Kohler 12RESM1 User's Manual
Contents
1. Thermostat Heater Bulkhead opening for carburetor heater access Carburetor heater cord with thermostat 120 VAC receptacles for carburetor heater and battery charger Figure 1 24 Carburetor Heater 17 18 kW 1 Carburetor heater location Figure 1 25 Carburetor Heater Location 17 18 kW TP 6516 4 09 12 kW Carburetor Heater 17 18 kW Carburetor Heater 1 Thermostat 2 Connector 3 Heater Figure 1 26 Carburetor Heaters 1 11 Prestart Installation Check Review the entire installation section Inspect all wiring and connections to verify that the generator set is ready for operation Check all items in the following Prestart Checklist Prestart Checklist Air Cleaner Check that a clean air cleaner element is installed to prevent unfiltered air from entering the engine See the generator set Operation Manual for instructions 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 Exhaust System Check for exhaust leaks and blockages Check the muffler condition e Inspect the exhaust system components for cracks leaks and corrosion Check for tight exhaust system connections e Check for corroded or broken metal parts and replace them as2. 1782 lL V 7341 B Sheet 1 AD 17 18 kW Models IMENSIONS Figure 1 4 Generator Set Mounting Details and D TP 6516 4 09 Installation 16 Section 1 2 a IVEL NaV NOP anos ANIYd NOISN3WIG SER CATIA ARI E 30 SLHOIY TTY 09 BJIHON HLIM NOIL9INNOO a 7065 Im SNIISAS USNOJ x SEEE8 13349 335 T3AY89 zum OD Y THOM ann Bron SUNS hal NI 53191151902 YIHLO NO SANYHS SINV d ON 031410845 38 IIO ESTAN 13431 NOISIAZU 403 ON LUVd 335 SONG 311508802 NO 138 JHL OL 35012 001 9NIMOY9 WOBI SQ33M 9 SSYYO 1N3A38d OL 31907 3SV8 13AVH9 WOIHL HON u3luuvg 033M SINIVHISNOO NOIIVITVISNI YIHLO SHu3NMO OL 43438 13S 30 GNA 1SNVHX3 1334 8 1SV31l LY COLI 3uniiNHnd OllVd SINWId 3AILISN3S SINIVHISNOO NOIIVTIVISNI Y3HLO 804 TVANVW SY3NMO OL 43334 01 138 30 ONJ LSNYHXI 13S 40 QN3 LSNYHX3 WOUui 1334 01 1SV31 LV S3NVINI YVIINIS H3H1O ANY 3OvNunJ NOYA 1334 1SV31 lv 3 013 3unliNun4d IL SINVId 3AILISN3 C SE VE IAN 29 SOLI NANI EN AIN 85 038019 3UY STIVA LN3OVCQV NO SMOINIM 3UNLINULS WOY 138440 H3dOUd SVH 135 1002 YOLVHYINI9 U3dOud JUNSNI OL 1334 30 3ONVISIQ WNWINIW V 3Av31 OL 38
3. LOA 21 398VH9 one Aava Figure 2 2 Schematic Diagram 12 kW Models ADV 7351 TP 6516 4 09 30 Section 2 Wiring Diagrams i 1 7059 un EZ NB VE TTT ut 10 2 2 Say M ZI Suo ONISIM AVIDVIO PA ERES TEE 0 m A IMON ETON HUA NOLIANNCO NI 195003 0380 38 JON ISAN remos sovane CNY QO ETON Si ILI ONY NOSSO MI ALA SIL VEN PYOSS IM TIHON SNIISAS W3WOd Merny AJIHON E Y sono or wor x om xc o oc esee ISEL AAY 335 OlUVW3HOS 04 COD za GS GO goo E 1zd CAZZI fa se g 024 18 ZM z 1zd s 9 z ozd 19 9M 1 19 ZM EM 181 EM JA 1 024 IM SM 802 e d OL 6 1 bd NOI um g um 18 25 z 19 z SM ZM if SM IM If Nid NNOO Led NNOD OZd 1HM nB XXL NOI S9 AINO l a Noob noob E co 9 an9 z1 3 YIDYVHO AY3LIV8 3SVHd 319NIS SL8S AQV 33S SNOILO3NNOO MNOIVH3N39 HOJ 310N 000 S9 N vis Ni O o 8 6
4. 300 18 CRIVOdN SNOLJINNOD HAMOISNO 1 v G 8 eizig 300v 914 v 8 031V0dn SNOLDINNOO Old Y id 6 0 62464 anna man NOISA36 O vis ss SS Srl v 0 09 IL 083 N Z u Zd 8 1 ld Z3d r 181 v c 181 17 181 111189 1 115 I 21 181 2141760 avol ann Wins v us UA lVls 07 181 0 4 _ uos 808 di 9 91 Stl ON9 181 and Oe NOI UND SS dvi Wf Nid SNOILO3NNOO 91d AV 1331 YILYVIS s 11 vis 1 304 OL IVNOLLAO SNOILO3NNOO IY vid 908 7 94 983 ENO9D z eid NOL r id NZE Z 21 914 VZ3d if Nid 19 19 01 119 8 118 8 11 L ttd Wid ZL N LL OL OL NOI 6 Zid 8 ZN OL 9 11 S N z vid Nze S N 6 19 NOL SNOIIO3NNOO vid SNOIIO3NNOO Eid XO8 MJTIOHINOO 203 GN090 Za 983 983 91d 1 912 dvi as 519 21 1 EEN 81 19 V SNOTDINNOI 4012 L Z 91d N NOI GN Z 11d
5. 1015 11 34 Qvis v en TE 2 szisg aacav DEL ARI wawis 1 9 DT 8Ly8 031038809 NOUVINSRIO OVA ONV ASIA 181 7 1 22868 4 3 Calvan 119 eevee 91 SVM LI MOOIBTUL 2 3 FINSNI SYM IM FV OL 181219 300v Eid p 8 31 09 SNOUO3NNOO Old id 5 9 vNOILdO S1108 man SNOLLO3NNOO ale 908 vol 1 9ld dil S N S N v 0ld OD 0ld OD Z Old al 1 019 0 az Lit Nid SNOILOANNOD Id 01 19 81 19 IHM VA Nid SNOIIOJNNOO Sd 2 n 81 19 GIIVINSNINN 15 ay p B 9 19 038 ano 2919 N eu SN 9 9N N 61 119 EN Ud Ez Ld IN 3NION3 1 94 zm Mm ld NOL rela Nee 7 19 If Nid 1 14 Vidd ZL 9 11d 9N N LL S N 01 119 0 OL z vid NZE 6 NOI 6 S N Zid NOZ 0 19 ZN Z Ibba SNONO3NNO9 vid Nos SNOIIO3NNOO ld MN3TIOMINOO DOY 1 80 Homs Ga 3N
6. Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ib ft min ftp 9 gal gen genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W xD height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext I O IP ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrate
7. Installation Residential Commercial Generator Sets Models 12RESM1 12 17 18RESL 12 17 18RESNT 12 18RESHD Controller DC RET Digital Control NATIONALLY REGISTERED KOHLER POV VER SISIEMS meri California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Generator Set Identification Numbers Engine Identification Record the product identification numbers from the Record the product identification information from the generator set nameplate s engine nameplate Model Designation Manufacturer Specification Number Model Designation Serial Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Table of Contents Product Identification Information enhn hn 2 Safety Precautions and Instructions rr rar rr rr KAR RKA RR KKR RK RR RK RR KRA 5 Introduction E ALIA a oh a Re Rm eA 9 Service Assistance u u a sne ua a aa 11 Section 1 Installation u rer 13 dele xGeneralJ alten ee erh 13 ATA a rar td ect oe et 13 1 3 Generator Set Inspection rer rss rr rr
8. analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6516
9. equipment contact adverse weather conditions and environmental damage TP 6516 4 09 10096 7596 50 25 LP Vapor m hr cfh 100 75 50 25 LP vapor conversion factors 8 58 3 1 Ib 0 535 m 1 kg 36 39 ft 3 1 gal Nominal fuel rating Natural gas LP vapor 37 MJ m 1000 Btu ft 3 93 MJ m 2500 Btu ft 3 Figure 1 12 Fuel Consumption 17 18 kW Models Section 1 Installation 19 1 6 2 Fuel Pipe Size Ensure that the natural gas pipe size and length meet the specifications in Figure 1 13 or Figure 1 14 Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet Add 2 4 m 8 ft to the measured length for each 90 degree elbow Compare the total pipe length with the chart in Figure 1 13 or Figure 1 14 to find the required pipe size Contact the local LP provider for LP installation information Maximum Pipe Length m ft 9 2 30 30 0 100 68 6 225 Pipe Size in NPT Figure 1 13 12 kW Models Fuel Pipe Size Natural Gas Minimum Gas Pipe Size Recommendation in NPT Pipe Length Natural Gas LP Vapor m ft 242 000 Btu hr 280 000 Btu hr 8 25 15 50 30 100 46 150 61 200 Figure 1 14 17 18 kW Models Fuel Pipe Size Natural Gas 20 Section 1 Installation 1 7 Fuel Conversion The multi fuel system allows conversion from natural gas to LP vapor o
10. 4 09 cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept DFMEA dia DI EO DIN DIP DPDT DPST DS DVR E emer ECM EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ES ESD cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department Design Failure Mode and Effects Analysis diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor
11. Dimensions 12 kW Models ADV 7466 Sheet 1 14 Section 1 Installation TP 6516 4 09 9 aan INIHd NOISN3WIG SE QD mr SINIVYLSNOD NOIIVITVISNI Y3H1O iia 084 1333 8 1SV31 LY V 3UNLINUNI ON L vd 335 SOMO 3115000 VITVISNI HIHIO IVANVA SHINMO Ol 43334 15 Installation Section 1 IBNLINUNI 13S 30 QN3 OllYd SINVId JA SNENOS 83H 09 uvd 314034 031238 Yo I TEVLAIZIOV S ONIN and 38NnLIN4YLS 03141220 onuls 03141 1N3A3UA ud WARKI TJ S LEN NOUS 3NNO23H FHL 310N 13S 30 UVIIWIS YIHLO N3ovrav 9440 u3dOHd SVH 135 yooq 31V9349 O3NIV A13131dNO2 EEE ERE 3unionuis Figure 1 3 Generator Set Clearances 12 kW Models ADV 7466 Sheet 2 TP 6516 4 09 IVEL AaV NiHd NOISN3WIG 40 sion 09 831803 sn d3AN3S3H JUN NOIINJANI HO N91530 NYOM 09 HI HOW HLIM NOI1238N02 1da9x3 d39n 38 LON 1 ONY 1834084 81 11130 ONV NOIS30 NI ONIMYWO SIHL YFOES IM UITHON SNALSAS YIMOd ua OD WAT IHOM ET 90L 8 031Y20138 131N 1V21812313 1 9 oe grow sun tix Tax SECE8 ISVO Y 34008
