accessed and the load priorities can be divided among all of the
generator sets. For instance, Generator #1 can support Load Priorities 1 and 4, Generator #2 can support Priorities 2 and 5 and
Generator #3 can support Priorities 3 and 6. This configuration requires the optional relay module on each generator and perm its
partial load control functionality even if one controller is powered down or fails (redundancy).
Load Priority 1 is shed last and added first. The priorities are added in increasing sequence and shed in decreasing sequence.
All load priorities are immediately shed when load control is initiated. Load control is initiated when the system receives a start
signal (a system start, a remote start, or a start by communication). In a paralleling application, the controller can receiv e a start
signal from any generator set which is connected to the PGEN communication network. Pressing RUN on the controller will not
cause the loads to shed.
All loads are added immediately when load control is de-activated. Load control is de-activated when the start signal is removed.
Load management adds loads based on the capacity of the system—loads will add more quickly if the available capacity is
higher.
Load management sheds loads based on the degree of overload of the system—loads will shed more quickly as the degree of
the system overload increases.
Note:
If paralleling and using generator management, the Generator Management Start Percentage setting should be significantly
lower than the Overload Shed Threshold so that additional generator sets will come online before a load is shed. Go to the Gen
Management group in SiteTech to adjust the Generator Management Start Percentage setting. The Overload Shed Threshold
can be adjusted at Metering>Load Manage>Status>System. See the Load Management Setup Section for more information.
An under frequency event or overload event will also shed load. If a load priority is shed due to one of these events, the load
management system can be configured to leave the priorities as shed until a related event occurs to allow them to be add back .
This prevents the system from entering a shed and add cycle. For example, if the load is shed due to overload and removing
the load removes the overload condition, if the load is added back it could cause the overload condition again and shed the l oad
again.
TP-7141 11/22 57
The load control will shed subsequent loads more quickly if shedding a load did not remove the overload or underfrequency
condition.
In a single-generator set application the load management logic uses the generator metering.
In a paralleling application the load management logic uses the bus metering. The priorities are set as a system so the load
management settings are identical in each controller and each controller will shed and add a given load priority at the same time.
In a paralleling application where Generator Management is used, some generator sets may be shut down (turned Off) by the
Generator Management. Even if the generator set is Off, it will manage load priorities as part of the system, performing a lo ad
add and load shed as needed. This may seem contrary to intuition, but the generator sets are acting as a system. If voltage and
frequency of the paralleling bus are adequate, and Load Add accumulators are met, the loads will be enabled, even if a partic ular
generator set is shut down by the Generator Management.
58 TP-7141 11/22
4.5.1 Metering, Load Management Overview Screen
The overview provides a simple graphical view of the load management system.
Procedure to View Load Management Overview

1. In the navigation panel on the left side, touch Metering or the gauge symbol.
2. Touch Load Manage or the three horizontal bars symbol.
3. Touch Overview or the globe symbol.
4. Observe the load management status.
The numbers below correspond to the numbered steps in the Procedure to View Load Management Overview.
1 3
2 4
Figure 44 Metering Screens, Load Management Overview

The loads are listed in order of priority. If the loads were provided a custom name during the system set up, the name will appear.
If not, the name will appear as Priority X, where X is the priority number.
Note:
Custom names for loads can be set up through SiteTechTM. Contact a Kohler authorized distributor or dealer.
If a load is in the process of being add or shed, the load will have an indication of % until that occurs. It is shown as a p ercentage
since the time varies based on the capacity available. When the % reached 100%, the load management will initiate the add or
shed.
The key at the bottom of the display shows the current load as well as the total online capacity and available capacity. If a
generator is offline (either due to a shutdown via Generator Management or a fault or the generator is not commun icating via
PGEN), unavailable capacity will be shown as well.
Total Load is the value of all the loads on the system. This includes loads that are not assigned a priority and are always
connected.
Online Capacity is the capability of the system with all the generators that are currently online. For a single-generator set
application, this is the total capacity of the generator. For a paralleling system, this is the sum of capacity for all online generators.
Available Capacity indicates the difference between the Online Capacity and the Total Load. It is remaining capacity available
for additional loads to be potentially added.
TP-7141 11/22 59
4.5.2 Metering, Load Management, Status
The status screens provide a listing of the load management metered values as well as key settings for reference.
4.5.2.1 Status, System
The Load Management System Status provides indication of key settings and values related to the overall operation of the load
management system.
Procedure to View Load Management System Status

3. Touch Status or the list icon.
4. Touch System or the list icon.
The numbers below correspond to the numbered steps in the Procedure to View Load Management System Status.
1 3
2 4
Figure 45 Metering, Load Management, Status, System
60 TP-7141 11/22
Parameter Units
Load Management Enabled Yes/No
Total Load kW
Online Capacity kW
Available Capacity kW
Total Bus Capacity kW
Generators Online
Generators Failed
Next Priority to Shed
Time Based Load Add Enabled Yes/No
Time Based Add Time Seconds
Time Based Load Add Timer Active Yes/No
kW Capacity Add Threshold %
kW Capacity Add Accumulator %
Require Reset After kW Shed Yes/No
Overload Shed Threshold %
Overload Shed Accumulator %
Under Frequency Shed Threshold %
Under Frequency Shed Accumulator %
Require Reset After UF Shed Yes/No
Under Frequency Inhibit Enabled Yes/No
Under Frequency Inhibit Time Seconds
Under Frequency Inhibit Time Remaining Seconds
New Gen Online As Reset Yes/No
Stage Loads After Utility Return Yes/No
Figure 46 Load Management System Status Parameters
Load Management Enabled indicates a Yes if the load management system is being used on the generator or paralleling
system. If No, load management is not being used and will not drive any of the outputs.
Total Load indicates the value of all the loads on the system. This includes loads that are not assigned a priority and are always
connected.
Online Capacity indicates the capability of the system with all the generators that are currently online. For a single-generator
set application, this is the total capacity of the generator. For a paralleling system, this is the sum of capacity for all online
generators.
Available Capacity indicates the difference between the Online Capacity and the Total Load. It is remaining capacity available
for additional loads to be potentially added.
Generators Online indicates the number of generators online. For a single-generator set application, this will be 1. For
paralleling systems, it will be the total number of generators that are on the closed to the bus.
Generators Failed indicates in a paralleling system if any of the generators on PGEN are in a shutdown (fault) condition. Note
that as long as the controller is still communicating on PGEN, load management can control the outputs on the controller for a
generator this is in a shutdown condition. For a single-generator set application this will be 0.
Next Priority to Shed indicates the priority number of the next load that will be shed should the system enter a condition that
requires a load shed.
TP-7141 11/22 61
Time Based Load Add Enabled indicates if the Time Based Load Add functionality is enabled. This function will add the loads
in the priority order based on time once the system has reached an acceptable voltage and frequency. This technique does not
consider load capacity or expected kW for each priority. The loads are staged sequentially at a time interval defined by the Time
Based Load Add Time. For example, if the Time Based Load Add Time is set to 10 seconds, once the system reaches an
acceptable voltage and frequency, a 10 seconds timer will start. When that time expires, Priority 1 will be added. The 10 second
timer will start again and Priority 2 will be added when it expires. This will continue until all priorities are added.
Note:
Time Based Load Add does not consider the capacity of the generator set or generator system or the expected load of each
priority before adding and may overload the system. If an under frequency or overload shed becomes active, Time Based Load
Add will abort and not add any additional loads.
Time Based Load Add sheds all priorities at startup. It is not configurable to shed fewer loads.
Time Based Load Add Time is the amount of time between each load priority addition when using Time Based Load Add.
Time Based Load Add Timer Active indicates if a timer is currently in use and the system is preparing to add a load when the
timer expires. If this is Yes, the system will add a load when it expires. If this is No, no additional loads will be added based on
Time Based Load Add.
kW Capacity Add Threshold sets the maximum total load that the load management system will intentionally add to the
generator set or generator system. To determine whether adding the next priority load will push the system over the threshold,
the resulting total is calculated by adding the expected load to the current load. For example, if the threshold is set at 90%, the
current load is at 70% of total capacity, and adding the next priority load will add 15% of total capacity, adding the load will put
the system at 85% of total capacity, which is below the threshold. The kW Capacity Add Accumulator will start. If adding the load
would put the system at 92% capacity, the load will not be added.
The total load may exceed the kW Capacity Add Threshold value if the power required by a load is higher than the expected
kW.
kW Capacity Add Accumulator indicates progress until the next priority load will be added. The timer starts if adding the next
priority load will not exceed the kW Capacity Add Threshold for the system. Load management will add the next priority load
when the kW Capacity Add Accumulator reaches 100%.
The kW Capacity Add Accumulator is a weighted timer. The Accumulator will speed up or slow down depending upon the
available capacity and the expected kW. The time required will increase as the calculated total load increases and will decrease
as the calculated total load decreases.
Require Reset After kW Shed forces the system to lock out adding loads if an overload shed occurs. The overload shed is not
expected to operate, so an overload condition is an indication of a misconfiguration of the system (such as an incorrect expe cted
kW load level for a priority). Requiring a reset prevents load cycling due to a misconfiguration. See New Gen Online As Reset.
Overload Shed Threshold is an indication of the amount of overload a system can experience before load shed initiates. For
example, if this is set to 100%, if the total load exceeds 100% then the Overload Shed Accumulator starts. Load management
will shed the next priority load when the Overload Shed Accumulator reaches 100%.
Overload Shed Accumulator is an indication of progress until the load will be shed due to an overload situation.
The time to shed a priority will increase as the overload condition increases and will decrease as the overload condition
decreases. The Accumulator is not a fixed time but will speed up or slow down depending upon the overload.
Under Frequency Shed Threshold is the frequency droop (operation below nominal) allowed before the system will shed a
load. For example, if this is set to 90% and the frequency of the generator drops below 90% of nominal then the Under Frequency
Shed Accumulator starts. When the Under Frequency Shed Accumulator reaches 100%, load management will shed the next
priority load.
Under Frequency Shed Accumulator is an indication of progress until the load will be shed due to an under frequency situation.
The time to shed a priority will increase as the under frequency condition increases and will decrease as the under frequency
condition decreases. The Accumulator is not a fixed time but will speed up or slow down depending upon the amou nt exceeding
the under frequency threshold.
Require Reset After UF Shed forces the system to lock out adding loads if an under frequency shed occurs. The under
frequency shed is not expected to operate, so an under frequency condition is an indication of a misconfiguration of the system
(such as an incorrect expected kW load level for a priority). Requiring a reset prevents load cycling due to a misconfiguration.
See New Gen Online as Reset.
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Under Frequency Inhibit Enabled indicates if the load management system will ignore any under frequency conditions for a
period of time as the generator is starting up. This allows the system to reach the rated voltage and frequency before the un der
frequency shed is detected and forces a load shed.
Note:
This setting is only necessary on applications where some of the load priorities are not shed on start up.
Under Frequency Inhibit Time is the period of time during start up when an under frequency condition is ignored. This is only
applicable if the Under Frequency Inhibit is enabled.
Under Frequency Inhibit Time Remaining indicates the amount of time left before the under frequency shed logic will begin
operating.
New Gen Online as Reset allows the load management to see an additional generator connecting the paralleling bus as a reset
condition. If a load was shed based on an overload shed or under frequency shed, the load will now be considered for addition
again if the kW Capacity threshold is met.
Stage Loads After Utility Return reduces the inrush loading to the utility when returning loads after a power failure. This is
used to reduce fluctuations in the utility voltage during a transition from the generator system to the utility when the util ity source
impedance is relatively high. The loads are added based on Time Based Add Time settings.
4.5.2.2 Load Management Status, Load
The Load Management Status Load screen provides indication of the shed status for each load priority.
Procedure to View Load Management Status, Load
3. Touch Status or the list icon.
4. Touch Load or the horizontal bars icon.
The numbers below correspond to the numbered steps in the Procedure to View Load Management Status, Load.
1 3
2 4
Figure 47 Load Management Status, Load
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Parameter Units
Priority 1 Load Shed Yes/No
Figure 48 Load Shed Status Parameters
A Yes indicates the load is currently shed due to load management. A No indicates that load management is not requiring the
load to be shed. If load management indicates No and the load is not powered, there are other issues in the system.
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4.5.3 Load Management Setup Details
The setup details screen provides a table view of key settings for the load management configuration.
Procedure to View Load Management Setup Details

3. Touch Setup Details or the details symbol.
The numbers below correspond to the numbered steps in the Procedure to View Load Management Setup Details.
1 3
2 4
Figure 49 Metering, Load Management, Setup Details

The loads are listed in order of priority. If the loads were provided a custom name during the system set up, the name will appear.
If not, the name will appear as Priority X, where X is the priority number.
Note:
Custom names for loads can be set up through SiteTech. Contact a Kohler authorized distributor or dealer.
The table indicates the expected kW for each load.
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66 TP-7141 11/22
Section 5. Setup Menus and Screens
5.1 Setup Menus

Parameter settings are loaded onto the controller using a configuration file. Configuration files are created and loaded at the
factory. Configuration files are created according to the model and options ordered for each generator set. Custom configuration
files can be provided on request if the default settings are not correct for the application.
The values displayed in the Setup Menus are parameter settings. They are not actual measured values. Refer to the Metering
Displays for measured values.
The Setup Menus display the controller configuration settings as shown in the following sections. Some of the settings can be
adjusted by an operator, installer, or service technician with Operator access or higher.
The setup screens include:
• Electrical, including generator, battery charger, and paralleling
• Engine
• Communication
• Event Configuration
• Genset Info
Figure 50 Setup Menu

5.1.1 Changing Settings
Some settings can be changed by an operator or service technician with Operator access or higher. Settings that can be changed
are highlighted in blue when an operator or higher level password has been entered.
Note:
Have setup and adjustments of the generator set controller performed only by an authorized Kohler distributor. The setup and
adjustments are password protected.
General Procedure to Change Settings (for authorized Kohler distributors or service technicians)
1. Use an external flash drive or SiteTech to export the configuration data and save the file for future reference, if needed.
See the APM603 Controller Service Manual for instructions.
2. Go to Controller Settings and log in with the Operator or Technician level password. See the Controller Settings section
for instructions.
Note:
The access level login expires after 1 hour. See the Controller Settings Section for instructions to change the session
duration, if necessary.
3. In the navigation menu on the left side of the screen, touch Setup.
4. Touch the desired category (Electrical, Engine, etc.)
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5. Touch the desired subcategory.
6. The settings are displayed. Settings that can be changed appear in a blue box.
7. Touch the blue box with the setting that you wish to change. A keypad window opens on the screen.
8. Use the keypad to enter the new setting and touch the green arrow.
9. Check the setting for the new value.
Notes:
There may be clicking sounds coming from the controller when some settings are changed.
Some changes may require the controller to restart.
5.2 Electrical Setup

5.2.1 Generator Electrical Setup
The generator setup screens display generator electrical settings such as system voltage, frequency, kW ratings, and other
electrical data listed in Figure 52.
Procedure to View Generator Setup Parameters

1. In the navigation menu on the left side of the screen, touch Setup or the settings symbol.
The numbers below correspond to the numbered steps in the Procedure to View Generator Setup Parameters.
1 3
2 4
Figure 51 Generator Setup Screen
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Parameter Units Write Access Notes
System Voltage L-L V Technician
System Voltage L-N V Technician
System Frequency Hz N/A Factory-set to 50 or 60 Hz
Phase None Technician Single Phase, Single Phase Dogleg, Three Phase Wye, or Three Phase Delta
kW Rating kW Technician
Rated Current A Technician
Voltage Adjust V Operator
Speed Adjust RPM Operator
Operating Mode None N/A Factory-set to Standby or Prime
Maximum Power Limit kW N/A 102% of Standby Rating, 112% of Prime Rating
Maximum Current A N/A Factory configured
Figure 52 Generator Settings, Electrical Setup
5.2.2 Battery Charger Setup Screens

The battery charger setup screens do not apply to model KD generator sets. Refer to the Installation and Operation Manual
provided with the battery charger for setup and operation instructions.
5.2.3 Paralleling Setup

The paralleling setup screen indicates if the system has onboard paralleling enabled and if the speed and voltage bias inputs
are configured.
Note:
The Paralleling menu will appear on the Home screen if Paralleling Enabled is set to Yes in this menu.
Procedure to View Paralleling Setup Parameters

1. In the navigation menu on the left side of the screen, touch Setup or the settings symbol.
3. Touch Paralleling or the two generator symbol.
4. Observe the paralleling parameters.
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The numbers below correspond to the numbered steps in the Procedure to View Paralleling Setup Parameters.
1 3
2 4
Figure 53 Paralleling Setup Screen
Parameter Units Write Access Level

Paralleling Enabled Yes/No Technician
Speed Bias Input Off Operator
Voltage Bias Input 0 to 5 Operator
Neg (-) 5 to 5
0 to 10
Neg (-)10 to 10
Figure 54 Paralleling Setup Parameters, Electrical Setup
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5.3 Engine Setup
The Engine Setup screen includes the engine settings shown below.
Procedure to View Engine Settings

1. In the navigation panel on the left side of the screen, touch Setup or the setup symbol.
3. Touch the arrows to scroll through the screens.
The numbers below correspond to the numbered steps in the Procedure to View Engine Settings.
1 3
Figure 55 Setup Screen, Engine

ECU Power Override On/Off Operator
Generator Rated Speed RPM N/A
Crank Disconnect Speed RPM N/A
Start Aid Time Seconds Technician
Cranking Start Aid Time Seconds Technician
Crank On Time Seconds Technician
Crank Off Time Seconds Technician
Crank Cycle Limit Integer Technician
Cooldown Time Limit Seconds Technician
Cooldown Temp Limit Degrees (F) Technician
Figure 56 Engine Setup Parameters
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ECU Power Override provides power to the engine’s ECU without cranking the engine. This feature may be turned on for some
troubleshooting or service procedures; otherwise, it should be off.
Engine Speed displays the target engine speed. Typically, this is 1800 RPM but may be adjusted if the system is required to
operate at a slightly modified speed.
Crank Turning Speed is the limit between engine rotating and engine stopped. When the engine speed (RPM) is above this
limit, the controller considers the engine to be turning. Until the speed falls below this limit, the controller will prevent
reengagement of the starter.
Start Aid Time displays the time programmed to allow the engine starting aid to warm up before cranking the engine.
Cranking Start Aid Time indicates the time programmed to allow operation of a preheat or ether system during the engine
crank cycle.
Crank On Time indicates the time allocated for generator set crank in seconds, from 10 to 30 seconds.
Crank Off Time indicates the time allocated for generator crank pause in seconds, from 1 to 60 seconds.
Crank Cycle Limit indicates the allowed number of crank attempts before the system indicates that crank failed, from 1 to 6
cycles.
Cooldown Time Limit indicates the amount of time allocated for the engine cooldown period.
Cooldown Temp Limit indicates the required temperature the engine must reach during cooldown before the engine will shut
off.
Note:
When the engine is signaled to stop, it will continue to run through the cooldown cycle unless the unit is OFF or a shutdown fault
occurs. In a paralleling application, if a shutdown occurs the generator will still perform a cool down for a period of time defined
by Trip to Shutdown Delay in Protective Relay functions.
The cool down will run until the engine reaches the cooldown temperature limit or the cooldown time expires, whichever happens
first. If you want to skip a cool down, set the Time Limit to 0. To force the unit to run the full Time Limit every time, set the Temp
Limit to an extremely low number that cannot possibly be achieved before the Time Limit expires.
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5.4 Setup, Communication Screen
The communication setup screen provides a list of Modbus and network communication settings.
Procedure to view Communication Setup:
1. In the navigation panel on the left side, touch Setup or the settings symbol.
2. Touch Communication or the serial connector symbol.
3. Touch the arrows on the right to scroll through the communication settings.
The numbers below correspond to the numbered steps in the Procedure to View Communications Setup.
1 3
Figure 57 Setup, Communication, Modbus

The following Modbus interfaces are available:
Connection Description Customer Connection

