Kohler 2000ROZD Generator Set

⚠ Verify that engine compression and the ignition system meet specifications before adjusting the carburetor.

⚠ Some engines have sealed carburetors that are not adjustable.

1. Start the generator set and run it at approximately half load.
2. Adjust the engine fuel mixture screw until the engine runs smoothly.
3. Apply varying loads and readjust the carburetor as necessary to achieve smooth engine performance at all load levels.
4. Stop the generator set.

⚠ Not all fuel regulators require spring and retainer removal for fuel conversion. A hang tag on the fuel regulator identifies the conversion procedure.

1. Remove the fuel regulator cover plug.
2. Remove the adjustment screw and spring from the fuel regulator. Save them for conversion back to natural gas.
3. Reinstall the cover plug.

⚠ Lower-than-specified pressures may result in poor response to load changes or lack of power.

Tools: Manometer

1. Remove the fuel regulator cover plug.
2. Replace the spring and adjustment screw.
3. Connect a manometer to check fuel supply pressure on the carburetor side of the regulator, downstream of accessories.
4. With the generator set running at full load, rotate the adjustment screw until manometer pressure matches the specified pressure.
5. Reinstall the cover plug.

⚠ Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

1. With the generator set idle, open the output line circuit breaker to disconnect the load.
2. Remove the controller cover.
3. Install the J1 jumper if the set is connected for 139/240 V (low wye) or 277/480 V (high wye) 3-phase, 4-wire, 60 Hz. Remove it for all other voltages.
4. Replace the cover.

⚠ Do not use the safeguard circuit breaker in place of the line circuit breaker.

⚠ Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Tools: Digital AC voltmeter, Insulated-handle screwdriver, RTV sealant

1. Disconnect the engine starting battery, negative (--) lead first. Disconnect power to the battery charger.
2. With the generator set idle, open the output line circuit breaker to disconnect the load.
3. Remove the controller cover.
4. Wrap the shaft of an insulated-handle screwdriver with electrical tape. Turn potentiometer R41 or R42 fully clockwise.
5. Connect a digital AC voltmeter to terminals V0 and V7 on the controller terminal block.
6. Reconnect the battery, negative (--) lead last.
7. Start the generator set by placing the master switch in the RUN position.
8. Adjust output voltage to 115% of nominal (approximately 160 V across V0 and V7 for low wye/high wye; approximately 140 V for all other voltages).
9. Slowly rotate R41 or R42 counterclockwise until red LED4 lights. The set should shut down on overvoltage in approximately 2 seconds.
10. Turn the voltage adjustment potentiometer counterclockwise to reduce output voltage, restart, and slowly increase voltage to verify the shutdown setting.
11. Reduce output voltage, restart, and readjust the generator set output to nominal voltage.
12. Stop the generator set. Seal potentiometer R41 with RTV sealant or equivalent. Replace the controller cover.

⚠ Read the entire procedure before beginning.

1. Set the generator set master switch to the OFF/RESET position.
2. Set the reactive droop rheostat at minimum (full counterclockwise position).
3. Move the voltage-sensing lead inside the controller from terminal V7 to terminal V9.
4. Start the generator set and adjust the voltage to the rated system voltage using the voltage-adjusting potentiometer.
5. Apply a resistive load (1.0 power factor) at rated current and adjust the reactive droop rheostat to achieve a 6%--8% droop in voltage.
6. Remove the load from the generator set.
7. Shut down the generator set by placing the master switch in the OFF/RESET position.
8. Move the voltage-sensing lead inside the controller from terminal V9 to terminal V7. Repeat for additional generator sets.

⚠ Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the selected line voltage.

⚠ Affix a notice to the generator set after reconnecting to a voltage different from the nameplate voltage.