12. MAN 1031438 Ol GISIAIY SNOISN3NIQ 8 SM3lA Had 1108 ONIMYYO MIN A8 13431 NOISIAZU 404 ON LUVd 335 SOMO 311508902 NO 1I V130 MOHS OL Q3AON3H TANVd NI MAIA LNOYS 6 pel 289 QA3ANI9N LON 030015N1 5371972 ABILLVE CQ3Qn 10NI Y398VHO AUd3llVd O 201 71991919313 031539915 L31VN34 LdN 2 1 91 9115 1315 NOI1V201 QNnOS9 103091003 u3yv3ug8 LINDYID QAYOT C OLNV 13S38 440 NNU HOLIMS HU31SVW 137NI SIN31VA1003 NOI1V201 HONI NI SNOISNINIQ SALON TIWLIG MOHS OL Q3AON3H 13NYd UVIU Y Y000 M3IA 3015 uOOQ 3914435 2 Lv 6611 JAVA NIVUO 110 YIILSdIQ 110 YILTIA HIV dvd 1114 110 I LY 9611 3018 8000 3914835 S370H 9N11411 09 11 1 8 XY 131100 0 92 099 LSNYHX3 uolsiuuv MUVdS HLIM 3919 LSNVHX3 1S0 YHX3 SE 06 IE 08 9
13. NI 301 ONINIVN3H NO 13AY49 NI 9 QN3 ISNVHXS IV 038 TIAVYO 14 v SINVId 3AILISN3S 38NLINYNS NAVI Ol 3ONVISIQ 3000 BEN 7213 NO 13AVUO 13AVHO 13 v Y00d 321AU39 li 8 30N3WN0233 SINVId 3AILISN3S 11 q 3uniiNund NAVT OL 3ONVISIQ T SINVId JAILISNIS JYNLINYNA NMYT Ol 3ONVISIQ Q30N3WN0238 313 ES eom za S lt mo gt lt zm pal gt Clo rm gt gt mp xA gt Tim gt TE gt ale ln ma om ma oo GLF 4000 3911835 53015 ONINIVNI 4000 391 xis 3unionuls IUNLONBLS 041401220 03140220 3uniomnsls 03141220 3UNLINULS 431941220 17 Installation Section 1 Figure 1 5 Generator Set Clearances 17 18 kW Models ADV 7341 B Sheet 2 TP 6516 4 09 1 4 1 Exhaust Requirements A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 ifinhaled for even a shorttime Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator setinside a b
14. needed e Check that the exhaust outlet is unobstructed TP 6516 4 09 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 1 12 Startup Notification Complete the startup and installation checklists supplied with the startup notification form Complete and sign the startup notification form and return copies to Kohler Co and the distributor dealer as instructed on the form Standby systems not registered within 60 days of startup are automatically registered using the manufacturer s ship date as the startup date Section 1 Installation 27 Notes 28 Section 1 Installation TP 6516 4 09 Figure 2 1 lists the wiring diagram drawing numbers and drawing references Wiring Diagram Description Schematic Diagram 12 kW Models Drawing Number ADV 7351 Section 2 Wiring Diagrams Reference Figure 2 2 Point to Point Wiring Diagram 12 kW Models GM52471 Figure 2 3 Schematic Diagram 17 18 kW Models ADV 7353 Figure 2 4 Point to Point Wiring Diagram 17 18 kW Models Figure 2 1 Wiring Diagrams and Schematics TP 6516 4 09 GM52541 Figure 2 5 Section 2 Wiring Diagrams 29 LSELTAOV mwa SII MN ZL OLLV JHOS AV
15. the controller junction box Refer to the generator set Operation Manual for battery charger operation information Section 1 Installation 23 1 9 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled batte
16. the risk of electrocution 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 Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Short circuits Hazardous voltage current can 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 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 utility electrical system can cause severe injury or death to utility personnel
17. when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seeki
18. 1 YLVIS NS 831411939 O3TIOMINOO NOOHIS HIS QuvOB 3OV3NH3INI AVTIY GI 103NNOO MIND N090 YOLOINNOO d do old OLLINIVA dN HOLIMS 3UNSS3YA MOT dO1 ANIS 07 N3TIOMINOO 01 SOLO3NNOO Fr 7OMINOO NOILINOI NOI ONnOH9 XOB H3TIOMINOO ON9 3NWA TANA Ad asn4 4 ANNOYS ANIONS 4583 Y30N3S 3UNIVYIANIL INVIOOD S19 SONVAGY MUYdS WLO IVSA 30010 403 yaad ninos 80 QON3931 YS NIS Na 8 64 Na 29 308 9 NIS dd 6d I 64 18 19 495 9 399 980 N AVTIY 31s voc UL 4 68 vis 99 9 64 134 SS zd SS Id voL ss Id An Gz id 14d 7 X zd 24 Pens Zid ASS ET 14 SS3NNVH ANIONS OL vis ss SS sei 0 9 au r i81 181 17 181 11 91182 H i as 1 1180 21 1280 avol INN 9 15 v T ENS z IE 1viS 01 181 07 I 6 9Ld 5 189 1 ZOV Y0S 99 808 amp and aN9 181 and NOL GM N 7 SS avi 1 Nid SNOIIO3NNOO 91d AVT3H YILUvIS