Terminals
RS-485 isolated Dedicated connection for paralleling (PGEN) TB12-8, 9, 10
RS-485 isolated For connection to Modbus devices TB12-19, 20, 21
RS-485 non-isolated For connection to the RSA III remote serial annunciator TB12-22, 23, 24
RJ-45 Ethernet connection For Modbus TCP, SNMP, and BACnet® Ethernet module
BACnet® is a registered trademark of ASHRAE.
The communication protocol for each port is factory set and not adjustable. Operator-level access is required to change the
other communication settings. Contact a Kohler authorized distributor or dealer for assistance.
Communication Protocol
The RS-485 ports are factory-set for the communication protocol applicable to each port.
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Baud Rates
The following baud rates can be selected. All devices in the Modbus network must use the same baud rate.
• None
• 9600 bps
• 19200bps
• 38400 bps
• 57600 bps
• 115200 bps
Modbus Address
Each generator set controller in a system must have a unique Modbus ® address.
Modbus TCP Unit ID

A unit ID is required for Modbus over TCP communication (Ethernet). The unit ID for TCP communication is analogous to the
Modbus address for serial communication.
Parameter Write Access Level
RSA Baud Rate Operator
RSA Comm Protocol Factory-set
RSA Modbus Address Operator
Modbus RTU Baud Rate Operator
Modbus RTU Comm Protocol Factory-set
Modbus RTU Modbus Address Operator
Modbus TCP Unit ID Operator
DHCP Enabled Operator
IP Address Operator
Subnet Mask Operator
Default Gateway Operator
DNS Server 1 Operator
DNS Server 2 Operator
Modbus TCP Connection Timeout Operator
Figure 58 Communication Settings
Modbus® Communications
The controller communicates using Modbus ® as a slave connection with the Modbus ® master initiating the communication.
The controller seeks the parameters and diagnostic information then responds back to the Modbus ® master. In addition, the
controller accepts information to alter controller parameters including generator set starting and stopping. Refer to the List of
Related Materials for available Modbus ® literature.
Note:
Only one Modbus® master can be connected to the controller when using Modbus RTU. Examples include the remote serial
annunciator, monitoring software, and switchgear applications.
Modbus® is a registered trademark of Schneider Electric USA, Inc.
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5.5 Event Configuration
The Event Configuration (Config) screen displays the setup of fault messages (warnings and shutdowns). Time delays, warning
limits, and shutdown limits for the faults are shown.
Procedure to View Event Configuration
1. In the navigation panel on the left, touch Setup.
2. Touch Event Config or the bell symbol with gears.
3. Touch the up and down arrows on the right to scroll through the event settings.
The numbers below correspond to the numbered steps in the Procedure to View Event Configuration.
1 3
Figure 59 Setup, Event Config
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Tier 2 Generator Sets (KD700-KD4000) Tier 4 Generator Sets (KD1250-4, KD2500-4, KD3250-4)
Event Units Write Event Units Write
Access Access
Under Voltage Warning Delay Seconds Operator Under Voltage Warning Delay Seconds Operator
Under Voltage Warning Limit % Operator Under Voltage Warning Limit % Operator
Under Voltage Shutdown Delay Seconds Operator Under Voltage Shutdown Delay Seconds Operator
Under Voltage Shutdown Limit % Operator Under Voltage Shutdown Limit % Operator
Over Voltage Warning Delay Seconds Operator Over Voltage Warning Delay Seconds Operator
Over Voltage Warning Limit % Operator Over Voltage Warning Limit % Operator
Over Voltage Shutdown Delay Seconds Operator Over Voltage Shutdown Delay Seconds Operator
Over Voltage Shutdown Limit % Operator Over Voltage Shutdown Limit % Operator
Under Frequency Warning Delay Seconds Operator Under Frequency Warning Delay Seconds Operator
Under Frequency Warning Limit % Operator Under Frequency Warning Limit % Operator
Under Frequency Shutdown Delay Seconds Operator Under Frequency Shutdown Delay Seconds Operator
Under Frequency Shutdown Limit % Operator Under Frequency Shutdown Limit % Operator
Over Frequency Warning Delay Seconds Operator Over Frequency Warning Delay Seconds Operator
Over Frequency Warning Limit % Operator Over Frequency Warning Limit % Operator
Over Frequency Shutdown Delay Seconds Operator Over Frequency Shutdown Delay Seconds Operator
Over Frequency Shutdown Limit % Operator Over Frequency Shutdown Limit % Operator
Over Power Warning Delay Seconds Operator Over Power Warning Delay Seconds Operator
Over Power Warning Limit % Operator Over Power Warning Limit % Operator
Over Power Shutdown Delay Seconds Operator Over Power Shutdown Delay Seconds Operator
Over Power Shutdown Limit % Operator Over Power Shutdown Limit % Operator
Over Current Warning Delay Seconds Operator Over Current Warning Delay Seconds Operator
Over Current Warning Limit % Operator Over Current Warning Limit % Operator
Over Current Shutdown Delay Seconds Operator Over Current Shutdown Delay Seconds Operator
Over Current Shutdown Limit % Operator Over Current Shutdown Limit % Operator
AC Signal Recovery Time Seconds Operator AC Signal Recovery Time Seconds Operator
Over Speed Shutdown Delay Seconds Operator Over Speed Shutdown Delay Seconds Factory
Over Speed Shutdown Limit % Operator Over Speed Shutdown Limit % Factory
Low Battery Voltage Warning Delay Seconds Operator Low Battery Voltage Warning Seconds Operator
Delay
Low Battery Voltage Warning Limit % Operator Low Battery Voltage Warning Limit % Operator
High Battery Voltage Warning Delay Seconds Operator High Battery Voltage Warning Seconds Operator
Delay
High Battery Voltage Warning Limit % Operator High Battery Voltage Warning Limit % Operator
Weak Cranking Battery Delay Seconds Operator Weak Cranking Battery Delay Seconds Operator
Weak Cranking Battery Limit % Operator Weak Cranking Battery Limit % Operator
Battery Voltage Event Recovery Seconds Operator Battery Voltage Event Recovery Seconds Operator
Delay Delay
Low RTC Battery Delay Seconds Operator EPS Supplying Load Delay Seconds Operator
Low RTC Battery Limit % Operator EPS Supplying Load On Limit % Operator
EPS Supplying Load Delay Seconds Operator EPS Supplying Load Off Limit % Operator
EPS Supplying Load On Limit % Operator Low Fuel Level Warning Limit % Operator
EPS Supplying Load Off Limit % Operator Critically Low Fuel Level Warning % Operator
Limit
Low Fuel Level Warning Limit % Operator Low Fuel Level Shutdown Limit % Operator
Critically Low Fuel Level Warning % Operator High Fuel Level Warning Limit % Operator
Limit
Low Fuel Level Shutdown Limit % Operator Fuel Level Delay Seconds Operator
High Fuel Level Warning Limit % Operator Maximum Power Warning Delay Seconds Operator
Fuel Level Delay Seconds Operator Enable Fuel Level Events On/Off Operator
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Tier 2 Generator Sets (KD700-KD4000) Tier 4 Generator Sets (KD1250-4, KD2500-4, KD3250-4)
Event Units Write Event Units Write
Access Access
Maximum Power Warning Delay Seconds Operator Enable Low Fuel Level Switch On/Off Operator
Shutdown
Battery Charger 1 Fault On/Off Operator Enable Low DEF Level Warning On/Off Technician
Battery Charger 2 Fault On/Off Operator Low DEF Level Warning Limit % Technician
Enable Fuel Level Events On/Off Operator Enable Low DEF Level Shutdown On/Off Technician
Low DEF Level Shutdown Limit % Technician
Load Bank Power Rating kW Technician
High HC Warning Delay Seconds Factory
High HC Warning Active Limit % Technician
High HC Warning Clear Limit % Technician
Critically High HC Warning Delay Seconds Factory
Critically High HC Warning Active % Factory
Limit
Critically High HC Warning Clear % Factory
Limit
Load Bank Malfunction Delay Seconds Factory
Figure 60 Status and Event Configuration

Note:
In Figure 60, percent (%) indicates a value relative to nominal. For example, a limit of 90% for the Under Voltage Warning means
the limit is the nominal voltage times 0.9. For a 480 volt system, this is 480 x 0.9 = 432 Volts. A limit of 110% is 1.10 times the
nominal value.
The delay for each event indicates how long the condition must be present to trigger the event. The limit on each event indicates
the condition that triggers the time delay to begin. If the condition corrects itself before the time delay expires, no event is
indicated and the timer resets. If the condition reappears, the timer starts over.
Under Voltage displays the percentage of the system voltage that the generator set must drop below for an undervoltage
condition to be indicated.
Over Voltage displays the percentage of the system voltage that the generator set must exceed before an overvoltage condition
be indicated.
Under Frequency displays the percentage of the system frequency that the generator set frequency must drop below for an
under frequency condition to be indicated.
Over Frequency displays the percentage of the system frequency that the generator set frequency must exceed before an over
frequency condition be indicated.
Over Power indicates the percentage of the system rated power that the generator set must exceed before an over power
condition be indicated.
Over Current indicates the percentage of the system rated current that the generator set must exceed before an over current
condition be indicated.
AC Signal Recovery Time is the amount of time allowed for AC signal to be lost before an AC Loss is indicated.
Over Speed is the engine speed that the engine must exceed for an overspeed condition to be indicated.
Low Battery Voltage displays the system battery voltage that the battery must drop below for a low battery voltage condition to
be indicated.
High Battery Voltage displays the system battery voltage that the battery must exceed for a high battery voltage condition to
be indicated.
Weak Cranking Battery displays the system battery voltage that the battery must drop below during engine crank for a weak
cranking battery condition to be indicated.
Battery Voltage Event Recovery Delay indicates the amount of time allowed for the battery voltage to recover from a fault.
The controller uses this delay to recognize the voltage as fully recovered and to prevent multiple warnings due to oscillating or
fluctuating battery voltage.
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Low RTC Battery indicates the Real Time Clock battery voltage that the voltage must drop below for a low RTC battery condition
to be indicated.
EPS Supplying Load On Limit and Off Limit define the % of load the generator must be suppling to be considered supplying
load.
Low Fuel Level and Critically Low Fuel Level define the fuel level limits as a percentage that must be met before indication is
provided.
High Fuel Level indicates the fuel level limit to be exceeded before indication is provided.
Battery Charger Fault indicates if a fault is detected by the battery charger.
Low DEF Level Warning Limit and Low DEF Level Shutdown Limit (tier 4 generator sets only) are customer configurable
parameters that define the points at which the controller issues a Low DEF Level Warning or a Low DEF Level Shutdown.
Low DEF Level Warning (tier 4 generator sets only) provides an advanced warning that DEF is low and the operation should
add DEF. Low DEF Level Shutdown shuts down the generator set to avoid an inducement.
Load Bank Power Rating (tier 4 generator sets only) specifies the amount of load in kW that the load bank will add to the
system to reduce hydrocarbon levels.
High HC Warning Active Limit (tier 4 generator sets only) initiates an advanced warning indicating that the operator needs to
increase load to avoid hydrocarbon buildup on the SCR. If the hydrocarbon levels continue to increase, the controller will apply
the load bank.
Critically High HC Warning Active Limit notifies the operator that the load bank is not effectively reducing the hydrocarbon
levels in the SCR. Failure by the operator to immediately correct the issue will result in engine torque reduction.
High HC Warning Delay and Critically High HC Warning Delay (tier 4 generator sets only) indicates the period of time from
when hydrocarbon levels exceed the warning limit to when the warning is issued. If hydrocarbon levels fall below the warning
limit during the delay period, then the warning is not issued.
Load Bank Malfunction Delay (tier 4 generator sets only) indicates the period of time from the generator set kW output level
falling below the load bank kW rating to the warning being issued. If the generator set kW output level increases a bove the load
bank kW rating, then the malfunction warning is not issued.
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5.5.1 Generator Set Information (Genset Info)
The GENSET INFO screen displays information about the generator set, including the model and serial number, and engine
and alternator information. The generator set information is loaded at the factory or read from the engine ECM. The GENSET
INFO data cannot be changed in the field.
Procedure to View Generator Set Information

1. In the navigation menu on the left side of the screen, touch Setup.
2. Touch Genset Info or the i symbol.
3. Observe the generator set serial number and other information.
The numbers below correspond to the numbered steps in the Procedure to View Generator Set Information.
1 3
Figure 61 Genset Info Screen
Generator Set Information

Generator Model
Generator Serial Number
ECU Serial Number
Alternator Part Number
Engine Model Number
Engine Serial Number
Controller Serial Number
Firmware Version
Figure 62 Generator Set Information (Genset Info)
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5.6 Data Log Screens
Data log files can be created and saved to a flash drive.
Before starting the data log, insert a flash drive into the USB port on the front of the controller. When the controller reco gnizes
the flash drive, the symbol appears at the top of the screen. Select one or more parameters to log over a period of time, and
select the log rate (intervals from once per second to once a day).
The data logger will collect data until STOP is selected on the screen or until the flash drive runs out of memory.
When complete, remove the flash drive from the controller and insert it into a personal computer to view the data files. The data
file name includes the date, an alpha-numeric code, and the .csv extension. The file can be opened using a spreadsheet program
like Microsoft Excel. A word-processing program or Notepad can also open the file. The data entries in the file are time- and
date-stamped.
Data Logging Procedure

Refer to Figure 63 during this procedure.
1. Check for the flash drive symbol at the top of the screen to verify that the controller recognizes the flash drive installed
in the USB port.
2. In the navigation menu on the left side of the screen, touch Data Log.
3. Confirm that USB Connected appears on the screen. Touch the Circle icon with three dots near the upper right corner
of the screen. A list of categories opens.
4. Touch to select a category. A list of parameters within that category opens.
5. Touch each parameter that you want to log. Multiple parameters from different categories can be logged at the same
time. A check mark appears in the boxes for the selected parameters. Touch the left arrow at the bottom to close the
selection window. Repeat steps 4 and 5 for other categories and parameters as needed. The parameters to be logged
are listed on the left side of the screen.
6. Click on the blue box labeled Log Rate, located in the lower right corner of the screen. The Data Logger Sample Rate
window opens.
7. Select the desired log rate and touch the up arrow to close the window. The new log rate appears in the blue box at
the bottom of the screen.
8. Touch START LOG to begin collecting data. Data Log In Progress is displayed. The data is stored to the flash drive.
9. Touch STOP to end the data logging process. Wait at least 5 seconds to allow the data to be written to the files before
removing the flash drive from the controller.
Note:
If the flash drive memory becomes full, the controller will stop logging data.
To view the data, insert the flash drive into your PC and open the .csv file.
80 TP-7141 11/22
The numbers below correspond to the numbered steps in the Data Logging Procedure.
1 6
2 7
3 8
4 9
Figure 63 Data Logging
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Section 6. Paralleling
6.1 Introduction
Note:
The Paralleling menu will appear if Paralleling Screens Enabled is set to Yes in the Setup>Electrical>Paralleling menu.
While it may be common for a facility to install a single large generator to meet its power needs, paralleling two or more
generators offers a number of practical benefits and advantages over a single-generator system.
Redundancy
The redundancy provided by the paralleling of two or more generators delivers greater reliability and flexibility than a sing le
generator can provide. In critical applications, having more than one generator connected to the bus at all times ensures
continuous generator power in the unlikely event that a generator fails.
Efficiency
Instead of one large generator that might operate inefficiently at a low power level, several small generators can be paralleled
together and turned on and off as necessary to more efficiently support the varying demands of the load.
How Paralleling Works
When a loss of utility power occurs, almost every system responds with the basic sequence shown here.
1. Engine Start Delay. A timer starts when there is a loss of utility. If utility returns before the timer expires, the system
does not start. If the utility outage is long enough for the timer to expire, the system wil l commit to transferring to
generator power.
2. Start / Start-Up Load Shed. All available generators start. If the system is designed to supply power to loads as soon
as one generator is online (typical for systems serving critical and life-safety loads), low-priority loads are shed or are
inhibited from transferring. This prevents the first-on generator from being overloaded.
3. First Generator Breaker Closes. The first generator to reach the rated voltage and frequency closes to the bus. First -
on logic prevents multiple generators from simultaneously closing to the bus. The bus is now energized, and power is
available to the load. Low-priority loads may remain shed.
4. Synchronization. The incoming generator’s voltage, frequency and phase are matched to the runnin g bus. When
matched, the generator paralleling breaker closes.
5. Second Generator Breaker Closes/Load Sharing. Additional generator power is available to the load. The system’s
load-sharing controls actively control the kW and kVAR output of each generator in order to proportionally share the
load (maintain the same percent load on each generator) and maintain rated frequency and voltage.
6. Load Management. As additional generators close to the bus, more power is available for the load. The load
management system actively adds loads based on available bus capacity.
7. Generator Management. Generator management optimizes the number of online generators based on the load, starting
and stopping as required. Generators are sequenced on in order of operator-assigned priority (or based on runtime)
and taken off in reverse priority. Defined setpoints determine the percent load level and time delay at which the
generator set will be brought on or taken offline.
Synchronization
The automatic synchronizer matches the incoming generator’s output (waveform) to the running bus. When the voltage,
frequency and phase are all matched, the synchronizer will close the incoming generator’s breaker.
Voltage Match. The synchronizer adjusts the incoming generator’s voltage to match the running bus.
Frequency Match. The synchronizer adjusts the engine speed for the incoming generator to match the frequency of the running
bus.
Phase Match. The synchronizer adjusts the engine speed for the incoming generator to match the phase of the running bus.
When all three are matched, the two sine waves will be the same.
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Tier 4 Load Bank Operation During Paralleling
Parallel operation for a tier 4 generator set is similar to parallel operation for tier 2 generator set with the exception of the load
bank. Tier 4 generator sets use load banks to prevent hydrocarbon buildup. To utilize the load bank properly, the APM603 makes
some additional calculations related to the load of the generator sets in parallel.
• The load bank will only be applied in parallel with the customer’s load when applying the load will result in the total kW
of the generator set being at or greater than the kW rating of the load bank and the total kW output of the generator set
with the load bank’s load will not exceed 90% of the generator set’s rated capacity.
• When the HC levels of one generator set (running in parallel with multiple generator sets) needs to be reduced, and
adding the load will not result in the total kW output of the generator set being at or greater than the kW rating of the
load bank, then the following will occur:
o The APM603 will generate a “Go Offline for Regen Warning.”
o The generator set will have 90 seconds to shed its load and go offline.
o Once the generator set goes offline the load bank will be activated.
• When the generator is running and the HC buildup is over 50%, the controller will do one of the following depending on
status of the paralleling breaker, availability of other generator sets, and the bus capacity and other parameter settings:
o If the paralleling breaker is open, then the controller will activate the load bank.
o If the breaker is closed then the controller will do one of the following based on the following conditions:
- If this is the only generator online, and there is enough remaining available power on the generator to power
the load bank and total power output of the generator with the load bank does not exceed 90% of the
generator’s rated power, then the load bank will be activated.
- If this is the only generator online, and there is not enough remaining available power on the generator to
power the load bank and be under 90% of the generator’s rated power, then the load bank will be inactive.
o If there are multiple generators online and the sum of the powers is more than the rating of the load bank and less
than 90% of the generator’s rated power, then the load bank will be activated. The sum of the powers is a
combination of the following:
- Current output power of the generator set without the load bank connected.
- Power rating of the load bank divided by the number of generator sets online.
o If there are multiple generators online and the sum of the powers is more than the rating of the load bank and
exceeds 90% of the generator’s rated power, then the load bank will not be activated. The sum of the powers is a
combination of the following:
- Current output power of the generator without the load bank connected.
- Power rating of the load bank divided by the number of generators online.
o If there are multiple generators online and the sum of the powers is less than the rating of the load bank, then the
generator will shed its loads and go offline and then apply the load bank. The sum of the powers is a combination
of the following:
- Current output power of the generator without the load bank connected.
- Power rating of the load bank divided by the number of generators online.
• While the generator is running and the load bank is active, and the HC Level drops at or below 0% the generator will
do the following:
o Deactivate the load bank and clear the regen active event.
o Resume normal operation.
• Stopping the generator while the load bank is active, will result in the following:
o Load Bank shall immediately go inactive.
o Aftertreatment Regen Active Warning event shall clear immediately.
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o High HC Level Warning shall remain in its current state until the HC drops to or below the clear threshold.
o Load Bank Control Malfunction Warning shall remain in its current state until the generator has been restarted with
appropriate amount of load to clear the event.
• Stopping the generator remotely, will cause the generator to go into Low Idle Cooldown.
• Stopping the generator using the OFF button, E-Stop, or any shutdown event, will cause the generator to immediately
shutdown and bypass the Low Idle Cooldown.
6.2 Metering
This section provides a list of paralleling metering screens that display the status of the paralleling system and generators within
that system. Metering screens are display screens only; there are no adjustable parameters in the metering screens.
6.2.1 Paralleling, Metering, Overview