Tools: Voltmeter, Screwdriver

1. Place the generator set master switch in the OFF/RESET position.
2. Disconnect the engine starting battery, negative (--) lead first. Disconnect power to the battery charger.
3. Use the reconnection schematics to determine the voltage configuration. Route leads through current transformers and connect per the diagram.
4. If the controller has meters, reposition the meter scale lamp jumper to match the desired voltage.
5. Recalibrate the overvoltage shutdown if reconnecting to or from 139/240 V (low wye) or 277/480 V (high wye) 3-phase 4-wire 60 Hz.
6. Set the phase selector switch to L1-L2 or connect a voltmeter across leads L1 and L2.
7. Reconnect the starting battery, negative (--) lead last. Start the generator set and verify the voltage changed to the desired value; adjust if needed.
8. Stop the generator set after completing the voltage adjustment. Replace the controller cover.

⚠ Correct any fuel leaks encountered during the priming procedure.

⚠ Trapped air in the fuel system causes difficult starting and/or erratic engine operation.

Tools: Hand prime pump kit

1. Place the fuel valves in the fuel system prime position. Close the fuel valve between the pipe tee and the engine.
2. Open the fuel valves on each side of the fuel prime pump.
3. Loosen the bleed screw at the engine. Refer to the engine operation manual for bleed screw location.
4. Rotate the hand prime pump handle counterclockwise until fuel flows from the bleed screw. Stop pumping.
5. Tighten the bleed screw. Wipe up any fuel leakage.
6. Place the fuel valves in the normal operation position: open the engine-side valve, close the prime pump valves.

⚠ Dispose of all waste materials (oil, fuel, coolant, filters, and gaskets) in an environmentally safe manner.

1. Deenergize the block heater, if equipped.
2. Remove the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow.
3. Open the radiator and/or engine block coolant drain valve(s) and allow the system to drain.
4. If the radiator has mineral deposits or the coolant contains dirt or grease, flush and clean the system.

⚠ Do not add coolant to a hot engine.

⚠ Do not use alcohol or methanol antifreeze or mix them with the specified coolant.

⚠ Check the coolant level in the recovery tank after each operation until the level stabilizes.

1. Remove the pressure cap.
2. Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose clamps.
3. Open the air-bleed petcocks, if equipped. Close them when coolant begins to flow.
4. Add coolant additives or water pump lubricants per the engine manufacturer's recommendations.
5. Fill the cooling system with the recommended 50% ethylene glycol and 50% clean, softened water mixture.
6. Replace the pressure cap.
7. Fill the coolant recovery tank to the low mark.
8. Operate the generator set until the thermostat opens when the upper cooling system hose warms.
9. Stop the engine and allow it to cool.
10. Remove the pressure cap.
11. Add coolant to bring the level to just below the overflow tube opening of the filler neck.
12. Replace the pressure cap.
13. Maintain the coolant level in the coolant recovery tank between the high and low marks.
14. Reenergize the block heater, if equipped.

⚠ The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage caused by overlubrication.

Tools: Grease gun, Poly V-belt tension gauge

1. Place the generator set master switch in the OFF/RESET position.
2. Disconnect the engine starting battery(ies), negative (--) lead first, and disconnect power to the battery charger.
3. Remove the belt guards to expose the fan shaft and idler shaft bearings.
4. Inject grease into the two fan shaft bearings and the two idler shaft bearings until a 3--6 mm (0.13--0.25 in.) grease column shows at each pressure relief port.
5. Remove excess grease from the bearing pressure relief ports.
6. Inspect the fan drive belt and replace if damaged or worn. Check belt tension with a poly V-belt tension gauge and adjust if necessary.
7. Reinstall the belt guards using the original hardware.
8. Reconnect the starting battery(ies), negative (--) lead last.
9. Test run the generator set for a few minutes and listen for belt noise (squeal) indicating a slipping belt. Stop the generator set.

⚠ If the alarm switch is in the SILENCE position the alarm horn will not sound should a fuel leak occur.

1. Move the alarm switch to the SILENCE position to stop the alarm horn. The lamp remains lit.
2. Disconnect the generator set from the load with the line circuit breaker or automatic transfer switch.
3. Repair or replace the inner fuel tank.
4. Move the generator master switch to the OFF/RESET position and then to RUN for startup. Alarm horn sounds and lamp goes out.
5. Reconnect the generator to the load via the line circuit breaker or automatic transfer switch.
6. Move the master switch to AUTO for remote startup and move the alarm switch to the NORMAL position.