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20. N3L INVIOOO 41 19 n amp YOLVIS LVLS HOIH YOSNIS dN3L INVIOOO 81 19 1HM GION3IOS NH3lNVIS SS AWIY YILUVIS ys 1 01 8Z YONYIAO9 ANNOYS 4 19 IS YOLOW N3lNVIS WS HOIH HOSNIS YA S Ld M 038 831411939 Q3TIOMLNOO NOONMIS NOS F_Old VE MONYIA09 MOT YOSNIS 9 14 4 18 Q3vO8 3OVJM3lNI AVT3H 8l3 193NNOO MOIMD N090 ama f d HOLIMS 3YNSS3YA JO SdO NADIA OLLINOVN dW NL T 3TIOHL O ENOID nr S Z Old 81 NONN3AOD Z dOlS INNIS 310W34 6 Idle TOBLNOO NOILINDI NOI 0ld YL MONN3A09 1 9015 19 15 310W3N 8 Ld y T ANNOYS H3JTIOHLNOO AND NOOD 3NTVA 1303 Ad 3sn4 4 NOILINOI 3ONVAGV AYVAS IVLIDIO IVSQ amp 30N3S JSNLVHIANAL LNVI009 SLI 30010 fos M3xv3N8 Linozio 80 8 64 100 AVIIY HSVli GN3531 9 64 SMA IAYO OM SONIM 39VLIOA NAY LLL Nnu 9 6d 1ndNI ONIONIM XAY ovon oy VER 21714 pe iymo L 6d 9NIONIM xnv ONISNIS HSV14 OL Ld ke nny HOLIMS 3YNSSIUA WO 2 1d 6 11d ONNOSI NOILINOI Ol LLd TINI HOLIMS 9 19 INBA INVIGNIN Iysa 193NNOO LON OQ svo dl LUVHO 335 1 19 N OL S9 193NNOO SVO IV
21. NOVIQ su DS SAY NOUNSANI WO DEN 20 SIDE TY OR 00 NIHON HA NOLDINNOD NI 1003 036038104 ISAN OY 09 UTHON SL INLO ONY 0650 NI CONGO SIL WEN FOES UA SN3ISAS AMOS 09 US HO YOLON N3ddils WIS YOLVIS 191 GION310S N3lNVIS SS YOLON Y3lWVIS WS 831411939 Q3T1081NOO NOOTIIS NOS QuVOB 30VIY3LNI EIN 103NNOO N090 amd HOLIMS 35055359 TIO MOT GALS 07 X08 N3TIONINOO O1 AVI3H SH TOBINOO NOLLINOI NOI ANNOYS XOB N3TIONINOO AND SMA 1304 AS asn4 4 YANIS 3YUNIVYIANIL LNVIOOD S19 NOILINOI SONVAGY MYVdS IVLIDIO IVSA ONNOGI 52018 3NION3 30010 d a saves Linozio 89 43070H Hsnag 3SVHd FIONIS SL8S AQV 33S SNOLLO3NNO9 YOLVYVINIO 310N Av130 03S 0 033dS33AO AvI30 935 S 1 6d 3SN3S OV 93S 01 0334 YIONN YIAO 2 64 asNas oy AVIS 935 OL NMOQINHS 36v HONOR 1O3NNO9 LON OG sva dl N OL S9 193NNOO SVO IVUNIVN OyLH9 IdAL 1303 INDI AVI30 235 Z NMOGInHS J9vLTOAN3AO O38 3OVLIOA OV 193NNOOSIO ANVIO QNnONO 91 14 ea non YOSN3S INVIOOO 1 14 HOIH YOSNIS dW3l INVIOOO 81 14 NMOGLNHS 03AW130 8 64 1 Avi3H HSW1
22. NS IVIYILVH 37181 1SN8NO9 NON YVIN SNOILYTIVISNI YOY iviu3lvW 3181 LSNENOI V WOu3 1334 S 1831 39 GINOHS dONVISIO SIHL S31VIS SINIBBNL SVO ANY S3NI9N3 NOILSNGNOD AYVNOILVLS JO 3SN NOILVTIVLSNI JHL SQUVONVIS LE VddN S3002 17201 31VLS NO I1N3QON3d3Q SI 3UNLINYLS V WOYJ 3ONVISIO Q3QN3AWOO3H 3Hl 310N v3uv 13AVvU9 NI G3MO11V S318I1Sn8 OO U3HlO YO SANYHS SINVId ON LAS 3H1 30 ONG LSNYHX3 JHL 1333 S 1SV31 LV SI ONINIdO OOO ON VET Goran 3UNLINULS Hv1IWIS HO HOOQ LINFA MOONIM LSIUVIN JHL 1N3A38d Ol 031 201 38V8 13AVJO MDIHL ANY u3lUsuvd 033M 9 31V93H9NOO 3714034 JYSHM SVIUV 13S 40 QN3 1S VHX3 Y3HLO YO SOllVd sv3uv AVId LV 03193910 LON SI LSNYHX3 1333 01 18V37 LV S3NVINI HVIINIS H3HlO ANY 39VNUNI NI FUNLONYLS JHL AVMV O3WIV A13131dNOO S LSNYHXI CIHHISIHA 038019 Juv STIVM LN3IVYFAV NO 55000 Y SMOONIM 3UNLINULS HOYA 135330 YIdOYd SVH 135 138 3HL 30 QN3 I1SnVHX3 JHL WOYW3 1334 S 1SV31 LV SI 9NIN3dO 3UNLINYLS YVTINIS YO NOOQ INIA MOGNIM 1S3NV3N JHL 31V9349N09 31d03d JYSHM SVIYV YFHLO YO SOILYd Sv3uv LV 03124810 LON SI ISNVHX3 Z 38N19NY1S OL 1311vuvd YO AVMV Q3WNIV SI ISNVHX3 I 1 9 1913 SINVId 3AILISN3S 3unliNund NAVI OL 3ONVISIQ Q3Q0N3WWO23 li 8 NI QN3 ISNYHX3 IV 038 13AVHO 13 v 53015 ONINIVN3U NO 13AVU9 9 11 8 AGNAWNODAY
23. ONE SHL YS Pose UA UTIHON USNALSAS WAMOd 09 AJIHON G A0V 335 OLIVA3HOS 2 84 001 02222 Ad 807 LM IL v z id IM doz Z 6 4 1 Nid SNOILO3NNOO 01 118 OZ a em 9 9 LN 8 ano IND GNoo0 000 E 289 71 34 3SVHd FIONIS SZ8S AGgV 3335 SNOILO3NNOO MOIVH3N39 HOJ LON SNOOD 289 E H3JONVHO AYILLVO ONODO LL BE Isa T izd zi EE ce 181 9 ozd ig SEH z izd 29 29 181 9 ALZA z 0zd 19 9M 1 124 N EA em 1 024 IM sm 8d co passa EM SN 335 NOLLINOI um za um 193NNOO LON OG SVI dl zo 7 19 z N Ol S9 193NNOO SV9 IVINLVN SM ZM 1f Nid SM IM Wf Nid 086H9 1303 SNOIO3NNOO 164 SNOILOJNNOO OZd ONINIL_NOLLINO IVNOILAO A 100 39 VS9 GISN AINO 3AWA 1303 QNOO3S XO8 NOLONNAF KINO SVI IWN YO4VA d1 Ad ino NI IM 802 EM rN YOLON N3ddils NIS SOlVIS LVIS QION310S BILUVIS SS