The overview provides a simple graphical view of the paralleling system.
Procedure to View Paralleling Overview
1. In the navigation panel on the left side, touch Paralleling or the symbol of two generators.
3. Touch Overview or the globe symbol.
4. Observe the Overview graphic, which is described below.
The numbers below correspond to the numbered steps in the Procedure to View Paralleling Overview.
1 3
2 4
Figure 64 Paralleling, Metering, Overview Screen

From the overview screen, you get a simplified view of the status of each generator and the paralleling bus. Each generator in
the system is shown on either the right side or left side of the display. If the generators were provided a custom name durin g the
system set up, the name will appear. If not, the name will appear as Gen X, where X is the system assigned generator number.
Note:
Custom names for generators can be set up through SiteTechTM. Contact a Kohler authorized distributor or dealer.
TP-7141 11/22 85
The top of the display provides a key to explain the color designation.
• A generator shown in green with lines through it is running. It may or may not be on the bus depending upon the status
of the electrically operated breaker or contactor.
• A generator in solid green is in standby and disconnected from the bus. The generator is ready to start as required.
• A generator in blue is in cool down. It is disconnected from the bus but still running.
• A generator in yellow has a warning. This generator may be running and connected to the bus or it may be in cooldown
or it could be in standby waiting for a start signal.
• A generator in red has a shutdown fault. It is not running, not connected to the bus and not available for paralleling.
Along with each color, a text description is provided to indicate the generator status.
Note:
The fact that a generator is not running does not automatically mean it has a fault. Generator Management may shut down a
generator when it is not needed.
The lines on the display indicate the status of the bus and electrically operated breaker or contactor.
• Green indicates that the component is not powered.
• Red indicates the component is powered.
Each generator has a breaker symbol to indicate if the electrically operated breaker or contactor is open or closed. When the
breaker is open, the breaker symbol does not appear connected to the bus lines and the breaker symbol is green. When the
breaker is closed, the breaker symbol will appear connected to the bus lines and the breaker symbol will be red.
As soon as one generator closes to the bus, the bus line up the center of the display will show as red. As each generator closes,
the bus line changes to red.
The bottom of the display shows the frequency, load and voltage of the bus. It does not show the information for a single
generator but each generator closed to the bus should have a matching frequency and voltage. Each generator closed to the
bus will share load so that each generator has an equal percentage loaded.
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6.2.2 Paralleling, Metering Status
The status screens provide a listing of the paralleling metered values.
The Paralleling System Status provides indication of key settings and values related to the overall operation of the paralle ling
system.
Procedure to View Paralleling System Status Metering
1. In the navigation panel on the left side, touch Paralleling or the symbol with two generators.
3. Touch Status or the list symbol.
4. Touch the up and down arrows on the right to view the status parameters, which are described below.
1 3
2 4
Figure 65 Paralleling, Metering Status Screen
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Parameter Units
Bus Voltage Average L to L V
Bus Voltage Average L to N V
Bus L1 L2 Phase Angle Degrees
Bus L1 L3 Phase Angle Degrees
Bus Frequency Hz
Bus Voltage L1 L2 V
Bus Voltage L2 L3 V
Bus Voltage L3 L1 V
Bus Voltage L1 L0 V
Bus Voltage L2 L0 V
Bus Voltage L3 L0 V
Paralleling State
Start Active Yes/No
Synch Active Yes/No
In Sync Yes/No
Frequency Matched Yes/No
Phase Matched Yes/No
Voltage Matched Yes/No
Close Breaker True/False
Trip Breaker True/False
Figure 66 Paralleling Metering Status Parameters
The electrical metering of the bus is shown. If the generator is not closed to the bus but trying to synchronize, the generator is
adjusting the speed and voltage outputs to match the voltage, frequency and phase of the bus in order to close.
Start Active indicates if the generator has a start signal. This signal could be from a transfer switch, from the control buttons on
the front of the generator or through PGEN.
Synch Active indicates if the generator is trying to sync to the bus.
In Sync indicates if the generator has successfully synced to the bus. The generator has not yet closed to the bus. All three
parameters that follow, Frequency Matched, Phase Matched and Voltage Matched must be Yes for In Sync to be Yes.
Frequency Matched indicates the difference between the generator set frequency and the bus frequency is within the
acceptable window.
Phase Matched indicates the difference between the generator set phase and the bus phase is within the acceptable window.
Voltage Matched indicates the difference between the generator set voltage and the bus voltage is within the acceptable
window.
Close Breaker indicates if the controller has commanded the electrically operated breaker or contactor to close.
Trip Breaker indicates if the controller has commanded the electrically operated breaker or contactor to trip based on a
protective function.
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6.2.3 Paralleling, Metering, Details
The Paralleling System Generator Details provides details for each generator in the system. It provides the ability to view k ey
data on other generators in the system from a single generator.
Procedure to View Paralleling System Generator Metering
3. Touch Details Gen 1-4 or Details Gen 5-8 or the list symbol for either.
4. Touch the specific generator to view.
5. Touch the up and down arrows on the right to view the parameters, which are described below.
The numbers in the list below correspond to the numbered steps in the Procedure to View Paralleling System Generator
Metering.
1 4
2 5
Figure 67 Paralleling, Metering, Details
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Parameter Units
Synch Status
Real Power Percentage %
Reactive Power Percentage %
Run Time Hours Hours
Fuel Level %
Rated Power kW
Engine Speed RPM
Bus Percent Voltage %
Connected Yes/No
Was Connected Yes/No
Online Yes/No
Faulted Yes/No
Bus Energized Yes/No
Start Signal Yes/No
Figure 68 Paralleling System Details Parameters

Synch Status indicates the synchronization status for the generator.
Real Power Percentage indicates the percentage load on the generator of real power (kW). All generators paralleled together
should share load in order to have equal percentage.
Reactive Power Percentage indicates the percentage load on the generator of reactive power (kVAR). All generators paralleled
together should share load in order to have equal percentage.
Run Time Hours indicates the total run time hours on the generator.
Fuel Level indicates the percentage of fuel level for the generator.
Rated Power indicates the rated power of the generator.
Engine Speed indicates the current engine speed for the generator.
Bus Percent Voltage indicates the measured voltage as percent of system voltage.
Connected indicates if the generator is connected through the PGEN communication with the other generators.
Was Connected indicates at one point the generator was connected through the PGEN communication with other generators
but is not connected at this time.
Online indicates if the generator is currently closed to the paralleling bus.
Faulted indicates if the generator is faulted and not available for paralleling.
Note: If the controller is still communicating through PGEN with other generators, the load management implemented on the
generator controller is still operational.
Bus Energized indicates if the generator is sensing that the bus has voltage and frequency.
Start Signal indicates if the generator has a start signal. This signal could be from a transfer switch, from the control buttons on
the front of the generator or through PGEN.
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6.2.4 Paralleling, Metering, PGEN
The PGEN metering provides details related to the paralleling system communication.
Procedure to view Paralleling PGEN Metering

3. Touch PGEN or the serial connector symbol.
4. Observe the PGEN information, which is described below.
1 3
2 4
Figure 69 Paralleling, Metering, PGEN
PGEN Metering Parameters

Connected Nodes
Disconnected Nodes
Scheduler ID
Figure 70 PGEN Metering Parameters
Connected Nodes indicates how many generators are currently on the PGEN communication network. This should match the
total number of paralleled generators in the system.
Disconnected Nodes indicates how many generators have been on the PGEN communication network before but are not
communicating at this time. In a fully functioning system this would be 0. If a unit is out of service or the controller has stopped
communicating, then there will be a value greater than 0.
Scheduler ID indicates which controller, based on PGEN ID, is the master in the system.
Note:
If a master scheduler controller stops communicating another controller takes over the as the Scheduler ID.
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6.3 Setup
The screens in this section show the settings for systems using the onboard paralleling features.
Paralleling system setup and commissioning must be performed by a trained and authorized Kohler distributor or dealer. A
separate Commissioning and Setup manual provides more information and instructions for setting up a paralleling system. See
the List of Related Materials in this manual for the document part number for the Commissioning and Setup Manual for your unit.
Technician-level access is required to adjust the paralleling parameters on the controller display. Additional paralleling
parameters are only accessible using SiteTech software. A personal computer (laptop) and Kohler SiteTech software are
required to adjust these settings. SiteTech software is available only to Kohler authorized distributors and dealers.
6.3.1 Paralleling, Setup, PGEN

The Paralleling System PGEN provides indication of key settings related to the PGEN communication network.
Procedure to view Paralleling System PGEN Setup
1. In the navigation panel on the left side, touch Paralleling or symbol with two generators.
2. Touch Setup or the setup symbol.
3. Touch PGEN or the serial connector symbol.
4. Observe the PGEN parameters, which are described below.
1 3
2 4
Figure 71 Paralleling, Setup, PGEN Screens
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PGEN Baud Rate BPS Factory set
PGEN Comm Protocol Factory set
PGEN Node ID Technician
PGEN Version N/A
PGEN Scheduler Yes/No Technician
Figure 72 PGEN Setup Parameters
PGEN Baud Rate is fixed from the factory. All controllers must use the same baud rate and the rate is fixed for optimal
performance.
PGEN Comm Protocol is fixed from the factory to support the same setting on all controllers in the system.
PGEN Node ID is unique for each controller in the system.
PGEN Version indicates the version of PGEN communication used in the system and is fixed from the factory.
PGEN Scheduler indicates Yes if the controller is the master scheduler in the system.
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6.3.2 Paralleling, Setup, Protect Relay Screen
The Paralleling System Protective Relays provides indication of key settings related to the protective relay functions relate d to
paralleling.
Procedure to View Paralleling System Protective Relays Setup
1. In the navigation panel on the left side, touch Paralleling or symbol with two generators.
2. Touch Setup or the setup symbol.
3. Touch Protect Relay or the relay symbol.
4. Touch the up and down arrows on the right to view the protective relay setup parameters, which are described below.
1 3
2 4
Figure 73 Paralleling, Setup, Protect Relay Screen
Parameters Units Write Access Level

Under Voltage Trip Delay Seconds Technician
Under Voltage Trip Limit % Technician
Over Voltage Trip Delay Seconds Technician
Over Voltage Trip Limit % Technician
Over Current Trip Delay Seconds Technician
Over Current Trip Limit % Technician
Under Frequency Trip Delay Seconds Technician
Under Frequency Trip Limit % Technician
Over Frequency Trip Delay Seconds Technician
Over Frequency Trip Limit % Technician
Over Power Trip Delay Seconds Technician
Over Power Trip Limit % Technician
Reverse Power Trip Delay Seconds Technician
Reverse Power Trip Limit % Technician
Reverse VAR Trip Delay Seconds Technician
Reverse VAR Trip Limit %
Trip to Shutdown Delay Seconds
Figure 74 Protective Relay Parameters
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Trip to Shutdown Delay indicates the time allowed to clear the trip condition to avoid the shutdown. It also serves as a cooldown
period for the generator in a case where the protective relay function is causing the trip.
6.4 Generator Management

Generator Management is intended to minimize wear and tear, fuel consumption, pollutant/sound emissions, and generated
heat. It acts by signaling each generator set to stop when it is unneeded. If generator management for a generator set is dis abled,
the generator set will start (if already stopped by generator management) or or be prevented from turning off in the future.
Generator management sequences the generators off in an order determined by configuration parameters and operating
conditions (load, runtime, fuel level). The highest order generator sets stop first (when load is low enough) and re-start last (when
load is too high). The order can be viewed on the front panel of the controller, but can only be adjusted under certain condi tions
(see Gen Management Order later in this section).
The time to start a generator set (if the load increases) varies with the degree of overload as a percent of online capacity (the
sum of rated power for those generators that are connected to the bus).
The time to stop a generator set (if the load is low enough) varies with the degree of load as a percent of total available capacity
(the sum of rated power for all generators in the system whether connected to the bus or not). A generator with a fault or in Off
mode is not considered available.
Note:
Receipt of a start signal will cause all generator sets to start, synchronize, and close to the bus.. If a generator set is f aulted or
manually stopped and then placed back in Auto, generator management will require the generator set to start and connect to
the bus before it is permitted to stop again—even if generator management had previously signaled the generator set to stop.
TP-7141 11/22 95
The overview provides a simple graphical view of the generator management status.
Procedure to View Generator Management Overview
1. In the navigation panel on the left side, touch PARALLELING or the symbol of two generators.
2. Touch GEN MANAGEMENT or the three horizontal bars with a generator symbol.
3. Touch OVERVIEW or the globe symbol.
4. View the graphical display.
1 3
2 4
Figure 75 Paralleling Screens, Gen Management Overview
Understanding the Overview Screen
The generators are listed in order of priority. If the generators were provided a custom name during the system set up, the name
will appear. If not, the name will appear as Gen X, where X is the system assigned generator number.
• Custom names for generators can be set up through SiteTech.
• Depending upon the Generator Management Mode, the priority of a generator can change over time. For example, if
the mode is Fuel Level, as the fuel level of each generator changes the order of priority for each generator will change.
The top of the screen provides a key to explain the symbol and color designation used on the overview. A timer face in white
indicates a timer is active to either turn a generator on or off. The timer face will appear on the line of the generator for which
the timer applies. A red circle indicates the stop kW setting for the generator. A green arrow indicates the start kW setting for the
generator. If a generator is running, it will show the stop setting. If a generator is stopped, it will show the start settin g.
The key at the bottom of the display shows the current load as well as the total online capacity (green) and available capacity
(yellow). If a generator is offline (either due to a shutdown via Generator Management or a fault, or the generator is not
communicating via PGEN), the capacity of that generator is shown as unavailable (white). A vertical blue dotted line indicates
the current load on the system.
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6.4.1 Paralleling, Generator Management Status
The status screens provide a listing of the generator management metered values as well as key settings for reference.
6.4.1.1 Status, System
The Gen Management System Status provides indication of key settings and values related to the overall operation of the load
management system.
Procedure to View Generator Management System Status
2. Touch Gen Manage or the three horizontal bars with a generator symbol.
4. Touch System or the generator symbol.
The numbers below correspond to the numbered steps in the Procedure to View Paralleling System Status Metering.
1 3
2 4
Figure 76 Paralleling Screens, Generator Management Status

Generator Management Enabled Yes/No Technician
Generator Management Mode See below Technician
Total Online Capacity kW N/A
Total Available Capacity kW N/A
Total Bus Power kW N/A
Total Bus Capacity kW N/A
Remove for Maintenance Yes/No Operator
Figure 77 Generator Management Status Parameters
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Generator Management Enabled indicates whether generator management is turned on for the generator.
Note:
This parameter can be set individually for each generator set and will inhibit the Generator Management Configuration Mismatch
Warning for this generator set if set to OFF.
Note:
Disabling the generator management on one generator set in a paralleling system will not keep the other generator sets in the
paralleling system from alarming if the generator management configuration of any of the other nodes differs from the disabled
generator set.
Note:
Generator sets with Generator Management disabled are not taken into consideration for generator management on the other
generator sets. It is not recommended to disable any of the generator sets in a paralleling system where generator management
is intended to be used; the generator management may operate too many generator sets in these cases.
Generator Management Mode indicates which form of generator management is active. See Section 6.4.2 for descriptions of
the available modes.
Total Online Capacity indicates the capability of the system with all the generators that are currently online.
Total Available Capacity indicates the difference between the Online Capacity and the Total Load.
Total Bus Power indicates the total load on the system.

Total Bus Capacity indicates the capability of the system if all the generators available were online.
Stop by Gen Management indicates whether the generator set has been stopped by the gen management function.
Start by Gen Management indicates whether the generator set has been started by the gen management function.
6.4.2 Gen Management Modes
The Gen Management Mode is the method that generator management uses to determine the starting and stopping order of the
available generator sets. All of the generator sets in the system must have the same setting for this parameter for the generator
management to operate correctly. This parameter can be set to one of the following:
Manual/Fixed. The order of the generator sets is manually set. In this mode, the order is set once by the user.
Note:
The controllers require that the order be valid. If two nodes share a common order or there is a gap in the order sequence, t he
controllers will attempt to re-sort the order until it is valid. If the order is not valid (automatic re-sorting failed) generator
management will be disabled and all generator sets will run all of the time.
Run Time. The generator management start/stop order is determined by the runtime hours on the generator sets. In this mode,
the order is determined to ensure that the generator set with the fewest runtime hours is the last to stop. Each subsequent order
is assigned to generator sets with increasing runtime hours.
If a generator set is not running, the system will add the Run Time Threshold to the runtime hours for that generator set before
it considers it in the order—this allows the generator sets to avoid starting and stopping continuously. The actual runtime will
have to differ by more than the threshold to force the generator set order to switch (the stopped generator set will start,
synchronize to the paralleling bus, and begin sharing load—the running generator set will soft-unload, disconnect from the bus,
cool down and stop).
The generator management order is not user adjustable in runtime mode.
Note:
If the load on the system requires an additional generator set to start, the generator set with the most runtime hours will always
be the first one to stop if the load decreases enough to permit it (the threshold is no longer taken into consideration as so on as
the generator set is connected to the paralleling bus).
Fuel Level. The generator management start/stop order of the generator sets is determined by the level of the fuel in the tank
which supplies each generator set. In this mode, the order is determined to ensure that the generator set with the most fuel is
the last to stop. Each subsequent order is assigned to generator sets with decreasing fuel percentage.
If a generator set is running, the system will add the Fuel Level Threshold to the measured Fuel Level fo r that generator set
before it considers it in the order. This allows the generator sets to avoid starting and stopping continuously. The actual f uel level
will have to differ by more than the threshold to force the generator set order to switch. The stopped generator set will start,
98 TP-7141 11/22
synchronize to the paralleling bus, and begin sharing load. The running generator set will soft-unload, disconnect from the bus,
cool down, and stop.
The generator management order is not user-adjustable in Fuel Level mode.
Note:
Fuel Level Order Selection mode requires separate fuel tanks for the generator sets and fuel level senders connected to the
controller to operate. Operation of Fuel Level mode without sensors is not defined.
Note:
If the load on the system requires an additional generator set to start, the generator set with the lowest fuel level will always be
the one to stop (the threshold is no longer taken into consideration as soon as the generator set is connected to the paralleling
bus).
6.4.3 Gen Management System Status, Generator
The Gen Management System Generator provides details on each generator in the system. Each generator has a page of data
so as you page down you will see the information for each generator on a single screen.
Procedure to View Generator Management System Generator
2. Touch Gen Manage or the three horizontal bars with a generator symbol.
The numbers below correspond to the numbered steps in the Procedure to View Generator Management System Status,
Generator.
1 3
2 4
Figure 78 Paralleling, Gen Management, Status, Generator
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Parameter Units
Priority 1 Generator Name String
Priority 1 Generator Capacity kW
Priority 1 Start Power kW
Priority 1 Start Accumulator %
Priority 1 Stop Power kW
Priority 1 Stop Accumulator %
Priority 1 Generator Online Yes/No
Priority 1 Generator Fault Yes/No
Figure 79 Generator Management Status, Generator Parameters

Note:
The order of generators in this list is fixed by priority so if a generator priority is changed, its order in the list will c hange. The first
value in the list is Generator Name to provide clarity as to which generator is referenced.
Generator Name is the descriptive name of the generator. If the generators were provided a custom name during the system
set up, the name will appear. If not, the name will appear as Gen X, where X is the system assigned generator number.
Note:
Custom names for generators can be set up through SiteTechTM. Contact a Kohler authorized distributor or dealer.
Generator Capacity indicates the rated capacity of the generator.
Start Power indicates the kW setting that needs to be exceeded in order for the generator management to begin a timer to add
the generator back to the bus.
Start Accumulator is an indication of progress until generator management will start the generator.
Note:
The time to start will decrease as the load demand increases and will decrease as the load demand decreases. The Accumulator
is not a fixed time but will speed up or slow down depending upon the load demand.
Stop Power indicates the lower limit kW setting for gen management. When the load drops below this kW limit, generator
management starts a timer to stop the generator.
Stop Accumulator is an indication of progress until generator management will stop the generator.
Note:
The time to stop will decrease as the load demand decreases and will increase as the load demand decreases. The Accumulator
is not a fixed time but will speed up or slow down depending upon the load demand.
Generator Online indicates if the generator is currently on the bus.