24. Requirements m min cfm Cooling Air 26 9 950 Combustion Air 1 1 39 2 Total Inlet Air 28 0 990 22 4 790 0 9 32 6 23 4 826 28 0 989 1 62 57 3 29 6 1045 22 6 798 1 42 50 1 24 0 848 Figure 1 8 Air Requirements 1 5 Power Supply Power must be supplied from a source that is GFCI protected to the generator set location for the battery charger and the optional carburetor heater See Section 1 8 Connect power from a circuit on the essential loads panel to the 120 VAC receptacles Figure 1 9 lists the power requirements for the battery charger and accessories Power Requirement Max Watts Volts Equipment Amps Battery charger Carburetor heater 12 kW 17 18 kW Battery heater Figure 1 9 Power Requirements TP 6516 4 09 1 6 Fuel Requirements The generator set operates using natural gas or LP vapor fuel The generator set is EPA certified for both natural gas and LP vapor fuels The fuel system installation must comply with the NEC and local codes 1 6 1 Because of variable climates and geographical considerations contact the local fuel supplier for fuel system planning and installation Figure 1 10 lists the recommended fuel ratings and other fuel supply information for natural gas and LP vapor fuels Fuel Supply Fuel types Natural Gas LP Vapor 1 2 NPT Fuel supply inlet Fuel supply p
25. UNLYN ONINIL NOLLINOI 086H9 3dAL 1313 ONINIL NOLLINOI IVEA vZ ld ONNOYO 14 Sd sN I1 1d OS 04 0 1 8 ld 6 Sld NI 96 1d SSINYVH 3NION3 8 91 234 8 ld LSI LEd 9 Sld N gt 9 f ld UA _1 1d IOYLNO9 TINI ld M NOL gt Z ld NOWWOO Z ld NzE 9 1d VEN L bld M VZJ4 9 Z1 1d ele IVNOLLAO cerea 5 6d 908 9 8 szise azaay 540 vsa 1 9 84r8 031938309 NOLVINGRO QY31 Man IEL 8 0 22928 d300v SNOu23NNOO 20SSV ONY Lau eevee 91 LI L V IINSNI SYM IM 9 0 181218 axoav SNOLLIINNOO 919 G3LYOdN SNOLIINNOD Old le AMBLLVB 51108 onmvao man o 6 0 1 B3 W3 63 77 6516 4 09 Figure 2 4 Schematic Diagram Single Phase 17 18 kW Models ADV 7353 32 Section 2 Wiring Diagrams 17502909 pa OMO 199350 won ml ET ONIMIM Avuovia sini TRESS y NODI 20 0530 0 SIFON TV Son EIN LA MOLTNN09 N 02053 SO 38 LON ISAN ONY AD04084 UNIRON SUIZO ONY 030 NI
26. VHBN3N em Nid 91d S N N 0L Nol Zdd ZN 9N S N 9 N S N S N IL 11 19 zi 1d 1V8A 01 1d OLMW wa 898 Lov os zov uos 49S 29 405 9N000 L 6 135387130 Hd em IN x I S N Nd O N pap 9 N UM V Sd 1HM aL i 8 94 LI na SLI GBLVINSNINN ZS 94 S N GL Im S N vl vr 1 Nid o amp SNOIIO3NNOO TTd SNOIIO3NNOO 6d 7 99 wc v 2 99 vi 2 99 a 2 LA Nid SNOILO3NNOO Old HOLIMS Ivan 1 94 amp HOLIMS HOLIMS insni ANSNI AN CILVINSNINN 1NO20 8d SNOILO3NNOO Id IS 9 N S N i 9 N 9 L 8 Figure 2 5 Point to Point Wiring Diagram Single Phase 17 18 kW Models GM52541 33 Section 2 Wiring Diagrams TP 6516 4 09 Notes 34 Section 2 Wiring Diagrams TP 6516 4 09 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC AD ADC adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP htr bps br BTDC Btu Btu min C cal CAN CARB CB cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current
27. ZN 7N l 1 Lg EN 9 14 9N 87 14 IN S N N 04 Nol 25 ZN 9N S N S N S N S N IL 11 14 NN 21 19 1v8 01 1d oL Ni nl LE a 1597210 m or 6 Lov wos 980 ZOV 805 A OO N 29 805 E I sNoo vv 8 L 9 Ei y 4 1 Nid 3 va 983 ez HOLIMS HOLIMS Ivan NOY zz HOLIMS OLNW r4 LINSNI ZINSNI E A gl 8 LI S10 GIIVINSNINN a s i v L Nid t et SNOIIO3NNOO Lid SNOILO3NNOO 6d SNOIIO3NNOO u S N S N S N S N J N S N 9 8 Figure 2 3 Point to Point Wiring Diagram 12 kW Models GM52471 31 Section 2 Wiring Diagrams TP 6516 4 09 ESEL AAV 20 22 mel MOELAN won 777 10 1 2 SII MY LI ud 3SVHd 310NIS S 89 A0Y SIIVWN3HOS NYY9VIa UE mE 13345 SNOLLO3NNOO PEIUS et ey Ta YOLVYINZI 303 310N A ET 033dSu3A0 VEN KOSG UM WTIHON 31545 WMO 2 13 so r 1 64 3SN3S Ov LISIHNI 235 OL 0244 YIONN Y3AO ATIHOA ECC M 2 03 ov 93S OL NMOGINHS 39WLIOAWZONN AY13Q O3S Z NMOGInHS 39VLIOAHINO 938 39VLIOA IV ROM LIINNOOSIO HNWYO GNNOYXS 30018 INIONI FP TTM DINOS FM QNnoNO 91 144 zs YOLOW 4399215 n NMOGLAHS a non MOSN3S d
28. adedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately andremain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble TP 6516 4 09 Hazardous Noise A 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