Generator Fault indicates if the generator has a fault and is not connected to the bus.
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6.4.4 Paralleling, Gen Management, Setup Details
The setup details screen provides a table view of key settings for the generator management configuration. See Figure 80 for
an illustration of the screen, which is located at PARALLELING>GEN MANAGEMENT>SETUP DETAILS.
Procedure to View Generator Management Setup Details
1. In the navigation panel on the left side, touch PARALLELING or the symbol of two generators.
2. Touch GEN MANAGEMENT or the three horizontal bars with a generator symbol.
3. Touch SETUP DETAILS or the details symbol.
4. View the setup details for each generator in the system.
1 3
2 4
Figure 80 Paralleling Screens, Gen Management Setup Details

The generators are listed in order of priority. If the generators were provided a custom name during the system set up, the n ame
will appear. If not, the name will appear as Gen X, where X is the system assigned generator number.
Note:
Custom names for generators can be set up through SiteTech.
The table indicates the kW Capacity of the generator along with the Start kW and Stop kW settings and the start and stop timer
settings. Generator Start kW, Stop kW, Start Time and Stop Time can be adjusted using SiteTech. See Figure 81 for the
SiteTech Group. Start and Stop kW values are calculated from the configuration parameters and the respective capacity values.
The actual settings are made using percentages: parameters Start Percentage and Stop Percentage.
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Figure 81 Generator Management Settings Adjustable in SiteTech
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Section 7. Remote Monitoring Display, Tier 4 Only
Home screen
Remote monitor
Menu Screen
Lower electrical box

Navigation icons
Navigation buttons
Menu button
Figure 82 Remote Monitor Display

Tier 4 generator sets (KD1250-4, KD2500-4, KD3250-4) have a remote monitor display mounted on the door of the lower
electrical box. See Figure 82. The remote monitoring screens are designed for viewing only. Settings cannot be changed through
the remote monitoring screens. Note that the screen display shows navigation icons which correspond to the five navigation
buttons directly below.
7.1 Home Screen

The DEF Display (Home) screen displays basic monitoring parameters. After 5 minutes of inactivity, the remote display will
return to the DEF Display screen. The navigation of the remote monitor follows this basic layout:
• DEF Display (Home) Screen
o Menu Screen
- Engine Overview Screens (1 – 3)
- Engine Fuel Screen
- Engine Temperature Screens (1 – 4)
- Engine Pressures Screens (1 – 2)

- Engine Aftertreatment Screens (1 – 5)
- Display Settings Screen
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7.2 Menu Screen
The Menu screen on the remote monitor displays a selectable list of available engine metering screens. See Figure 84.
Note:
The navigation icons correspond to the navigation buttons directly below them.
Selectable menu list
Enter (select) button

Arrow (scroll) buttons
Return-to-menu button
Use the Arrow buttons to highlight the
menu item and press Enter.
Figure 83 Menu Screen Navigation
Menu Items - Tier 4 Generator Models

Engine Overview
Engine Fuel
Engine Temperatures
Engine Pressures
Engine Aftertreatment
Display Settings
Figure 84 List of Selectable Menu Items
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7.2.1 Overview
The Engine Overview screens (1–3) on the remote monitor displays the engine overview data shown in Figure 86.
Note:

Press Next Menu button. Press Next Menu button. Press the Return-to-Menu button.
Figure 85 Engine Overview Navigation

Tier 4 Generator Models
Item Units
Engine Speed RPM
Oil Pressure kPa or PSI
Coolant Temp Deg C or Deg F
Run Time Hours hr
SCR System State Sleep, Wake, Norm, Err, Purg, HProt, CProt, Stopg, Diag, Test, DnOk, Prim
DEF Level %
SCR HC Level %
SCR Temp Deg C or Deg F
Coolant Level %
Aftercooler Lvl %
ECU Battery Volt V
ECU Keyswitch V
Op Induce Lvl 0,1,2,3,….
Derate Is Active No/Yes
Nox Torque Limit %
Engine State Stop, Pre, Start, Warm, Run, Cool, Post
Figure 86 Engine Overview Data
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7.2.2 Fuel
The Engine Fuel screen on the remote monitor displays the engine fuel data shown in Figure 88.
Note:
Use the Arrow buttons to highlight the Press the Return-to-Menu button.
Figure 87 Engine Fuel Navigation

Item Units
Total Fuel Used L
Fuel Consumption L/hr
Fuel Temperature Deg C or Deg F
Fuel Pressure kPa or PSI
Rail 1 Fuel Pres Bar
Water In Fuel No/Yes
Figure 88 Engine Fuel Data
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7.2.3 Temperature
The Engine Temperature screens (1–5) on the remote monitor displays the engine temperature data shown in Figure 90.
Note:

Press Next Menu button. Press Next Menu button.
Press Next Menu button. Press the Return to Menu button.
Figure 89 Engine Temperature Navigation
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Item Units
Coolant Temp Deg C or Deg F
Oil Temp Deg C or Deg F
SCR Temp Deg C or Deg F
DEF Temp Deg C or Deg F
Fuel Temp Deg C or Deg F
Intake Temp Deg C or Deg F
Ambient Temp Deg C or Deg F
Aux Cool Temp Deg C or Deg F
ECU Temp Deg C or Deg F
Turbo 1 T In Temp Deg C or Deg F
Turbo 2 T In Temp Deg C or Deg F
Turbo1 C In Temp Deg C or Deg F
Exh Gas P1 Temp Deg C or Deg F
Figure 90 Engine Temperature Data
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7.2.4 Pressure
The Engine Pressure screen on the remote monitor displays the engine pressure data shown in Figure 92.
Note:
Use the Arrow buttons to highlight the Press the Next Menu button. Press the Return-to-Menu button.
Figure 91 Engine Pressure Navigation

Item Units
Oil Pressure kPa or PSI
Fuel Pressure kPa or PSI
Crankcase Pres kPa or PSI
Barometric Pres kPa or PSI
Intake Man Pres kPa or PSI
DEF Dos Abs Pres kPa or PSI
Figure 92 Engine Pressure Data
TP-7141 11/22 109

7.2.5 Aftertreatment
The Engine Aftertreatment screens (1–5) on the remote monitor displays the engine aftertreatment data shown in Figure 94.
Note:

Press Next Menu button. Press Next Menu button. Press Next Menu button.
Press Next Menu button. Press the Return-to-Menu button.
Figure 93 Engine Aftertreatment Navigation
110 TP-7141 11/22

Item Units
SCR System State Sleep, Wake, Norm, Err, Purg, Hprot,
Cprot, Stopg, Diag, Test, DnOk, Prim
DEF Level %
DEF Temp Deg C or Deg F
DEF Concentrate %
DEF Consumption L/hr or gal/hr
SCR HC Level %
SCR Temperature Deg C or Deg F
DCU Ctrl Power V
DEF Dos Abs Pres kPa or PSI
DEF Dos Pump Spd RPM
DEF Dos Pump Cmd %
Derate Is Active No/Yes
Nox Torque Limit %
Op Induce Lvl 0,1,2,3,….
SCR Defrost Done No/Yes
DEF Defrost Done No/Yes
DEF Induce State None/Warn/Early/Sever
Fail Induce State None/Warn/Early/Sever
System Fail Time min
Next Induce
SCR Exh Gas Flow kg/h
DEF Line Heat 1 Off/On
DEF Line Heat 2 Off/On
AftrTrt1 In NOx ppm
AftrTrt1 Out NOx ppm
AftrTrt1 Out NH3 ppm
Figure 94 Engine Aftertreatment Data
TP-7141 11/22 111

7.2.6 Display Settings
On the User Settings screen, use the button interface to change brightness and contrast or units of measurement.
Note:
Use the Arrow buttons to highlight the Press the Return to Menu button.
Menu items
Arrow buttons - use to

Minus or plus buttons -
select menu items.
use to change menu item
settings.
Return to Menu button
Figure 95 User Settings Navigation

User Setting Menu Items, Tier 4 Generator Models
Brightness
Contrast
Units
Figure 96 User Settings Menu
112 TP-7141 11/22

Section 8. Troubleshooting
8.1 Introduction
This section contains generator set, controller, and general engine troubleshooting information. This section may refer to other
literature for procedures and additional information. See the list of related materials in the Introduction of this manual for literature
part numbers. The information in this section is a guideline for generator set operating technicians.
Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional problems caused
by incorrect repairs, have an authorized service distributor/dealer perform service.
Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting
battery or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, recommended
corrective actions, and references to detailed information or repair procedures.
Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and
repairs or adjustments made to the equipment.
8.2 Generator Set and Controller

Refer to the following charts for generator set and controller troubleshooting. Generator set maintenance schedules and
procedures are covered in the Generator Set Maintenance Manual. Some of the corrective actions may reference the alternator
and/or controller service manual for additional troubleshooting information.
8.3 Engine
Refer to the following charts for general engine troubleshooting. Refer to the engine operation manual and/or engine service
manual for all specific engine troubleshooting.
8.4 Transfer Switch

Some applications may use an automatic transfer switch. Some of the following charts may reference transfer switch
components and/or literature. Refer to the transfer switch manuals as needed.
TP-7141 11/22 113

114
Trouble Symptoms
8.5
start
voltage
High fuel
Overheats
inoperative
Starts hard
Lacks power
consumption
Excessive or
Displays error
Does not crank

Stops suddenly
abnormal noise
Section or
No or low output
Low oil pressure
Exercise run time
message/locks up
Publication
Cranks but does not

and/or event records
Probable Causes Recommended Actions Reference*
Controller and Emergency Stop Switch
X X Controller circuit board(s) inoperative Replace the controller.† Gen. S/M
X X Wiring fault Check the wiring. W/D
X Controller fault Troubleshoot the controller.† Gen. S/M

General Troubleshooting Chart
Power to the controller is interrupted; Check for power battery power to the controller. If W/D, Controller
X X X
no power to the controller. fuse does not auto-reset troubleshoot the controller S/M
wiring.†
X Controller master control buttons Replace the controller.† Controller S/M

inoperative
Controller master control button in

X Press the controller RUN or AUTO button. Operation Section
the OFF/RESET mode
Press the controller master control RUN button to Operation Section,

X Engine start circuit open test the generator set. Troubleshoot the engine W/D, Gen. I/M,
start circuit and time delays. S/M ATS O/M,
S/M
Reset the emergency stop switch.
Emergency stop switch activated, if
X X Check the remote emergency stop switch, if Operation Section
equipped
equipped.
Replace the junction box sensing fuses. If the fuse

X X Voltage regulation inoperative W/D, Gen. S/M
blows again, troubleshoot the controller.†
X Controller firmware error Review the controller display troubleshooting chart.
Verify that RS-485 cable shield wire is connected

X X Controller communication error W/D
on only one end.
TP-7141
* Sec./Section - numbered section of this manual; ATS - Automatic Transfer Switch; Eng. - Engine; Gen. - Generator Set; I/M - Installation Manual; O/M - Operation Manual;
M/M – Maintenance Manual; S/M - Service Manual; S/S - Spec Sheet; W/D - Wiring Diagram Manual
† Have an authorized service distributor/dealer perform this service.
11/22
Trouble Symptoms
TP-7141
voltage
records
not start
High fuel
Overheats
inoperative
Starts hard
and/or event
Lacks power
consumption
Excessive or
11/22
Section or
Displays error
Does not crank

Stops suddenly
abnormal noise
Publication
Cranks but does

No or low output
Low oil pressure
Exercise run time
message/locks up
Alternator
X AC output circuit breaker open Reset the breaker and check for AC voltage at the
generator set side of the circuit breaker.
X Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO ATS O/M
position position.
X Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. ATS O/M, S/M
Troubleshoot the transfer circuit and time delays.
X Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
field open
X Main field (rotor) inoperative (open or Test and/or replace the rotor. † Gen. S/M
grounded)
X Stator inoperative (open or grounded) Test and/or replace the stator.† Gen. S/M
X Vibration excessive Tighten loose components.†
X X Voltage regulator settings incorrect Check and adjust the voltage regulator.†
Electrical System (DC Circuits)
X X Battery connections loose, corroded, Verify that the battery connections are correct, clean, I/M or M/M
or incorrect and tight.
X X Battery weak or dead Recharge or replace the battery. The spec sheet S/S
provides recommended battery CCA rating.
X X Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
X X Engine harness connector(s) not Disconnect the engine harness connector(s) then W/D
locked tight reconnect it to the controller.
X Fault shutdown Identify and correct the fault condition. Then reset the Operation
fault on the controller.. Section
115
116
Trouble Symptoms
up
voltage
not start
High fuel
Overheats
inoperative
Starts hard
time and/or
Exercise run
Lacks power
consumption
Excessive or
event records
Displays error
Section or Publication
message/locks
Stops suddenly
abnormal noise
Cranks but does

No or low output
Low oil pressure
Does not crank

Engine
X X X X Air cleaner clogged Clean or replace the filter element. Eng. O/M
X X X X X Compression weak Check the compression.† Eng. S/M
X X X X X Engine overload Reduce the electrical load. See the generator set S/S
spec sheet for wattage specifications.
X Exhaust system leak Inspect the exhaust system. Replace damaged or I/M
broken exhaust system components.†
X Exhaust system not securely Inspect the exhaust system. Tighten the loose I/M
installed exhaust system components.†
X X X X Governor inoperative Adjust the governor.† Eng. S/M
X X Valve clearance incorrect Adjust the valves † Eng. S/M
X Vibration excessive Tighten all loose hardware.
X X X X X Engine ECM and/or sensors Troubleshoot the engine ECM and/or sensors.† Eng. O/M, Eng. S/M
Cooling System
X X Air openings clogged Clean the air openings.
X Coolant level low Restore the coolant to normal operating level. M/M or Eng. O/M
X Cooling water pump inoperative Tighten or replace the belt, if applicable. Replace Eng. O/M or S/M
the water pump.
X High temperature shutdown Allow the engine to cool down. Then troubleshoot M/M, orEng. O/M
the cooling system.
X Low coolant level shutdown, if Restore the coolant to normal operating level. M/M or Enigne O/M
equipped
X Thermostat inoperative Replace the thermostat. Eng. S/M
TP-7141
11/22
Trouble Symptoms
TP-7141
voltage
not start
High fuel
Overheats
Starts hard
and/or event
Lacks power
consumption
Excessive or
11/22
Displays error
Section or
Does not crank

Stops suddenly
abnormal noise
Cranks but does

No or low output
Low oil pressure
Publication
Exercise run time
message/locks up
records inoperative
Fuel System
X X Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position.
X X X Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
X X X X Fuel filter restriction Clean or replace the fuel filter. M/M or Eng. O/M
X X X Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the dirty or faulty fuel Eng. S/M
(diesel only) injector.†
X Fuel solenoid inoperative Troubleshoot the fuel solenoid.† Eng. S/M
X X X X Fuel injection timing out of adjustment Adjust the fuel injection timing.† Eng. S/M
(diesel only)
X X X Fuel feed or injection pump Rebuild or replace the injection pump.† Eng. S/M
inoperative (diesel only)
Lube System
X X X Oil level low Restore the oil level. Inspect the generator set for oil M/M or Eng. O/M
leaks.
X Low oil pressure shutdown Check the oil level. M/M or Eng. O/M
X X X X Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the M/M or Eng. O/M
ambient temperature operating climate.
M/M – Maintenance Manual: S/M - Service Manual; S/S - Spec Sheet; W/D - Wiring Diagram Manual
117
118
Section or
8.6
Publication
Trouble Symptoms Probable Causes Recommended Actions Reference*
Controller Display and Voltage Regulator
Display is black/off No/low battery charge Recharge/replace battery Generator M/M
Display is black/off Controller requires reset Disconnect and reconnect battery voltage to the
controller
Display locks up No/low battery charge Recharge/replace battery Generator M/M
Faulty or damaged exciter winding.

Voltage ramp on startup is normal, but
Output voltage ramps ramping past the target without Troubleshoot alternator components † Generator S/M
recovering may indicate additional
failures in the alternator or excitation
circuit.
Output voltage unstable Voltage regulation calibration incorrect Readjust voltage regulation. † Controller S/M
Controller Display and Voltage Regulation Troubleshooting Chart
TP-7141
11/22
Section 9. Accessories
Accessories are available to help finalize installation, add convenience to operation and service, and establish state and lo cal
code compliance. This section describes controller-related accessories available at print time of this publication. See Figure 97.
Obtain the most current accessory information from your local authorized service distributor/dealer.
Kit Description
Battery Charger
Input/ Output Modules
Manual Key Switch
Remote Emergency Stop
Remote Serial Annunciator
Shunt Trip Line Circuit Breaker
Figure 97 Optional Accessories

Some accessories are available as factory-installed kits only. Others are available as loose kits for installation in the field by a
Kohler trained and authorized distributor or dealer. Accessory kits generally include installation instructions. See the wiring
diagram manual for electrical connections. See the installation instructions and drawings supplied with the kit for information on
kit mounting location.
TP-7141 11/22 119

9.1 Battery Chargers
Factory-installed battery charger kits are available for KD model generator sets with a single starter or redundant starters. The
20 Amp, 24 VDC Kohler High Frequency Battery Charger is used with these models.
The battery charger sends a fault message to the APM603 controller in the event of a battery charger fault. See TP -7072, Battery
Charger Installation and Operation Manual, for information about fault conditions and for battery charger operation instructi ons.
Figure 98 Kohler High Frequency Battery Charger
120 TP-7141 11/22

9.2 Input/Output (I/O) Modules
The Digital 8 Input/Output Module Kit is available as an optional accessory. The modules are factory-installed in the customer
connection box. Module power and CAN communication with the controller are factory-connected. The module CAN address is
factory-set. Do not change the CAN address DIP switch settings.
The original DIOM provides 8 digital inputs and 4 digital (relay) outputs. The updated D8IOM adds more outputs, providing 8
digital inputs and 8 digital (relay) outputs. See Figure 99 to compare the original and updated designs. Full support of the new
D8IOM requires firmware version 3.6 or later for the APM603 controller and version 1.11 or later for the APM802 controller.
Original DIOM Updated D8IOM

CAN
communication
indicator
Factory connections
and settings.
DO NOT CHANGE.
Factory connections
and settings.
DO NOT CHANGE
Digital (relay) output

Digital input
connections 0 - 7
connections 0 - 7
Digital (relay) output

connections 0 - 3
Digital input
connections 0 – 7
(See detail)
DIGITAL INPUT CONNECTION DETAIL
DI0 DIR0
DI1 DIR1
DI2 DIR2
DI3 DIR3
DI4 DIR4
DI5 DIR5
DI6 DIR6
Note: The locations of the input and output connections on the
DI7 DIR7
updated module are different from the original.
11609000401
Figure 99 Digital Input/Output Modules, Original and Updated
TP-7141 11/22 121

See the table below for contact specifications. Refer to the D8IOM specification sheets, UL and CE versions, for additional
specifications.
Inputs
Number of inputs 8 configurable inputs
Input voltage 12 VDC / 24VDC
Contacts Normally open (NO). Activates on ground

connection
Connection 0.75 to 1.5 mm2 (20AWG-16AWG)
Inputs isolated Yes
Outputs
Number of outputs Binary outputs for power: 8
Contacts Form C, rated 3 A @ 250 VAC (UL version)

Form C, rated 3 A @ 30 VDC (CE version)
Connections 0.75 to 1.5 mm2 (20AWG-16AWG)
Voltage 250 VAC maximum (UL version)

30 VDC (CE version)
Current 3 Amps maximum
Power 375 VA maximum (UL version)

90 W (CE version)
Number of operation cycles at full load 100 000
Minimum current: 10 mAmps
Figure 100 Input and Output Specifications (updated D8IOM)

The updated module is equipped with one diagnostic LED to show the status of CAN communication between the module and
the generator controller. See Figure 101.
LED Description LED Operation

CANbus 1 Communication LED Flashing green: CAN communication is consistent.
Steady green: No CAN communication.
Off: No CAN communication.
Figure 101 CAN Communication Indicator
The DIOM kit includes two digital input/output modules, referred to as DIOM 1 and DIOM 2. The digital inputs and outputs on
DIOM 1 and DIOM 2 can be configured by an authorized service technician using Kohler SiteTech software.
122 TP-7141 11/22

On KD Series Generators equipped with the APM603 controller, one base D8IOM is supplied as standard equipment. It is
factory-installed and factory-configured. The base D8IOM connections and settings are not available to the customer.
Factory Settings
Digital Inputs/Outputs Module 0 (not configurable) Module 1 Module 2
Input DI0 Power Supply 1 Fault Warning Configurable Configurable
Input DI1 Power Supply 2 Fault Warning Configurable Configurable
Input DI2 Remote Reset Configurable Configurable
Input DI3 Auxiliary Shutdown Configurable Configurable
Input DI4 High Fuel Level Switch Warning Configurable Configurable
Input DI5 Auxiliary Warning Configurable Configurable
Input DI6 Low Oil Level Switch Warning Configurable Configurable
Input DI7 Reserved Factory Use Configurable Configurable
Output DO0 System Ready Configurable Configurable
Output DO1 Low Coolant Temp Configurable Configurable
Output DO2 Not In Auto Configurable Configurable
Output DO3 EPS Supplying Load Configurable Configurable
Output DO4 NA Configurable Configurable
Figure 102 Digital 8 I/O Module Default Settings (Tier 2 and Tier 4 Generator Sets)
TP-7141 11/22 123

9.3 Manual Key Switch
Controller
Manual Key Switch
Figure 103 Manual Key Switch Location

Optional Key Switch
A three-position key switch is available. The key switch allows the controller to be locked in standby mode, which may be required
by some local codes. See Figure 103 for the key switch location.
The RUN, OFF, and AUTO positions on the key switch operate as described below.
• RUN
When the key is moved to the RUN position, the generator set starts and runs. The generator will continue to run until
the key is moved to the OFF or AUTO button position or until a fault condition causes the generator set to shut down.
• OFF
When the key is placed in the OFF position, the generator set shuts down immediately, without running the engine
cooldown cycle. The generator set will not respond to remote start commands when the key is in the OFF position.
• AUTO
Moving the key to the AUTO position places the generator set in Standby mode. The generator set will start and run
when a remote start signal is received. The key can be removed only when the switch is in AUTO, locking the generator
set in standby mode. When the key is in the AUTO position, generator management may cause the generator to stop
and go to a standby state.
Controller Pushbuttons
When the controller is equipped with the optional key switch, the functions of the pushbuttons on the controller are affected.
• For normal starting and stopping, the key switch overrides the pushbuttons on the controller.
o When the key is in the RUN position, pressing OFF/RESET on the controller does not stop the generator set.
o When the key switch is in the OFF position, pressing the RUN button on the controller will not start the generator
set. Pressing AUTO + RUN simultaneously will signal the generator set to start.
• To clear a fault condition, press and hold the OFF/RESET button on the controller for 3 seconds. The key switch does
not clear faults from the controller.
• The Alarm Silence/Lamp Test button function does not change when a key switch is installed.
124 TP-7141 11/22

Emergency Stop
The Emergency Stop button overrides the key switch and the controller pushbuttons. Pressing the Emergency stop button will
shut down the generator set regardless of the key switch position. To clear the Emergency stop fault from the controller, first
reset the E-stop switch and then press the OFF/RESET button on the controller for 3 seconds. A remote reset signal can be
used, if so configured, to clear the E-Stop fault. The key switch cannot be used to clear the E-Stop fault.
9.4 Remote Emergency Stop Kit
The emergency stop (E-stop) kit allows immediate shutdown of the generator set from a remote location. If the emergency stop
switch is activated, the EMERGENCY STOP lamp lights and the unit shuts down immediately, bypassing the engine cooldown
cycle. Before attempting to restart the generator set, reset the emergency stop switch and reset the generator set by pressing
and holding the OFF/RESET button for 3 seconds.
Two emergency stop kits are available. See Figure 104 and the following instructions.
Insert lockout/tagout device

through these holes.
Remote Emergency Stop Switch Lockable Emergency Stop Switch
Figure 104 Remote Emergency Stop Switches

9.4.1 Remote emergency stop kit.
This switch uses a glass piece that must be replaced after activation.
1. To stop the generator set, pull down on the handle, breaking the glass piece.
2. To reset the emergency stop switch, return the handle to the original position and replace the glass piece with a new
one.
3. Press and hold the controller’s OFF/RESET button for 3 seconds.
Use the single glass piece located inside the switch for replacement and order additional glass pieces as service parts.
9.4.2 Lockable Emergency Stop Switch
This switch can be locked in the activated position to prevent generator set starting. Use a customer-provided locking device
inserted into the holes in the shroud to lock the switch until the generator set can be operated safely.
Operation
Press the red STOP button to shut down the generator set in an emergency.
Using the emergency stop button bypasses the engine cooldown cycle, stopping the engine immediately. The emergency stop
LED on the RSA III lights (if equipped) and the unit shuts down. The generator set cannot be restarted until the emergency stop
switch(es) is/are reset.
Lockout/Tagout
The emergency stop button can be locked in the STOP position. Insert a lock through two openings in the yellow shroud to
prevent the stop button from being pulled out. See Figure 104. Remove the lock for normal operation.
TP-7141 11/22 125

A lock is not required in order to keep the switch activated. The switch button will stay depressed until it is pulled out by the
operator.
Resetting the Emergency Stop Switch
To reset the E-stop switch, remove the locking device and pull the button out. Reset the controller by pressing and holding the
OFF/RESET button for 3 seconds.
9.5 Remote Serial Annunciator

The RSA III is an annunciator panel offered in several kit configurations to support Kohler power equipment. See Figure 105.
The RSA III is a remote serial annunciator that monitors the status of the generator set and/or ATS from a remote location. The
RSA III alerts the operator through visual and audible signals using LED indication and a horn. An alarm silence / lamp test
switch is included.
The RSA III meets NFPA 110, Level 1 (2005) applications that require remote controls and alarms be powered by a storage
battery such as the engine starting battery. AC adaptor kit GM62466-KP1 is available when NFPA is not required.
The front panel decals include areas that can be used to identify user-selected fault inputs and identify associated power system
equipment.
An RSA III annunciator can be used for a single generator set or with a combination of a generator set and automatic transfer
switch. In systems using more than a single RSA III, one must be designated as the master device to broadcast to additional
RSA III annunciators, designated as slave devices. Up to five RSA III slave devices can be used with an RSA III master device .
All RSA III annunciators are factory set as the master device, but can be changed to a slave device using a PC and SiteTech™
software that connects to the RSA III front panel via a universal serial bus (USB) connection.
The RSA II and RSA 1000 can be connected with the RSA III provided that the master remote annunciator is an RSA III.
Refer to TT-1625 Remote Serial Annunciator (RSA III) Kits for operation and installation instructions.
A personal computer with SiteTechTM software is required to make the RSA III functional. SiteTech is available to Kohler
authorized distributors and dealers. Refer to TP-6701, SiteTech Software Operation Manual, for more information.
The RSA III kits include components for surface mounting or flush mounting.
Figure 106 shows the status of the system ready LED, generator set running LED, communication status LED, common fault
LED, common fault output, and horn for each fault or status condition.
If a fault occurs, the RSA III horn activates and the corresponding LED illuminates. The following paragraphs describe specific
features of the RSA III.
If the RSA III is used with an Ethernet communication network, order Modbus ® Ethernet converter GM41143-KP2 and refer to
TT-1405 Converters, Connections, and Controller Setup for Network Communication for system installation.
RSA III with Single Generator Set RSA III with Single ATS Control RSA III with Four ATS Controls
Figure 105 Remote Serial Annunciator (RSAIII)
126 TP-7141 11/22

System Monitoring LEDs and Functions
System Common Common
Ready Generator Communications Fault Fault
Fault and Status Condition Fault LED LED Running LED Status LED LED Output Horn
Overcrank (Shutdown) Red SF Red SF Off Green Red SF On On
High Engine Temperature (Warning) Yellow SF Red SF Green Green Yellow SF On On
High Engine Temperature (Shutdown) Red SF Red SF Off Green Red SF On On
Low Oil Pressure (Warning) Yellow SF Red SF Green Green Yellow SF On On
Low Oil Pressure (Shutdown) Red SF Red SF Off Green Red SF On On
Overspeed (Shutdown) Red SF Red SF Off Green Red SF On On
Emergency Stop Red SF Red SF Off Green Red SF On On
Low Coolant Level/Aux (Shutdown) Red SF Red SF Off Green Red SF On On
Low Coolant Temperature Yellow SF Red SF Green or Off Green Yellow SF On On
Low Fuel (Level or Pressure) Yellow SF Red SF Green or Off Green Yellow SF On On
Low Cranking Voltage Yellow SF Red SF Off Green Yellow SF On On
Battery Voltage (Hi) Yellow Red SF Green or Off Green Yellow SF On On
Battery Voltage (Lo) Yellow SF Red SF Green or Off Green Yellow SF On On
Battery Charger Fail Yellow SF Red SF Green or Off Green Yellow SF On On
Common Fault (Warning) Yellow SF Green Green or Off Green Yellow SF On Off
Common Fault (Shutdown) Red SF Green Green or Off Green Red SF On On
User-Defined Digital Input 1 (Warning) Yellow SF Green Green or Off Green Off Off Off
User-Defined Digital Input 1 Red FF Green Green or Off Green Off On On
(Shutdown)
(Shutdown)
(Shutdown)
(Shutdown)
(Shutdown)
ATS Position N (RSA III with ATS only) Green Green Green or Off Green Off Off Off
ATS Position E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off
ATS Available N (RSA III with ATS Green Green Green or Off Green Off Off Off
only)
ATS Available E (RSA III with ATS Red Red SF Green or Off Green Off Off Off
only)
ATS Test (RSA III with ATS only, Test Yellow Green Green or Off Green Off Off On
initiated at ATS)
ATS Test (RSA III with ATS only, Test Green Green Green or Off Green Off Off On
initiated at RSA)
ATS Fault (RSA III with ATS only, No Green Green Green or Off Green Off Off On
fault)
ATS Fault (RSA III with ATS only, With Red FF Red SF Green or Off Green Off Off On
fault)
EPS Supplying Load Green Green Green or Off Green Off Off Off
Not-In-Auto Red FF Red SF Off Green Yellow SF On On
Communication Status (Loss - Master) Red FF Off Off Red FF Off On On
Communication Status (Loss - Slave) Red SF Off Off Red SF Off On On
Note: SF = Slow Flash (once per second), FF = Fast Flash (five times per second)
Figure 106 RSA III System Monitoring LEDs and Functions
TP-7141 11/22 127

9.6 Shunt Trip Line Circuit Breaker
A shunt-trip line circuit breaker provides a 12- or 24-DC volt solenoid within the line circuit breaker case that can energize the
trip mechanism. This feature allows the circuit breaker to be tripped by a customer-selected fault or event such as alternator
overload, overspeed, overvoltage, or defined common fault. The shunt-trip kit is factory-installed and connected to the circuit
breaker. The output or event can be assigned using Kohler SiteTech software. SiteTech software is available to Kohler -
authorized distributors and dealers.
128 TP-7141 11/22

Appendix A. Abbreviations
A, amp ampere blk. htr. block heater DAC digital to analog converter
ABDC after bottom dead center BMEP brake mean effective pressure dB decibel
AC alternating current bps bits per second dB(A) decibel (A weighted)
A/D analog to digital br. Brass DC direct current
ADC advanced digital control; BTDC before top dead center DCR direct current resistance
analog to digital converter
adj. adjust, adjustment Btu British thermal unit DEF diesel exhaust fluid
ADV advertising dimensional drawing Btu/min. British thermal units per minute deg., ° degree
AGM absorbent glass mat C Celsius, centigrade dept. department
Ah amp-hour cal. Calorie dia. Diameter
AHWT anticipatory high water CAN controller area network DI/EO dual inlet/end outlet
temperature
AISI American Iron and Steel Institute CARB California Air Resources Board DIN Deutsches Institut fur Normung e.
V. (also Deutsche Industrie
Normenausschuss)
ALOP anticipatory low oil pressure CAT5 Category 5 (network cable) DIP dual inline package
alt. alternator CB circuit breaker DPDT double-pole, double-throw
Al aluminum CC crank cycle DPST double-pole, single-throw
ANSI American National Standards cc cubic centimeter DS disconnect switch
Institute (formerly American
Standards Association, ASA)
AO anticipatory only CCA cold cranking amps DVR digital voltage regulator
APDC Air Pollution Control District ccw. Counterclockwise E2PROM, electrically-erasable
EEPROM programmable read-only memory
API American Petroleum Institute CEC Canadian Electrical Code E, emer. emergency (power source)
approx. approximate, approximately cert. certificate, certification, certified EATS Exhaust Aftertreatment System
APU Auxiliary Power Unit cfh cubic feet per hour ECM electronic control module, engine
control module
AQMD Air Quality Management District cfm cubic feet per minute EDI electronic data interchange
AR as required, as requested CG center of gravity EFR emergency frequency relay
AS as supplied, as stated, as CID cubic inch displacement e.g. for example (exempli gratia)
suggested
ASE American Society of Engineers CL centerline EG electronic governor
ASME American Society of Mechanical cm centimeter EGSA Electrical Generating Systems
Engineers Association
assy. Assembly CMOS complementary metal oxide EIA Electronic Industries Association
substrate (semiconductor)
ASTM American Society for Testing com communications (port) EI/EO end inlet/end outlet
Materials
ATDC after top dead center coml commercial EMI electromagnetic interference
ATS automatic transfer switch Coml/Rec Commercial/Recreational emiss. Emission
auto. Automatic conn. Connection eng. Engine
aux. auxiliary cont. continued EPA Environmental Protection Agency
avg. average CPVC chlorinated polyvinyl chloride EPS emergency power system
AVR automatic voltage regulator crit. Critical ER emergency relay
AWG American Wire Gauge CRM Common Rail Manifold ES engineering special, engineered
special
AWM appliance wiring material CSA Canadian Standards Association
bat. Battery CT current transformer ESD electrostatic discharge
BBDC before bottom dead center Cu copper est. estimated
BC battery charger, battery charging cUL Canadian Underwriter’s E-Stop emergency stop
Laboratories
BCA battery charging alternator cu. in. cubic inch etc. et cetera (and so forth)
BCI Battery Council International cw. Clockwise exh. exhaust
BDC before dead center CWC city water-cooled ext. external
BHP brake horsepower cyl. Cylinder F Fahrenheit, female
blk. black (paint color), block (engine) D/A digital to analog FDS Fluid Dosing System
TP-7141 11/22 129

FHM flat head machine (screw) in. inch Lpm liters per minute
fl. oz. fluid ounce in. H2O inches of water LOP low oil pressure
flex. flexible in. Hg inches of mercury LP liquefied petroleum
freq. frequency in. Lb. inch pounds LPG liquefied petroleum gas
FS full scale Inc. incorporated LS left side
ft. foot, feet ind. Industrial Lwa sound power level, A weighted
ft. lb. foot pounds (torque) int. internal LWL low water level
ft./min. feet per minute int./ext. internal/external LWT low water temperature
ftp file transfer protocol I/O input/output m meter, milli (1/1000)
g gram IP internet protocol M mega (106 when used with SI
units), male
ga. gauge (meters, wire size) ISO International Organization for m3 cubic meter
Standardization
gal. gallon J joule m3/hr. cubic meters per hour
gen. generator JIS Japanese Industry Standard m3/min. cubic meters per minute
genset generator set k kilo (1000) mA milliampere
GFI ground fault interrupter K kelvin man. manual
GND, ground kA kiloampere max. maximum
gov. governor KB kilobyte (210 bytes) MB megabyte (220 bytes)

gph gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker
gpm gallons per minute kg kilogram MCM one thousand circular mils
gr. grade, gross kg/cm2 kilograms per square meggar megohmmeter
centimeter
GRD equipment ground kgm kilogram-meter MHz megahertz
gr. wt. gross weight kg/m3 kilograms per cubic meter mi. mile
HxWx height by width by depth kHz kilohertz mil one one-thousandth of an inch
D
HC hex cap kJ kilojoule min. minimum, minute
HCHT high cylinder head temperature km kilometer misc. miscellaneous
HD heavy duty kOhm, kilo-ohm MJ megajoule
kΩ
HET high exhaust temp., high kPa kilopascal mJ millijoule
engine temp.
hex hexagon kph kilometers per hour mm millimeter
Hg mercury (element) kV kilovolt mOhm, milliohm
mΩ
HH hex head kVA kilovolt ampere MOhm, megohm
MΩ
HHC hex head cap kVAR kilovolt ampere reactive MOV metal oxide varistor
HP horsepower kW kilowatt MPa megapascal
hr. hour kWh kilowatt-hour mpg miles per gallon
HS heat shrink kWm kilowatt mechanical mph miles per hour
hsg. Housing kWth kilowatt-thermal MS military standard
HVAC heating, ventilation, and air L liter ms millisecond
conditioning
HWT high water temperature LAN local area network m/sec. meters per second
Hz hertz (cycles per second) LxWx length by width by height mtg. mounting
H
IBC International Building Code lb. pound, pounds MTU Motoren-und Turbinen-Union
IC integrated circuit lbm/ft3 pounds mass per cubic feet MW megawatt
ID inside diameter, identification LCB line circuit breaker mW milliwatt
IEC International Electrotechnical LCD liquid crystal display µF microfarad
Commission
IEEE Institute of Electrical and LED light emitting diode µF microfarad
Electronics Engineers
IMS improved motor starting Lph liters per hour
130 TP-7141 11/22

N, norm. normal (power source) PMG permanent magnet generator SCR silicon controlled rectifier
(electrical), selective catalytic
reduction (exhaust emissions)
NA not available, not applicable pot potentiometer, potential s, sec. second
nat. gas natural gas ppm parts per million SI Systeme international d’unites,
International System of Units
NBS National Bureau of Standards PROM programmable read-only SI/EO side in/end out
memory
NC normally closed psi pounds per square inch sil. Silencer
NEC National Electrical Code psig pounds per square inch gauge SMTP simple mail transfer protocol
NEMA National Electrical pt. pint SN serial number
Manufacturers Association
NiCd nickel cadmium PTC positive temperature coefficient SNMP simple network management
protocol
NFPA National Fire Protection PTO power takeoff SPDT single-pole, double-throw
Association
Nm newton meter PVC polyvinyl chloride SPST single-pole, single-throw
NO normally open PVC polyvinyl chloride spec specification
no., nos. number, numbers PWM pulse width modulated, pulse specs specification(s)
width modulation
NPS National Pipe, Straight qt. quart, quarts sq. square
NPSC National Pipe, Straight-coupling qty. quantity sq. cm square centimeter
NPT National Standard taper pipe R replacement (emergency) sq. in. square inch
thread per general use power source
NPTF National Pipe, Taper-Fine rad. radiator, radius SMS short message service
NR not required, normal relay RAM random access memory SS stainless steel
Ns nanosecond RDO relay driver output std. standard
OC overcrank ref. reference stl. Steel
OD outside diameter rem. Remote tach. Tachometer
OEM original equipment Res/Co Residential/Commercial TB terminal block
manufacturer ml
OF overfrequency RFI radio frequency interference TCP transmission control protocol
opt. option, optional RH round head TD time delay
OS oversize, overspeed RHM round head machine (screw) TDC top dead center
OSHA Occupational Safety and Health rly. Relay TDEC time delay engine cooldown
Administration
OSHPD Office of Statewide Health rms root mean square TDEN time delay emergency to
Planning and Development normal
(California)
OV overvoltage rnd. Round TDES time delay engine start
oz. ounce RO read only TDNE time delay normal to
emergency
p., pp. page, pages ROM read only memory TDOE time delay off to emergency
PC personal computer rot. rotate, rotating TDON time delay off to normal
PCB printed circuit board rpm revolutions per minute temp. temperature
pF picofarad RS right side term. Terminal
PF power factor RTDs resistance temperature THD total harmonic distortion
detectors
ph., ø phase RTU remote terminal unit TIF telephone influence factor
PHC Phillips® head Crimptiter RTV room temperature vulcanization tol. Tolerance
(screw)
PHH Phillips® hex head (screw) RW read/write turbo. Turbocharger
PHM pan head machine (screw) SAE Society of Automotive typ. typical (same in multiple
Engineers locations)
PLC programmable logic control scfm standard cubic feet per minute UF underfrequency
TP-7141 11/22 131