29. attery Location Air Intake End TP 6516 4 09 Battery Installation Procedure 1 Ensure that the starting battery is fully charged before placing the battery in service Clean the battery posts and or adapters if necessary Install the battery post adapters if needed Place the battery in the housing Verify thatthe controller master switch is in the OFF position Connect the positive lead to the engine starting battery Connectthe negative lead to the engine starting battery Refer to the generator set Operation Manual and the battery manufacturers instructions for battery maintenance instructions Section 1 Installation 25 1 10 Carburetor Heater optional Have accessories installed by an authorized distributor dealer or a licensed electrician Follow the installation instructions provided with each kit Use separate conduit for AC and DC leads to reduce the possibility of electrical interference Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas Verify that the electrical installation complies with the National Electrical Code NEC and all applicable local codes See Section 2 Wiring Diagrams for more information regarding generator set electrical connections An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 C 32 F The carbu
30. ckets Install the generator set outdoors Provide the minimum clearance around the generator set shown in Figure 1 3 or Figure 1 5 Locate the generator set so that the hot exhaust does not blow on plants or other combustible materials Do not install the generator set where exhaust gas could accumulate and seep inside or be drawn into a potentially occupied building The generator set is shipped on a plastic mounting pad Prepare a flat level mounting area covered with a weed barrier and gravel as shown in Figure 1 5 Set the plastic mounting pad directly on the gravel Do not install the mounting pad directly on grass Section 1 Installation 13 DIMENSION PRINT ADV 7466 VIEW_A A TONA ER KER CONNEC UIT BREA EQUIPMENT GROUND ELECTRICA TO CIR AMAT bs Note Fuel system may differ from drawing See Section 1 7 400 L SIDE 82 Kg E DOOR ERVIC O BATTERY S TW G WE N ana 39UvHOSIA A CH EQUIVALENTS N ARE INE I S NOTE DIMENSION NOT Figure 1 2 Generator Set Mounting Details and
31. d Nd 20 405 5 LUVHI NOLLINOI OvLHO Laon 983 SN 335 JO3NNO9 LON 00 SVI dl N OL S9 JOJNNO9 SV9 IVINIVN OyLH9 1303 NOLLINSI IVNOLLAO Ad Ino NI dnOWw9 39 vso HLM 03SN AINO JAVA 1303 QNOO3S NOLLONNF A AINO SVI 1VN 3OdVA d1 cNo00 80L 19 vis di v 6d a34 6d gt lt YOS 9 ASG o 9 AVTIY Yalevis NO vis 99 6d 134 voz e 6d 930 ld me B 2 10 ldd vor DEI 14 983 N NOlVIS LVIS 5 Y3lWVIS SS HOLOW N3lNVlS WS 31411039 CITTOMINOO NOOMIS HIS QNvOB 30VIYILNI AVTIY GI 193NNOO MOMO N090 YOLOANNOOD d HOLIMS 38NSSIYH 10 MOT dO GALS O1 N3TIOMINOO 01 1 Fr 7OMINOO NOI ONnONO XO8 N3TIOMINOO QNO 3AWA 1303 A 3505 3 9078 INIONI 593 YIONIS 3M lVM3dW3l INVIOOO 519 3ONVAQv MUYdS IVIIDIO IVSA 30010 a M3wv3sg NONIO 89 ON3911 SS3NHVH 3NION3 OL cua sz198 DAL Aviad sanis 1 0 cszs8 03007 124
32. d circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 35 k K kA KB KBus kg kg cm kgm kg m kHz kJ km kOhm kQ kPa kph kV kVA kVAR kW kWh kWm kWth L LAN LxWxH Ib Ibm ft3 LCB LCD Id shd LED Lph Lpm LOP LP LPG LS Lwa LWL LWT m M m3 m hr m min mA man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilo 1000 kelvin kiloampere kilobyte 210 bytes Kohler communication protocol kilogram kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display load shed light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature m
33. diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay rms rnd ROM rot rpm RS RTU RTV SAE scfm SCR s sec SI SI EO sil SNMP SPDT SPST spec specs sq sq cm Sq in SS std stl tach root mean square round read only memory rotate rotating revolutions per minute right side remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number simple network management protocol single pole
34. double throw single pole single throw specification specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6516 4 09 TP 6516 4 09 Notes 37 38 Notes TP 6516 4 09 TP 6516 4 09d O 2007 2008 2009 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
35. e OFF position 11 Reconnect the generator set engine starting battery leads negative lead last 12 Reconnect power to the battery charger 13 Startthe generator set by moving the generator set master switch to the RUN position 14 Check for leaks using a gas leak detector 15 Move the generator set master switch to the OFF RESET position to shut down the generator set To convert from LP vapor to natural gas remove the fuel orifice and connect the DSAl leads together 1 8 Electrical Connections A 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 Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electricalleads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a tra
36. ecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Connecting the battery and the battery charger Hazardous voltage can 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 Use a 12 volt battery with a minimum rating of 525 cold cranking amps at 0 F The generator set uses a negative ground with a 12 volt engine electrical system See Figure 1 21 for battery connections Make sure that the battery is correctly connected and the terminals are tight y fp Go a say Ep Pd EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 1 21 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection TP 6516 4 09 Note The generator set will not start and circuit board damage may occur if the battery is connected in reverse Figure 1 22 shows the location of the engine starting battery Standard battery cables provide easy connection to the battery Use the following procedure to install and connect the battery ADV 7341A B 1 Engine starting battery location Figure 1 22 B
37. eter milli 1 1000 mega 108 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm m milliohm MOhm MQmegohm MOV MPa mpg mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean time between failure 36 Appendix MTBO mtg MTU MW mW ur N norm NA nat gas NBS NC NEC NEMA NFPA OZ p PP PC PCB pF PF ph D PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC at aty R rad RAM RDO ref rem Res Coml RFI RH RHM rly mean time between overhauls mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside
38. fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 exhaustfumes when working on or near the generator set Never operate the generator set inside a building Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows air intake vents or other openings Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light he
39. ion Fuel system detail Controller user interface Gas regulator assembly Generator set master switch RUN OFF RESET AUTO Fuel solenoid valve Load circuit breaker Fuel inlet Field connection terminal block location Air intake Spark plug locations both sides Engine starting battery location Oil drain hose battery purchased separately Oil drain valve O Q gt GQ N Figure1 Generator Set Component Locations 12 kW Models TP 6516 4 09 9 il N Ono tO Control detail top view Muffler Oil check Oil fill Air cleaner Spark plug locations both sides Oil filter Oil cooler location DC RET Digital Control display Generator set master switch RUN OFF RESET AUTO Line circuit breaker Fuses RS 232 connector for application program updates Engine starting battery location battery purchased separately See control detail ADV 7341A B Oil drain hose Nameplate location on base Oil drain valve Exhaust outlet Field connection terminal block location LP fuel orifice location inside hose fitting Gas regulator assembly DSAI leads Fuel inlet Air intake Battery cables Battery charger 120 VAC receptacle for battery charger Figure 2 Generator Set Component Locations 17 18 kW Models TP 6516 4 09 For professional advice on generator set power requirements and conscientio
40. l Electrical Code NEC and local code requirements Do not install this generator set indoors Use the generator set and transfer switch dimension drawings and wiring diagrams for installation 1 2 Lifting A WARNING HEN Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Approximate generator set weights are shown in Figure 1 1 Uselifting bars inserted through the holes in the skid to lift the unit See Figure 1 2 or Figure 1 4 for lifting hole locations Mode Weight kg b 12 kW 186 410 17 18 KW 227 500 Figure 1 1 Approximate Weights TP 6516 4 09 Section 1 Installation 1 3 Generator Set Inspection Complete a thorough inspection of the generator set Check for the following 1 Inspect the generator set for loose or damaged parts or wires Repair or tighten any loose parts before installation 2 Check the engine oil Fill if necessary with the recommended viscosity and grade of oil Use synthetic oil API American Petroleum Institute Service Class SG or higher See TP 6517 Operation Manual for additional information 1 4 Location and Mounting See Figure 1 2 12 kW or Figure 1 4 17 18 kW for the generator set dimensions and fuel and electric inlet locations The drawing dimensions are shown in millimeters with inches in bra