UHF ultrahigh frequency
UIF user interface
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
URL uniform resource locator (web
address)
US undersize, underspeed
UV ultraviolet, undervoltage
V volt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
W watt
WCR withstand and closing rating
w/ with
WO write only
w/o without
wt. weight
xfmr transformer
132 TP-7141 11/22

Appendix B. Engine Data
Tier 2 Engine Data (KD700 – KD4000)

The controller display showing engine information is dependent upon the engine manufacturer and the corresponding Engine
Control Module (ECM). The following lists indicate the engine displays that are available for the KD series engines. This
information is subject to change by the engine manufacturer.
Note:
Two lists are included in the appendix, one for tier 2 generator sets (KD700-KD4000) and a second for tier 4 generator sets
(KD1250-4, KD2500-4, KD3250-4).
Controller Displays as Provided by the Engine ECM
Ambient temperature
Charge air pressure
Charge air temperature
Common rail fuel pressure
Coolant level
Coolant temperature
Crankcase pressure
Engine model number
Engine serial number
Engine speed
Fuel pressure
Fuel consumption rate
Fuel temperature
Intercooler coolant temperature (K175 engines only)
Oil pressure
Oil temperature
Run time hours
A message is sent each time there is a change in a monitored engine condition (i.e. fault becomes active, fault is cleared). Upon
broadcast of this message, the controller will request another message that contains the following information for each fault :
• SPN (Suspect Parameter Number) is a 3-to 5-digit code that represents an engine component. See the Engine
Operation Manual for SPN codes.
• FMI (Failure Mode Indicator) is a two-digit code that represents the type of fault that occurred (i.e. short circuit, value is
high).
Tier 2 Engine Data (KD700 – KD4000)

The following chart shows the Diagnostic Troubleshooting Codes (DTC) from Engine Control Module (ECM) on the tier 2 KD
series engines (KD700 – KD4000). The following table provides descriptions of system events and their types – warning,
shutdown, status, or notice.
Tier 2 Engine Fault Codes (KD700-KD4000) Tier 2 Engine Fault Codes (KD700-KD4000)
Event ID Type Level FMI Event ID Type Level FMI
Fuel Supply Pressure Severely Low Warning 1 Water In Fuel Unknown Failure Shutdown 11
Fuel Supply Pressure Shorted High Warning 3 Water In Fuel Condition Exists Shutdown 31
Fuel Supply Pressure Shorted Low Warning 4 Oil Pressure Severely Low Shutdown 1
Fuel Supply Pressure Condition Exists Warning 31 Oil Pressure Plausibility Shutdown 2
Water In Fuel Severely High Shutdown 0 Oil Pressure Shorted High Shutdown 3
Water In Fuel Shorted High Shutdown 3 Oil Pressure Shorted Low Shutdown 4
Water In Fuel Shorted Low Shutdown 4 Oil Pressure Low Warning 17
Water In Fuel Open Circuit Shutdown 5 Oil Pressure Condition Exists Shutdown 31
TP-7141 11/22 133

Crankcase Pressure Severely High Shutdown 0 Rail 1 Pressure Condition Exists Shutdown 31
Crankcase Pressure Shorted High Shutdown 3 Ambient Air

Shorted High Warning 3
Temperature
Crankcase Pressure Shorted Low Shutdown 4 Ambient Air
Shorted Low Warning 4
Temperature
Crankcase Pressure High Warning 15 Ambient Air
Open Circuit Warning 5
Temperature
Crankcase Pressure Condition Exists Shutdown 31 Ambient Air
Condition Exists Warning 31
Intake Manifold Temperature
Severely High Shutdown 0
Pressure Fuel Temperature Severely High Warning 0
Intake Manifold
Plausibility Shutdown 2
Pressure Fuel Temperature Shorted High Warning 3
Intake Manifold
Shorted High Shutdown 3 Fuel Temperature Shorted Low Warning 4
Pressure
Intake Manifold
Shorted Low Shutdown 4 Fuel Temperature Open Circuit Warning 5
Pressure
Intake Manifold
High Shutdown 15 Fuel Temperature Condition Exists Warning 31
Pressure
Intake Manifold Oil Temperature Severely High Shutdown 0
Condition Exists Shutdown 31
Pressure
Intake Manifold Oil Temperature Shorted High Warning 3
Severely High Shutdown 0
Temperature
Intake Manifold Oil Temperature Shorted Low Warning 4
Shorted High Shutdown 3
Temperature
Intake Manifold Oil Temperature Open Circuit Warning 5
Shorted Low Shutdown 4
Temperature Oil Temperature High Warning 15
Intake Manifold
Open Circuit Shutdown 5
Temperature Oil Temperature Condition Exists Warning 31
Intake Manifold
High Warning 15
Temperature Engine Speed Severely High Shutdown 0
Intake Manifold
Condition Exists Shutdown 31 Engine Speed Plausibility Shutdown 2
Temperature
Air Filter Pressure Severely High Warning 0 Engine Speed Shorted High Shutdown 3
Air Filter Pressure Unknown Failure Warning 11 Engine Speed Shorted Low Shutdown 4
Air Filter Pressure Condition Exists Warning 31 Engine Speed Open Circuit Shutdown 5
Barometric Pressure Plausibility Warning 2 Special
Engine Speed Shutdown 14
Instructions
Barometric Pressure Condition Exists Warning 31 Engine Speed Condition Exists Shutdown 31
Coolant Temperature Severely High Shutdown 0
Proprietary Network 1 Open Circuit Warning 5
Coolant Temperature Shorted High Shutdown 3
Proprietary Network 1 Unknown Failure Warning 11
Coolant Temperature Shorted Low Shutdown 4 Engine Position
Plausibility Warning 2
Sensor
Coolant Temperature Open Circuit Shutdown 5 Engine Position
Sensor
Coolant Temperature High Warning 15 Engine Position
Coolant Temperature Condition Exists Shutdown 31 Sensor
Engine Position
Coolant Level Severely Low Shutdown 1 Sensor
Engine Position
Abnormal Signal Warning 8
Coolant Level Shorted High Shutdown 3 Sensor
Engine Position Special
Coolant Level Shorted Low Shutdown 4 Warning 14
Sensor Instructions
Engine Position
Coolant Level Unknown Failure Shutdown 11 Condition Exists Warning 31
Sensor
Coolant Level Low Shutdown 17 Engine Timing
Plausibility Shutdown 2
Sensor
Coolant Level Condition Exists Warning 31 Engine Timing
Sensor
Rail 1 Pressure Severely High Shutdown 0 Engine Timing
Sensor
Rail 1 Pressure Shorted High Shutdown 3 Engine Timing
Sensor
Rail 1 Pressure Shorted Low Shutdown 4
134 TP-7141 4/21
134 TT- XX/16


Engine Timing Injector 7 Open Circuit Warning 5
Abnormal Signal Shutdown 8
Sensor
Engine Timing Special Injector 7 Abnormal Signal Warning 8
Shutdown 14
Sensor Instructions
Engine Timing Injector 8 Warning Warning 0
Sensor
Primary J1939 Injector 8 Shorted High Warning 3
Network 1
Injector 8 Shorted Low Warning 4
Primary J1939
Unknown Failure Warning 11
Network 1
Injector 8 Open Circuit Warning 5
Injector 1 Warning Warning 0
Injector 8 Abnormal Signal Warning 8
Injector 1 Shorted High Warning 3
TP-7141 4/21 135
TT- XX/16 135

Injector 15 Shorted High Warning 3 Inlet Air Heater Grounded Circuit Warning 6
Injector 15 Shorted Low Warning 4 Inlet Air Heater Unknown Failure Warning 11
Injector 15 Open Circuit Warning 5 Inlet Air Heater 2 Shorted High Warning 3
Injector 15 Abnormal Signal Warning 8 Inlet Air Heater 2 Shorted Low Warning 4
Injector 16 Warning Warning 0 Inlet Air Heater 2 Open Circuit Warning 5
Injector 16 Shorted High Warning 3 Inlet Air Heater 2 Grounded Circuit Warning 6
Injector 16 Shorted Low Warning 4 Inlet Air Heater 2 Unknown Failure Warning 11
Injector 16 Open Circuit Warning 5 Fuel Lift Pump Plausibility Shutdown 2
Injector 16 Abnormal Signal Warning 8 Injection Pump

Control Valve
Injector 17 Warning Warning 0 Injection Pump
Control Valve
Injector 17 Shorted High Warning 3 Injection Pump
Control Valve
Injector 17 Shorted Low Warning 4 Injection Pump
Grounded Circuit Shutdown 6
Control Valve
Injection Pump
Unknown Failure Shutdown 11
Control Valve
ECU Temperature Warning Shutdown 0
ECU Temperature High Warning 15
ECU Temperature Condition Exists Shutdown 31
Cylinder Exhaust
Warning Shutdown 0
Injector 18 Open Circuit Warning 5 Temperature 1
Cylinder Exhaust
Injector 18 Abnormal Signal Warning 8 Temperature 1
Cylinder Exhaust
Injector 19 Warning Warning 0 Open Circuit Warning 5
Temperature 1
Cylinder Exhaust Abnormal Data
Injector 19 Shorted High Warning 3 Warning 9
Temperature 1 Rate
Cylinder Exhaust
Injector 19 Shorted Low Warning 4 Unknown Failure Warning 11
Temperature 1
Injector 19 Open Circuit Warning 5 Cylinder Exhaust
Device Failure Warning 12
Temperature 1
Injector 19 Abnormal Signal Warning 8 Cylinder Exhaust Special
Warning 14
Temperature 1 Instructions
Injector 20 Warning Warning 0 Cylinder Exhaust
High Warning 15
Temperature 1
Injector 20 Shorted High Warning 3 Cylinder Exhaust
Warning Shutdown 0
Temperature 2
Cylinder Exhaust
Injector 20 Open Circuit Warning 5 Temperature 2
Cylinder Exhaust
Injector 20 Abnormal Signal Warning 8 Temperature 2
Cylinder Exhaust Abnormal Data
Starter Relay Shorted High Warning 3 Warning 9
Temperature 2 Rate
Cylinder Exhaust
Starter Relay Shorted Low Warning 4 Unknown Failure Warning 11
Temperature 2
Cylinder Exhaust
Starter Relay Open Circuit Warning 5 Device Failure Warning 12
Temperature 2
Starter Relay Grounded Circuit Warning 6 Cylinder Exhaust Special
Warning 14
Starter Relay Unknown Failure Warning 11 Cylinder Exhaust
High Warning 15
Temperature 2
Starter Relay Condition Exists Warning 31 Cylinder Exhaust
Warning Shutdown 0
Temperature 3
Inlet Air Heater Shorted High Warning 3 Cylinder Exhaust
Temperature 3
Inlet Air Heater Shorted Low Warning 4
Cylinder Exhaust
Inlet Air Heater Open Circuit Warning 5 Temperature 3
136 TP-7141 4/21
136 TT- XX/16


Cylinder Exhaust Abnormal Data Cylinder Exhaust
Warning 9 Device Failure Warning 12
Temperature 3 Rate Temperature 7
Cylinder Exhaust Cylinder Exhaust Special
Unknown Failure Warning 11 Warning 14
Temperature 3 Temperature 7 Instructions
Cylinder Exhaust Cylinder Exhaust
Device Failure Warning 12 High Warning 15
Temperature 3 Temperature 7
Cylinder Exhaust Special Cylinder Exhaust
Warning 14 Warning Shutdown 0
Temperature 3 Instructions Temperature 8
High Warning 15 Plausibility Warning 2
Warning Shutdown 0 Open Circuit Warning 5
Cylinder Exhaust Cylinder Exhaust Abnormal Data
Plausibility Warning 2 Warning 9
Temperature 4 Temperature 8 Rate
Open Circuit Warning 5 Unknown Failure Warning 11
TP-7141 4/21 137
TT- XX/16 137


High Warning 15 Open Circuit Warning 5
Warning Shutdown 0 Warning 9
Plausibility Warning 2 Unknown Failure Warning 11
Open Circuit Warning 5 Device Failure Warning 12
Cylinder Exhaust Abnormal Data Cylinder Exhaust Special
Warning 9 Warning 14
Temperature 13 Rate Temperature 17 Instructions
Unknown Failure Warning 11 High Warning 15
Device Failure Warning 12 Warning Shutdown 0
Warning 14 Open Circuit Warning 5
High Warning 15 Warning 9
Warning Shutdown 0 Unknown Failure Warning 11
Plausibility Warning 2 Device Failure Warning 12
Open Circuit Warning 5 Warning 14
Warning 9 High Warning 15
Unknown Failure Warning 11 Warning Shutdown 0
Device Failure Warning 12 Open Circuit Warning 5
Cylinder Exhaust Special Cylinder Exhaust Abnormal Data
Warning 14 Warning 9
Temperature 14 Instructions Temperature 19 Rate
High Warning 15 Unknown Failure Warning 11
Warning Shutdown 0 Device Failure Warning 12
Open Circuit Warning 5 High Warning 15
Unknown Failure Warning 11 Open Circuit Warning 5
Device Failure Warning 12 Warning 9
Warning 14 Unknown Failure Warning 11
High Warning 15 Device Failure Warning 12
Warning Shutdown 0 Warning 14
138 TP-7141 4/21
138 TT- XX/16


Cylinder Exhaust Injector Rail 2
High Warning 15 Warning Shutdown 0
Temperature 20 Pressure
Turbo 1 Compressor Injector Rail 2
Shorted High Shutdown 3 Shorted High Shutdown 3
Temperature Pressure
Shorted Low Shutdown 4 Shorted Low Shutdown 4
Open Circuit Shutdown 5 Condition Exists Shutdown 31
Turbo 1 Compressor Intake Manifold
Temperature Temperature Hi Warning Shutdown 0
Turbo 1 Compressor Resolution
Warning Warning 0
Pressure Intake Manifold
Turbo 1 Compressor Temperature Hi Shorted High Shutdown 3
Severely Low Warning 1
Pressure Resolution
Turbo 1 Turbine Intake Manifold
Warning Shutdown 0
Temperature Temperature Hi Shorted Low Shutdown 4
Turbo 1 Turbine Resolution
Temperature Intake Manifold
Turbo 1 Turbine Temperature Hi Open Circuit Shutdown 5
Open Circuit Warning 5 Resolution
Temperature
Turbo 1 Turbine Intake Manifold
Unknown Failure Warning 11 Temperature Hi High Warning 15
Temperature
Turbo 1 Turbine Resolution
Device Failure Warning 12 Intake Manifold
Temperature
Turbo 1 Turbine Special Temperature Hi Condition Exists Shutdown 31
Warning 14 Resolution
Temperature Instructions
Turbo 1 Turbine Main Radiator
High Warning 15 Shorted High Shutdown 3
Temperature Coolant Level
Warning Shutdown 0 Shorted Low Shutdown 4
Plausibility Warning 2 Unknown Failure Shutdown 11
Open Circuit Warning 5 Condition Exists Shutdown 31
Turbo 2 Turbine Alternate Low Idle
Unknown Failure Warning 11 Unknown Failure Warning 11
Temperature Switch
Turbo 2 Turbine Alternate Low Idle
Device Failure Warning 12 Condition Exists Warning 31
Temperature Switch
Turbo 2 Turbine Special Aftertreatment 1
Warning 14 Exhaust Gas Warning Shutdown 0
Turbo 2 Turbine Temperature 3
High Warning 15 Aftertreatment 2
Temperature
Intercooler Coolant Exhaust Gas Warning Shutdown 0
Warning Shutdown 0 Temperature 3
Temperature
Intercooler Coolant ECM Power Supply
Shorted High Shutdown 3 Severely Low Warning 1
Temperature Voltage
Shorted Low Shutdown 4 High Warning 15
Temperature Voltage
Open Circuit Shutdown 5 Low Shutdown 17
Temperature Voltage
High Warning 15 Condition Exists Warning 31
Temperature Voltage
Intercooler Coolant Engine Aftercooler
Condition Exists Shutdown 31 Severely Low Shutdown 1
Engine Aftercooler
J1939 Network 2 Open Circuit Warning 5 Shorted High Shutdown 3
Coolant Level
J1939 Network 2 Unknown Failure Warning 11 Engine Aftercooler
Coolant Level
Fuel Rail Leakage 1 Warning Warning 0 Engine Aftercooler
Coolant Level
Fuel Rail Leakage 1 Unknown Failure Warning 11 Engine Aftercooler
Coolant Level
Fuel Rail Leakage 1 Condition Exists Warning 31 Generator Speed
Bias
Fuel Rail Leakage 2 Warning Warning 0 Generator Speed
Fuel Rail Leakage 2 Unknown Failure Warning 11 Bias
Generator Speed
Fuel Rail Leakage 2 Condition Exists Warning 31 Bias
TP-7141 4/21 139
TT- XX/16 139


Generator Speed Common Rail PCV
Bias Opened Due To Unknown Failure Warning 11
Coolant Temperature Special Overpressure
Shutdown 14
2 Instructions Common Rail
Piston Cooling Oil Plausibility Error Of Unknown Failure Shutdown 11
Severely Low Shutdown 1
Pressure VCV Current
Piston Cooling Oil Common Rail
Pressure Pressure Remains Unknown Failure Shutdown 11
Piston Cooling Oil Above Setpoint
Pressure Common Rail
Piston Cooling Oil Pressure Remains Unknown Failure Shutdown 11
Low Warning 17 Below Setpoint
Pressure
Piston Cooling Oil Common Rail Start
Condition Exists Shutdown 31 Unknown Failure Warning 11
Pressure Pressure Too Low
Turbo Wastegate Common Rail 2 PCV
Shorted High Shutdown 3 Opened Due To Over Unknown Failure Warning 11
Actuator Command
Turbo Wastegate Pressure
Shorted Low Shutdown 4 Common Rail 2
Actuator Command
Turbo Wastegate Plausibility Error Of Unknown Failure Shutdown 11
Open Circuit Shutdown 5 VCV Current
Actuator Command
Turbo Wastegate Common Rail 2
Grounded Circuit Shutdown 6 Pressure Remains Unknown Failure Shutdown 11
Actuator Command
Turbo Wastegate Above Setpoint
Unknown Failure Shutdown 11 Common Rail 2
Actuator Command
Fuel Rail Pressure Pressure Remains Unknown Failure Shutdown 11
Shorted High Shutdown 3 Below Setpoint
Relief Valve
Fuel Rail Pressure Common Rail2 Start
Shorted Low Shutdown 4 Unknown Failure Warning 11
Relief Valve Pressure Too Low
Fuel Rail Pressure Common Rail
Open Circuit Shutdown 5 Pressure Sensor No Unknown Failure Shutdown 11
Relief Valve
Fuel Rail Pressure Signal Variation
Grounded Circuit Shutdown 6 Common Rail
Relief Valve
Fuel Rail Pressure Pressure Sensor 2 Unknown Failure Shutdown 11
Unknown Failure Shutdown 11 No Signal Variation
Relief Valve
Coolant Temperature ECU Temperature
Warning Shutdown 0 Sensor 2 Supply Out Condition Exists Shutdown 31
3
Coolant Temperature Of Range
Shorted High Shutdown 3 ECU Temperature
3
Coolant Temperature Sensor 3 Supply Out Condition Exists Shutdown 31
Shorted Low Shutdown 4 Of Range
3
Coolant Temperature Cylinder Head
Open Circuit Shutdown 5 Temperature Sensor Condition Exists Warning 31
3
Coolant Temperature Position Error
High Warning 15 Ignition Digital Input
3 Condition Exists Warning 31
Coolant Temperature Supply Out Of Range
Condition Exists Shutdown 31 Master Slave
3 Plausibility Shutdown 2
Injection Com Error
Water In Fuel 2 Warning Shutdown 0 Pressure Control
Valve 2 Current
Water In Fuel 2 Shorted High Shutdown 3
Pressure Control
Water In Fuel 2 Shorted Low Shutdown 4 Valve 2 Current
Pressure Control
Water In Fuel 2 Open Circuit Shutdown 5 Valve 2 Current
Pressure Control
Grounded Circuit Shutdown 6
Water In Fuel 2 Unknown Failure Shutdown 11 Valve 2 Current
Pressure Control
Water In Fuel 2 Condition Exists Shutdown 31 Unknown Failure Shutdown 11
Valve 2 Current
Monitoring System
Coolant Level 2 Shorted High Shutdown 3
ECU Internal Safety Unknown Failure Shutdown 11
Coolant Level 2 Shorted Low Shutdown 4 Error
Monitoring System
Coolant Level 2 Unknown Failure Shutdown 11 Emergency Stop Unknown Failure Shutdown 11
Safety Error
Coolant Level 2 Condition Exists Shutdown 31 Monitoring System
Injector Safety Error
Airfilter Pressure
Monitoring System
Switch Supply Out Of Condition Exists Warning 31 Unknown Failure Shutdown 11
Starter Safety Error
Range
Slave Digital Input
Out Of Range
140 TP-7141 4/21
140 TT- XX/16


Slave Digital Input Volume Control Valve
Condition Exists Warning 31 Shorted Low Shutdown 4
Out Of Range 2 Low Side
Starter Digital Input Volume Control Valve
Unknown Failure Warning 11 Unknown Failure Shutdown 11
Supply Out Of Range 2 Low Side
Starter Digital Input Pressure Control
Condition Exists Warning 31 Shorted High Shutdown 3
Supply Out Of Range Valve 2 Low Side
Testbench Digital Pressure Control
Unknown Failure Warning 11 Shorted Low Shutdown 4
Input Valve 2 Low Side
Testbench Digital Pressure Control
Condition Exists Warning 31 Unknown Failure Shutdown 11
Input Valve 2 Low Side
Volume Control Valve Starter Locked Due
Warning Warning 0 Condition Exists Warning 31
Current To Over Temperature
Volume Control Valve Heating Flange 2 Low
Severely Low Warning 1 Shorted High Warning 3
Current Side
Volume Control Valve Heating Flange 2 Low
Shorted High Shutdown 3 Shorted Low Warning 4
2 Side 2
Volume Control Valve Heating Flange Input
Shorted Low Shutdown 4 Shorted High Warning 3
2 1
Open Circuit Shutdown 5 Shorted Low Warning 4
2 1
Grounded Circuit Shutdown 6 Open Circuit Warning 5
2 1
Unknown Failure Shutdown 11 Shorted High Warning 3
2 1 Low Side
Condition Exists Shutdown 31 Shorted Low Warning 4
2 1 Low Side
Starter Digital Input 2 Unknown Failure Warning 11 Heating Flange Input
2
Starter Digital Input 2 Condition Exists Warning 31 Heating Flange Input
2
Turbo Wastegate Heating Flange Input
Shorted High Shutdown 3 Open Circuit Warning 5
Actuator Low Side 2
Turbo Wastegate Heating Flange Input
Shorted Low Shutdown 4 Shorted High Warning 3
Actuator Low Side 2 Low Side
Starter Low Side Shorted High Warning 3 Heating Flange Input
2 Low Side
Starter Low Side 2 Shorted Low Warning 4 ECU Com Error To
Power Reduction Slave
Low Shutdown 17
Boost Pressure Starter 2 Shorted High Warning 3
Heating Flange 1 Low
Side Starter 2 Shorted Low Warning 4
Heating Flange 1 Low
Shorted Low Warning 4 Starter 2 Open Circuit Warning 5
Side 2
Wastegate Valve
Condition Exists Shutdown 31 Starter 2 Grounded Circuit Warning 6
Short Circuit
Over Speed Test Starter 2 Unknown Failure Warning 11
Switch
Droop Request Starter 2 Condition Exists Warning 31
Switch
Frm Disable Switch Starter 2 Low Side Shorted High Warning 3
Supply
Frm Disable Switch Starter 2 Low Side 2 Shorted Low Warning 4
Supply Pressure Control
Volume Control Valve Valve Short Circuit Unknown Failure Shutdown 11
Low Side Load
Volume Control Valve Starter 1 Inhibition
Low Side Due To Short Circuit
Volume Control Valve Starter 2 Inhibition
Low Side 2 Due To Short Circuit
Volume Control Valve Air Pressure Sensors
Unknown Failure Shutdown 11 Condition Exists Shutdown 31
Electrical Error Error
Pressure Control Engine Can On
Valve Low Side Engine Connector Open Circuit Warning 5
Pressure Control Open Circuit
Valve Low Side Cylinder Head
Pressure Control High Warning 15
Shorted Low Shutdown 4 Temperature
Valve Low Side 2 Cylinder Head
Volume Control Valve High Shutdown 15
Shorted High Shutdown 3 Temperature2
2 Low Side
TP-7141 4/21 141
TT- XX/16 141


Slave Emission Engine Mean Torque
Condition Exists Warning 31 High Warning 15
Relevant Error During Life Time
ECU Maximum ECU Data Recorder
Runtime Reached Condition Exists Warning 31 Was Triggered
Without Reset Engine Starter
Speed Sensors Activated But No Condition Exists Warning 31
Sensor Position Condition Exists Warning 31 Rotation
Inversion Error Secondary Injection
Starters Not Control Unit ECU Condition Exists Warning 31
Connected In The Condition Exists Warning 31 Error Msgs
Output 1 To ECU Error Msgs From
Starters Not Secondary Injection Condition Exists Warning 31
Connected In The Condition Exists Warning 31 Control Unit
Output2 To ECU
Engine Mean Torque
High Warning 15
Last Day
Engine Mean Torque
High Warning 15
Last Hour
142 TP-7141 4/21
142 TT- XX/16

Tier 4 Engine Data (KD1250-4, KD2500-4, KD3250-4)
The following chart shows the Diagnostic Troubleshooting Codes (DTC) from Engine Control Module (ECM) on the tier 4 KD
series engines (KD1250-4, KD2500-4, KD3250-4). The following table provides descriptions of system events and their types –
warning, shutdown.
Tier 4 Engine Fault Codes (KD1250-4, KD2500-4, KD3250-4) Tier 4 Engine Fault Codes (KD1250-4, KD2500-4, KD3250-4)

Fuel Supply Pressure Severely Low Warning 1 Air Filter Pressure Condition Exists Warning 31
Fuel Supply Pressure Shorted High Warning 3 Barometric Pressure Shorted High Warning 3
Fuel Supply Pressure Shorted Low Warning 4 Barometric Pressure Grounded or Warning 30
Open Circuit
Fuel Supply Pressure Condition Exists Warning 31 Barometric Pressure Condition Exists Warning 31
Water In Fuel Severely High Shutdown 0 Coolant Temperature Severely High Shutdown 0
Water In Fuel Shorted High Shutdown 3 Coolant Temperature Shorted High Shutdown 3
Water In Fuel Shorted Low Shutdown 4 Coolant Temperature Shorted Low Shutdown 4
Water In Fuel Open Circuit Shutdown 5 Coolant Temperature Open Circuit Shutdown 5
Water In Fuel Unknown Failure Shutdown 11 Coolant Temperature High Warning 15
Water In Fuel Condition Exists Shutdown 31 Coolant Temperature Condition Exists Shutdown 31
Oil Pressure Severely Low Shutdown 1 Coolant Level Low Shutdown 1
Oil Pressure Plausibility Shutdown 2 Coolant Level Shorted High Shutdown 3
Oil Pressure Shorted High Shutdown 3 Coolant Level Shorted Low Shutdown 4
Oil Pressure Shorted Low Shutdown 4 Coolant Level Unknown Failure Shutdown 11
Oil Pressure Low Warning 17 Coolant Level Condition Exists Shutdown 31
Oil Pressure Condition Exists Shutdown 31 Rail 1 Pressure Severely High Shutdown 0
Crankcase Pressure Severely High Shutdown 0 Rail 1 Pressure Shorted High Shutdown 3
Crankcase Pressure Shorted High Shutdown 3 Rail 1 Pressure Shorted Low Shutdown 4
Crankcase Pressure Shorted Low Shutdown 4 Rail 1 Pressure Condition Exists Shutdown 31
Crankcase Pressure High Warning 15 Ambient Air Shorted High Warning 3
Temperature
Crankcase Pressure Condition Exists Shutdown 31 Ambient Air Shorted Low Warning 4
Temperature
Intake Manifold Severely High Shutdown 0
Pressure Ambient Air Open Circuit Warning 5
Temperature
Intake Manifold Shorted High Shutdown 3
Pressure Ambient Air Condition Exists Warning 31
Temperature
Intake Manifold Shorted Low Shutdown 4
Pressure Fuel Temperature Severly High Warning 0
Intake Manifold High Warning 15
Fuel Temperature Shorted High Warning 3
Pressure
Intake Manifold Condition Exists Shutdown 31 Fuel Temperature Shorted Low Warning 4
Pressure
Intake Manifold Severely High Shutdown 0 Fuel Temperature Open Circuit Warning 5
Temperature
Intake Manifold Shorted High Shutdown 3 Fuel Temperature Condition Exists Warning 31
Temperature
Intake Manifold Shorted Low Shutdown 4 Oil Temperature Severly High Shutdown 0
Temperature Oil Temperature Shorted High Warning 3
Intake Manifold Open Circuit Shutdown 5
Temperature Oil Temperature Shorted Low Warning 4
Intake Manifold High Warning 15
Temperature Oil Temperature Open Circuit Warning 5
Intake Manifold Condition Exists Shutdown 31
Temperature Oil Temperature High Warning 15
Air Filter Pressure Severely High Warning 0
Oil Temperature Condition Exists Warning 31
TP-7141 4/21 143
TT- XX/16 143


Engine Speed Severely High Shutdown 0 Injector 9 Shorted High Warning 3
Engine Speed Plausibility Shutdown 2 Injector 9 Shorted Low Warning 4
Engine Speed Shorted High Shutdown 3 Injector 9 Open Circuit Warning 5
Engine Speed Shorted Low Shutdown 4 Injector 10 Shorted High Warning 3
Engine Speed Open Circuit Shutdown 5 Injector 10 Shorted Low Warning 4
Engine Speed Special Shutdown 14 Injector 10 Open Circuit Warning 5

Instructions
Engine Speed Condition Exists Shutdown 31 Injector 11 Shorted High Warning 3
Engine Position Shorted High Warning 3 Injector 11 Shorted Low Warning 4

Sensor
Engine Position Shorted Low Warning 4 Injector 11 Open Circuit Warning 5
Sensor
Engine Position Open Circuit Warning 5
Sensor Injector 12 Shorted Low Warning 4
Engine Position Special Warning 14
Sensor Instructions Injector 12 Open Circuit Warning 5
Engine Position Condition Exists Warning 31
Sensor Injector 13 Shorted High Warning 3
Primary J1939 Open Circuit 5
Network 1 Injector 13 Shorted Low Warning 4
Primary J1939 Unknown Failure 11
Network 1
Injector 1 Shorted High Warning 3 Injector 14 Shorted High Warning 3
Injector 1 Shorted Low Warning 4 Injector 14 Shorted Low Warning 4
Injector 1 Open Circuit Warning 5 Injector 14 Open Circuit Warning 5
Injector 8 Shorted High Warning 3 Starter Relay Shorted High Warning 3
Injector 8 Shorted Low Warning 4 Starter Relay Shorted Low Warning 4
Injector 8 Open Circuit Warning 5 Starter Relay Open Circuit Warning 5
144 TP-7141 11/22


Starter Relay Condition Exists Warning 31 Cylinder Exhaust Unknown Failure Warning 11
Temperature 3
Inlet Air Heater Shorted High Warning 3 Cylinder Exhaust Device Failure Warning 12
Temperature 3
Inlet Air Heater Shorted Low Warning 4
Cylinder Exhaust Special Warning 14
Inlet Air Heater Open Circuit Warning 5
Cylinder Exhaust High Warning 15
Inlet Air Heater Grounded Circuit Warning 6 Temperature 3
Cylinder Exhaust Severely High Shutdown 0
Inlet Air Heater 2 Shorted High Warning 3 Temperature 4
Cylinder Exhaust Open Circuit Warning 5
Inlet Air Heater 2 Shorted Low Warning 4 Temperature 4
Cylinder Exhaust Abnormal Data Warning 9
Inlet Air Heater 2 Open Circuit Warning 5 Temperature 4 Rate
Cylinder Exhaust Unknown Failure Warning 11
Inlet Air Heater 2 Grounded Circuit Warning 6
Temperature 4
Engine Test Mode Condition Exists Warning 31 Cylinder Exhaust Device Failure Warning 12
Switch Temperature 4
Fuel Lift Pump Plausibility Shutdown 2 Cylinder Exhaust Special Warning 14
Injection Pump Shorted High Shutdown 3 Cylinder Exhaust High Warning 15
Control Valve Temperature 4
Injection Pump Shorted Low Shutdown 4 Cylinder Exhaust Severely High Shutdown 0
Injection Pump Open Circuit Shutdown 5 Cylinder Exhaust Open Circuit Warning 5
Injection Pump Grounded Circuit Shutdown 6 Cylinder Exhaust Abnormal Data Warning 9
Control Valve Temperature 5 Rate
Injection Pump Unknown Failure Shutdown 11 Cylinder Exhaust Unknown Failure Warning 11
ECU Temperature Severely High Shutdown 0 Cylinder Exhaust Device Failure Warning 12
Temperature 5
ECU Temperature High Warning 15 Cylinder Exhaust Special Warning 14
ECU Temperature Condition Exists Shutdown 31 Cylinder Exhaust High Warning 15
Temperature 5
Temperature 1 Cylinder Exhaust Severely High Shutdown 0
Temperature 6
Temperature 1
Temperature 6
Temperature 1 Rate
Temperature 6 Rate
Temperature 1
Temperature 6
Cylinder Exhaust Device Failure Warning 12
Temperature 1
Temperature 6
Temperature 1 Instructions Cylinder Exhaust Special Warning 14
Cylinder Exhaust Temperature 1 Warning 15
Temperature 1 High
Temperature 6
Temperature 2 Cylinder Exhaust Severely High Shutdown 0
Temperature 7
Temperature 2
Temperature 7
Temperature 2 Rate
Temperature 7 Rate
Temperature 2 Cylinder Exhaust Unknown Failure Warning 11
Temperature 7
Temperature 2 Cylinder Exhaust Device Failure Warning 12
Temperature 7
Temperature 2 Instructions Cylinder Exhaust Special Warning 14
Temperature 2
Temperature 7
Temperature 3
Temperature 8
Temperature 3
Temperature 8
Temperature 3 Rate Cylinder Exhaust Abnormal Data Warning 9
Temperature 8 Rate
TP-7141 11/22 145


Cylinder Exhaust Unknown Failure Warning 11 Cylinder Exhaust Unknown Failure Warning 11
Cylinder Exhaust Device Failure Warning 12 Cylinder Exhaust Device Failure Warning 12
Cylinder Exhaust Special Warning 14 Cylinder Exhaust Special Warning 14
Temperature 8 Instructions Temperature 13 Instructions
Cylinder Exhaust High Warning 15 Cylinder Exhaust High Warning 15
Cylinder Exhaust Severely High Shutdown 0 Cylinder Exhaust Severely High Shutdown 0
Cylinder Exhaust Open Circuit Warning 5 Cylinder Exhaust Open Circuit Warning 5
Cylinder Exhaust Abnormal Data Warning 9 Cylinder Exhaust Abnormal Data Warning 9
Temperature 9 Rate Temperature 14 Rate
146 TP-7141 11/22


Cylinder Exhaust Unknown Failure Warning 11 Turbo 2 Turbine High Warning 15
Temperature 18 Temperature
Cylinder Exhaust Device Failure Warning 12 Intercooler Coolant Severely High Shutdown 0
Cylinder Exhaust Special Warning 14 Intercooler Coolant Shorted High Shutdown 3
Temperature 18 Instructions Temperature
Cylinder Exhaust High Warning 15 Intercooler Coolant Shorted Low Shutdown 4
Cylinder Exhaust Severely High Shutdown 0 Intercooler Coolant Open Circuit Shutdown 5
Cylinder Exhaust Open Circuit Warning 5 Intercooler Coolant High Warning 15
Cylinder Exhaust Abnormal Data Warning 9 Intercooler Coolant Condition Exists Shutdown 31
Temperature 19 Rate Temperature
Cylinder Exhaust Unknown Failure Warning 11 J1939 Network 2 Open Circuit Warning 5
Temperature 19
Cylinder Exhaust Device Failure Warning 12 J1939 Network 2 Unknown Failure Warning 11
Temperature 19
Cylinder Exhaust Special Warning 14 Injector Rail 2 Severely High Shutdown 0
Temperature 19 Instructions Pressure
Injector Rail 2 Shorted High Shutdown 3
Cylinder Exhaust Severely High Shutdown 0 Injector Rail 2 Shorted Low Shutdown 4
Cylinder Exhaust Open Circuit Warning 5 Injector Rail 2 Condition Exists Shutdown 31
Cylinder Exhaust Abnormal Data Warning 9 Engine Starter Mode Unknown Failure Shutdown 11
Temperature 20 Rate Aftertreatment 1 DEF Severely Low Warning 1
Cylinder Exhaust Unknown Failure Warning 11 Tank Level
Temperature 20
Aftertreatment 1 DEF Plausibility Warning 2
Cylinder Exhaust Device Failure Warning 12 Tank Level
Temperature 20 Aftertreatment 1 DEF Shorted High Warning 3
Cylinder Exhaust Special Warning 14 Tank Level
Aftertreatment 1 DEF Shorted Low Warning 4
Cylinder Exhaust High Warning 15 Tank Level
Temperature 20 Aftertreatment 1 DEF Level Low Warning 17
Turbo 1 Compressor Shorted High Shutdown 3 Tank Level
Temperature
Aftertreatment 1 DEF Severely High Warning 0
Turbo 1 Compressor Shorted Low Shutdown 4 Tank Temperature
Temperature
Aftertreatment 1 DEF Severely Low Warning 1
Turbo 1 Compressor Open Circuit Shutdown 5 Tank Temperature
Temperature
Aftertreatment 1 DEF Shorted High Warning 3
Turbo 1 Compressor Condition Exists Shutdown 31 Tank Temperature
Temperature Aftertreatment 1 DEF Shorted Low Warning 4
Turbo 1 Turbine Severely High Shutdown 0 Tank Temperature
Temperature
Aftertreatment 1 DEF High Warning 15
Turbo 1 Turbine Plausibility Warning 2 Tank Temperature
Temperature
Aftertreatment 1 Mechanical Error Warning 7
Turbo 1 Turbine Open Circuit Warning 5 Intake Gas Sensor
Temperature Heater
Turbo 1 Turbine Unknown Failure Warning 11 Aftertreatment 1 Severely High Warning 0
Temperature Intake NOx Sensor
Turbo 1 Turbine Device Failure Warning 12 Aftertreatment 1 Plausibility Warning 2
Turbo 1 Turbine Special Warning 14 Aftertreatment 1 Shorted High Warning 3
Temperature Instructions Intake NOx Sensor
Turbo 1 Turbine Temperature Warning 15 Aftertreatment 1 Open Circuit Warning 5
Temperature High Intake NOx Sensor
Turbo 2 Turbine Severely High Shutdown 0 Aftertreatment 1 Condition Exists Warning 31
Turbo 2 Turbine Plausibility Warning 2 Aftertreatment 1 Plausibility Warning 2
Temperature Intake O2 Sensor
Turbo 2 Turbine Open Circuit Warning 5 Aftertreatment 1 Mechanical Error Warning 7
Temperature Intake Gas Sensor
Turbo 2 Turbine Unknown Failure Warning 11 Heater
Temperature Aftertreatment 1 Severely High Warning 0
Turbo 2 Turbine Device Failure Warning 12 Outlet NOx Sensor
Temperature Aftertreatment 1 Plausibility Warning 2
Turbo 2 Turbine Special Warning 14 Outlet NOx Sensor
TP-7141 11/22 147


Aftertreatment 1 Shorted High Warning 3 Oil Prelube Pump Shorted High Warning 3
Outlet NOx Sensor
Aftertreatment 1 Open Circuit Warning 5 Oil Prelube Pump Shorted Low Warning 4
Outlet NOx Sensor
Aftertreatment 1 DEF Shorted High Warning 3
Aftertreatment 1 Condition Exists Warning 31
Outlet NOx Sensor Line Heater 1 State
Aftertreatment 1 Plausibility Warning 2 Aftertreatment 1 DEF Shorted Low Warning 4
Line Heater 1 State
Outlet O2 Sensor
Aftertreatment 1 DEF Open Circuit Warning 5
Aftertreatment 2 Severely High Warning 0
Aftertreatment 2 Plausibility Warning 2 Aftertreatment 1 DEF Grounded Circuit Warning 6
Aftertreatment 2 Shorted High Warning 3 Aftertreatment 1 DEF Unknown Failure Warning 11
Aftertreatment 2 Open Circuit Warning 5 Aftertreatment 1 DEF Shorted High Warning 3
Line Heater 2 State
Outlet NOx Sensor
Aftertreatment 1 DEF Shorted Low Warning 4
Aftertreatment 2 Mechanical Error Warning 7
Aftertreatment 2 Unknown Failure Warning 11 Aftertreatment 1 DEF Open Circuit Warning 5
Aftertreatment 1 DEF Grounded Circuit Warning 6
Aftertreatment 1 DEF Severely High Warning 0 Aftertreatment 1 DEF Unknown Failure Warning 11
Tank Quality Line Heater 2 State
Aftertreatment 1 DEF Severely Low Warning 1 Aftertreatment 1 SCR Plausibility Warning 2
Tank Quality Cat Intake Gas
Temperature
Aftertreatment 1 DEF Unknown Failure Warning 11
Aftertreatment 1 SCR Shorted High Warning 3
Tank Quality
Cat Intake Gas
Turbo Compressor Plausibility Warning 2
Temperature
Bypass Actuator 1
Aftertreatment 1 SCR Shorted Low Warning 4
Aftertreatment 1 DEF Severely High Shutdown 0
Cat Intake Gas
Temperature 2
Temperature
Aftertreatment 1 DEF Severely Low Shutdown 1
Aftertreatment 1 SCR Open Circuit Warning 5
Temperature 2
Cat Intake Gas
Aftertreatment 1 DEF Shorted High Shutdown 3
Temperature
Temperature 2
Aftertreatment 1 SCR High Warning 15
Aftertreatment 1 DEF Shorted Low Shutdown 4
Cat Intake Gas
Temperature 2
Temperature
Aftertreatment 1 DEF High Warning 15
Aftertreatment 1 SCR Condition Exists Warning 31
Temperature 2
Cat Intake Gas
Aftertreatment 1 DEF Low Warning 17
Temperature
Concentration
Aftertreatment 1 SCR Severely Low Warning 1
ECM Power Supply Severely Low Warning 1
Conversion Efficiency
Voltage
ECM Power Supply High Warning 15
Outlet NH3
Voltage
Aftertreatment 1 Unknown Failure Warning 11
ECM Power Supply Low Shutdown 17 Outlet NH3 Sensor
Voltage
Power
Turbo Compressor Plausibility Warning 2
Aftertreatment 1 Plausibility Warning 2
Bypass Actuator 1
Outlet NH3 Gas
Position Sensor Heater
Turbo Compressor Condition Exists Warning 31
Aftertreatment 2 SCR Shorted High Warning 3
Bypass Actuator 1
Cat Intake Gas
Position
Temperature
Engine Aftercooler Severely Low Shutdown 1
Aftertreatment 2 SCR Shorted Low Warning 4
Coolant Level
Cat Intake Gas
Engine Aftercooler Shorted High Shutdown 3 Temperature
Coolant Level
Aftertreatment 2 SCR Open Circuit Warning 5
Engine Aftercooler Shorted Low Shutdown 4 Cat Intake Gas
Coolant Level Temperature
Engine Aftercooler Unknown Failure Shutdown 11 Aftertreatment 2 SCR Unknown Failure Warning 11
Coolant Level Cat Intake Gas
Engine Aftercooler Condition Exists Shutdown 31 Temperature
Coolant Level Aftertreatment 2 SCR High Warning 15
Generator Speed Shorted High Warning 3 Cat Intake Gas
Bias Temperature
Generator Speed Open Circuit Warning 30 Aftertreatment 2 SCR Condition Exists Warning 31
Bias Cat Intake Gas
Generator Speed Condition Exists Warning 31 Temperature
Bias
148 TP-7141 11/22


Aftertreatment 2 SCR Severely Low Warning 1 Common Rail PCV Unknown Failure Warning 11
Conversion Efficiency Opened Due To
Aftertreatment 2 Condition Exists Warning 31 Overpressure
Outlet NH3 Common Rail Error Unknown Failure Shutdown 11
Aftertreatment 2 Unknown Failure Warning 11 Of VCV Current
Outlet NH3 Sensor Common Rail Unknown Failure Shutdown 11
Power Pressure Remains
Aftertreatment 2 Plausibility Warning 2 Above Setpoint
Outlet NH3 Gas Common Rail Unknown Failure Shutdown 11
Sensor Heater Pressure Remains
Turbo Compressor Severely High Warning 0 Below Setpoint
Bypass Actuator 1 Common Rail Start Unknown Failure Warning 11
Temperature Status Pressure Too Low
Turbo Wastegate Shorted High Shutdown 3 Common Rail 2 PCV Unknown Failure Warning 11
Actuator Command Opened Due To Over
Turbo Wastegate Shorted Low Shutdown 4 Pressure
Actuator Command Common Rail 2 Error Unknown Failure Shutdown 11
Turbo Wastegate Open Circuit Shutdown 5 Of VCV Current
Actuator Command Common Rail 2 Unknown Failure Shutdown 11
Turbo Wastegate Grounded Circuit Shutdown 6 Pressure Remains
Actuator Command Above Setpoint
Turbo Wastegate Unknown Failure Shutdown 11 Common Rail 2 Unknown Failure Shutdown 11
Actuator Command Pressure Remains
Turbo Compressor Plausibility Warning 2 Below Setpoint
Bypass Actuator 1 Common Rail2 Start Unknown Failure Warning 11
Turbo Compressor Unknown Failure Warning 11 Pressure Too Low
Bypass Actuator 1 Common Rail Unknown Failure Shutdown 11
Turbo Compressor Out of Warning 13 Pressure Sensor No
Bypass Actuator 1 Calibration Signal Variation
Turbo Compressor Condition Exists Warning 31 Common Rail Unknown Failure Shutdown 11
Bypass Actuator 1 Pressure Sensor 2
Turbo Compressor Plausibility Warning 2 No Signal Variation
Bypass Actuator 1 ECU Machine Digital Shorted High Warning 3
Turbo Compressor Condition Exists Warning 31 Output 1
Bypass Actuator 1 ECU Machine Digital Shorted Low Warning 4
Operation Status Output 1
Fuel Rail Pressure Shorted High Shutdown 3 ECU Machine Digital Open Circuit Warning 5
Relief Valve Output 1
Fuel Rail Pressure Shorted Low Shutdown 4 ECU Machine Digital Grounded Circuit Warning 6
Fuel Rail Pressure Open Circuit Shutdown 5 ECU Machine Digital Unknown Failure Warning 11
Fuel Rail Pressure Grounded Circuit Shutdown 6 ECU Temperature Condition Exists Shutdown 31
Relief Valve Sensor 2 Supply Out
Aftertreatment 1 DEF Condition Exists Shutdown 31 Of Range
Dosing Unit Heater ECU Temperature Condition Exists Shutdown 31
Emission Operator Severely High Warning 0 Sensor 3 Supply Out
Inducement Severity Of Range
Emission Operator Unknown Failure Warning 11 Cylinder Head Condition Exists Warning 31
Inducement Severity Temperature Sensor
Emission Operator Severity High Warning 15 Position Error
Inducement Severity Master Slave Plausibility Shutdown 2
Emission Operator Moderately High Warning 16 Injection Com Error
Inducement Severity Aftertreatment 1 Unknown Failure Warning 11
Water In Fuel 2 Severely High Shutdown 0 Outlet NH3 Sensor
Communication
Water In Fuel 2 Shorted High Shutdown 3 Aftertreatment 1 Unknown Failure Warning 11
Outlet NH3 Sensor
Water In Fuel 2 Shorted Low Shutdown 4 Memory
Water In Fuel 2 Open Circuit Shutdown 5 Outlet NH3 Sensor
Resistance
Water In Fuel 2 Unknown Failure Shutdown 11
Water In Fuel 2 Condition Exists Shutdown 31 Outlet NH3 Sensor
Module
Aftertreatment DEF Condition Exists Warning 31 Aftertreatment 1 Plausibility Warning 2
Doser Cooldown Outlet NOx Sensor
Interrupt Status
Aftertreatment DEF Condition Exists Warning 31 Aftertreatment 1 Plausibility Warning 2
Doser Purge Interrupt Intake NOx Sensor
Status
TP-7141 11/22 149


Aftertreatment NOx Unknown Failure Warning 11 ECU Com Error To Condition Exists Warning 31
Sensor Installation Slave
Error Starter 2 Shorted High Warning 3
Pressure Control Shorted High Shutdown 3
Valve 2 Current Starter 2 Shorted Low Warning 4
Pressure Control Shorted Low Shutdown 4
Valve 2 Current Starter 2 Open Circuit Warning 5
Pressure Control Open Circuit Shutdown 5 Starter 2 Condition Exists Warning 31
Valve 2 Current
Pressure Control Grounded Circuit Shutdown 6 Pressure Control Unknown Failure Shutdown 11
Valve 2 Current Valve Short Circuit
Pressure Control Unknown Failure Shutdown 11 Load
Valve 2 Current Starter 1 Inhibition Unknown Failure Warning 11
Aftertreatment SCR Unknown Failure Shutdown 11 Due To Short Circuit
DEF Defrost Error Starter 2 Inhibition Unknown Failure Warning 11
Volume Control Valve Shorted High Shutdown 3 Due To Short Circuit
2 Air Pressure Sensors Condition Exists Shutdown 31
Volume Control Valve Shorted Low Shutdown 4 Error
2 Aftertreatment Plausibility Warning 2
Volume Control Valve Open Circuit Shutdown 5 Module
2 Communication Error
Volume Control Valve Grounded Circuit Shutdown 6 Slave Emission Condition Exists Warning 31
2 Relevant Error
Volume Control Valve Condition Exists Shutdown 31 Starters Not Condition Exists Warning 31
2 Connected In The
Turbo Wastegate Shorted High Shutdown 3 Output 1 To ECU
Actuator Side Starters Not Condition Exists Warning 31
Turbo Wastegate Shorted Low Shutdown 4 Connected In The
Actuator Side Output2 To ECU
Derate Aftertreatment High Warning 15 ECU Data Recorder Condition Exists Warning 31
Protection Was Triggered
Temperature Engine Starter Condition Exists Warning 31
Power Reduction Low Shutdown 17 Activated But No
Boost Pressure Rotation
Wastegate Valve Condition Exists Shutdown 31 Aftertreatment SCR Severely High Warning 0
Short Circuit Carbon Buildup
Volume Control Valve Shorted High Shutdown 3 Aftertreatment SCR High Warning 15
Side Carbon Buildup
Volume Control Valve Shorted Low Shutdown 4 Aftertreatment SCR Condition Exists Warning 31
Side DEF Defrost Time
Pressure Control Shorted High Shutdown 3 Exceeded
Valve Side Aftertreatment SCR Shorted High Warning 3
Pressure Control Shorted Low Shutdown 4 DEF Injector 1
Valve Side Aftertreatment SCR Shorted Low Warning 4
Volume Control Valve Shorted High Shutdown 3 DEF Injector 1
2 Side Aftertreatment SCR Shorted High Warning 3
Volume Control Valve Shorted Low Shutdown 4 DEF Injector 2
2 Side Aftertreatment SCR Shorted Low Warning 4
Pressure Control Shorted High Shutdown 3 DEF Injector 2
Valve 2 Side Aftertreatment SCR Shorted High Warning 3
Pressure Control Shorted Low Shutdown 4 DEF Injector 3
Valve 2 Side Aftertreatment SCR Shorted Low Warning 4
Turbo Wastegate Plausibility Shutdown 2 DEF Injector 3
Module Aftertreatment SCR Shorted High Warning 3
Communication Error DEF Injector 4
Heating Flange Input Shorted High Warning 3 Aftertreatment SCR Shorted Low Warning 4
1 DEF Injector 4
Heating Flange Input Shorted Low Warning 4 Aftertreatment SCR Shorted High Warning 3
1 DEF Injector 5
Heating Flange Input Open Circuit Warning 5 Aftertreatment SCR Shorted Low Warning 4
1 DEF Injector 5
Heating Flange Input Shorted High Warning 3 Aftertreatment SCR Shorted High Warning 3
2 DEF Injector 6
Heating Flange Input Shorted Low Warning 4 Aftertreatment SCR Shorted Low Warning 4
2 DEF Injector 6
Heating Flange Input Open Circuit Warning 5 Aftertreatment SCR Shorted High Warning 3
2 DEF Injector 7
ECU Communication Condition Exists Warning 31 Aftertreatment SCR Shorted Low Warning 4
Error With DEF Injector 7
Aftertreatment
150 TP-7141 11/22


Aftertreatment SCR Shorted High Warning 3 SCR Primary DCU Plausibility Warning 2
DEF Injector 8 CAN 2 Electrical Error
Aftertreatment SCR Shorted Low Warning 4 Aftertreatment SCR Shorted High Warning 3
DEF Injector 8 Secondary 1 DCU
Aftertreatment SCR Severely High Warning 0 Battery
DEF Pump Inlet Aftertreatment SCR Shorted Low Warning 4
Temperature Secondary 1 DCU
Aftertreatment SCR Severely Low Warning 1 Battery
DEF Pump Inlet Aftertreatment SCR Shorted High Warning 3
Aftertreatment SCR Plausibility Warning 2 Sensor Supply
DEF Pump Inlet Aftertreatment SCR Shorted Low Warning 4
Aftertreatment SCR High Warning 15 Sensor Supply
DEF Pump Inlet Aftertreatment SCR Shorted High Warning 3
Aftertreatment SCR Severely High Warning 0 Battery
DEF Pump Outlet Aftertreatment SCR Shorted Low Warning 4
Pressure Secondary 2 DCU
Aftertreatment SCR Severely Low Warning 1 Battery
DEF Pump Outlet Aftertreatment SCR Shorted High Warning 3
Aftertreatment SCR Plausibility Warning 2 Sensor Supply
DEF Pump Outlet Aftertreatment SCR Shorted Low Warning 4
Aftertreatment SCR High Warning 15 Sensor Supply
DEF Pump Outlet Aftertreatment 2 Unknown Failure Warning 11
Pressure Outlet NH3 Sensor
Aftertreatment SCR Moderately High Shutdown 16 Communication
Aftertreatment SCR Low Warning 17 Resistance
Aftertreatment SCR Severely High Warning 0 Module
Common Rail DEF Aftertreatment 2 Unknown Failure Warning 11
Aftertreatment SCR Severely Low Warning 1 Memory
Common Rail DEF Aftertreatment 3 SCR Severely Low Warning 1
Pressure Conversion Efficiency
Aftertreatment SCR Plausibility Warning 2 Aftertreatment 4 SCR Severely Low Warning 1
Common Rail DEF Conversion Efficiency
Pressure Smart Sensor Supply Shorted High Warning 3
Aftertreatment SCR High Warning 15 Relay 1
Common Rail DEF Smart Sensor Supply Shorted Low Warning 4
Pressure Relay 1
Aftertreatment SCR Moderately High Shutdown 16 Smart Sensor Supply Open Circuit Warning 5
Common Rail DEF Relay 1
Pressure Smart Sensor Supply Grounded Circuit Warning 6
Aftertreatment SCR Low Warning 17 Relay 1
Common Rail DEF Smart Sensor Supply Unknown Failure Warning 11
Pressure Relay 1
Aftertreatment SCR Shorted High Shutdown 3 Smart Sensor Supply Shorted High Warning 3
Primary DCU Sensor Relay 2
Supply Smart Sensor Supply Shorted Low Warning 4
Aftertreatment SCR Shorted Low Shutdown 4 Relay 2
Primary DCU Sensor Smart Sensor Supply Open Circuit Warning 5
Supply Relay 2
Aftertreatment SCR Shorted High Shutdown 3 Smart Sensor Supply Grounded Circuit Warning 6
Primary DCU Battery Relay 2
Aftertreatment SCR Shorted Low Shutdown 4 Smart Sensor Supply Unknown Failure Warning 11
Primary DCU Battery Relay 2
SCR Primary DCU Abnormal Data Warning 9 Smart Sensor Supply Shorted High Warning 3
Communication Error Rate Relay 3
With ECU Smart Sensor Supply Shorted Low Warning 4
SCR Primary DCU Abnormal Data Warning 9 Relay 3
Comm Error With Rate Smart Sensor Supply Open Circuit Warning 5
Secondary DCU 1 Relay 3
SCR Primary DCU Plausibility Warning 2 Smart Sensor Supply Grounded Circuit Warning 6
CAN 1 Electrical Error Relay 3
TP-7141 11/22 151


Smart Sensor Supply Unknown Failure Warning 11 Production Test Condition Exists Shutdown 31
Relay 3 Mode Expired
NOx Sensors Unknown Failure Warning 11
Installation Error
152 TP-7141 11/22

Appendix C. Alternator Protection
The controller has built-in thermal protection for the alternator. This feature functions similarly to a thermal circuit breaker. When
the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown. The amount of
time at which current is over the rating is inversely related to the amount of current above the nominal rating. In other words, the
higher the current, the shorter the acceptable time.
The current and time limits are defined by actual test data and are maintained in the personality parameter file. Alth ough the
equation for detecting a fault is proprietary, some of the important limits are shown below for informational purposes.
Rated Current Time Delay
200% 40 seconds
300% 10 seconds
425% 5 seconds
950% 1 second
TP-7141 11/22 153

Appendix D. Operating Hours and Service Log
Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were
performed. Enter hours to the nearest quarter hour.
Operating Hours Service Record
Total
Date Run Hours Run Hours Service Date Service
154 TP-7141 11/22

Operating Hours Service Record
Date Run Hours Run Total Hours Service Date Service
TP-7141 11/22 155

156 TP-7141 11/22
TP-7141 11/22 157
158 TP-7141 11/22
TP-7141 11/22c KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
Original Instructions (English) For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
© 2020 Kohler Co. All rights reserved. KOHLERPower.com

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Operation

Industrial Generator Set

Product Identification Information

Generator Set Identification Numbers

Model Designation _________________________________________________________

Specification Number _______________________________________________________

Serial Number: ____________________________________________________________

Accessory Number Accessory Description Accessory Number Accessory Description

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

WARNING Accidental starting.

WARNING Risk of fire.

WARNING Carbon monoxide.

WARNING Explosive fuel vapors.

CAUTION Hazardous noise.

Hazardous Voltage/Moving Parts

DANGER Hazardous voltage.

DANGER Hazardous voltage. Moving parts.

WARNING Hazardous voltage. Backfeed to the utility system.

WARNING Hot engine and exhaust system.

List of Related Materials

For professional advice and conscientious service, please China

1.2 Controller Specifications

1.3 Controller Features

Alarm Silence/Lamp Test button

Figure 2 APM603 Controller

• Large color touchscreen provides:

o System status and metering displays

o Data logging and trending

o Event display and fault reset

• Master control buttons with status LEDs

• Alarm horn and alarm silence button with LED

LED/Button LED Color Description

Figure 3 Annunciator LEDs

• Paralleling (if enabled)

• Active Events (Bell icon)

Figure 4 shows the important parts of the touchscreen.

Date and time

USB flash drive connected.

Touch arrows to scroll up

Figure 4 Screen Features and Functions

Access Level Password Required Description

Figure 5 Access Levels

Figure 6 Access Level Indication

Outputs Tier 2 Outputs Tier 4 Output Type

3.1 Prestart checklist

DANGER Hazardous voltage. Moving parts.

The controller allows operation of the generator set as detailed below.

3.2.1 Starting and Stopping Functions

3.2.2 Start Signal

• Communications-based start command from SiteTech™ or a Modbus-based remote panel.

3.2.3 Stop Signal

A stop signal can include any of the following:

• Communications-based stop command from SiteTech™ or a Modbus-based remote panel.

3.2.4.1 DEF Injector Cooldown (Tier 4)

Procedure to Reset the Generator Set after Emergency Stop

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

2. Reset the emergency stop switch.

3.2.5.1 Emergency Stop (Tier 4)