41. 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 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A 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 TP 6516 4 09 A CAUTION C j Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn offthe 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
42. low See Figure 1 15 for the fuel system component locations TP 6516 4 09 Procedure to Convert from NG to LP 6 Place the orifice into the hose fitting See Figure 1 16 1 Place the generator set master switch in the OFF position 2 Disconnect the power to the battery charger 3 Disconnect the generator set engine starting battery negative lead first 4 Turn off the fuel supply 5 Remove the hose clamp and fuel hose from the hose fitting See Figure 1 15 1 LP orifice 2 Hose fitting 3 Regulator Figure 1 16 LP Fuel Orifice Installation 7 Slide the hose onto the hose fitting and secure it with the clamp 8 Disconnect the digital spark advance module DSAI leads for LP Connect the leads for natural gas See Figure 1 17 and Figure 1 18 Fud TA ends Natural Gas Connect LP Disconnect Figure 1 17 DSAI Connection GM51561A D Hose fitting LP orifice fits inside see Figure 1 16 Regulator Fuel valve Fuel inlet 1 2 in NPT female Fuel hose with clamp DSAI connector location see Figure 1 18 Figure 1 15 Fuel System Components Air Inlet Side 17 18 kW Shown 1 DSAI leads 65 and N5 connect for natural gas disconnect for LP Figure 1 18 Digital Spark Advance DSAI Leads located in generator set air intake area TP 6516 4 09 Section 1 Installation 21 9 Connect and turn on the new fuel supply 10 Check that the generator set master switch is in th
43. mmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 5 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permitflames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away fromthe battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connection
44. nsfer switch in standby power installations to preventthe connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines 22 Section 1 Installation NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer Switch in accordance with Canadian Electrical Code Part 1 Have an authorized distributor dealer or a licensed electrician make the following electrical connections Verify that the electrical installation complies with the National Electrical Code NEC and all applicable local codes Ground the generator set from the GRD terminal inside the controller compartment according to applicable codes 1 8 1 Connections The generator set is equipped with a field connection terminal block located in the air inlet area near the junction box See Figure 1 19 and Figure 1 20 Also see Section 2 Wiring Diagrams Refer to the transfer switch specifications and Figure 1 20 for the acceptable cable sizes Route AC leads through flexible conduit Ensure that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas The electrical installation must comply with the National Electrical Code NEC and all applicable local codes Connection Procedure See Figure 1 20 Leads have been factory installed from
45. r vice versa in the field while maintaining emissions standard compliance A trained technician or authorized distributor dealer can convert the fuel system A WARNING D AS to 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 connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING ie Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels 1 7 1 Fuel Conversion For LP vapor fuel an orifice is used in the fuel line The unit is typically shipped set up for natural gas with the loose orifice tied near the fuel line To convert to LP vapor install the orifice and disconnect the spark advance leads as described be
46. ressure kPa in H20 12 kW Fuel supply pressure kPa in H20 17 18 kW 1 3 2 7 5 11 1 7 2 7 7 11 1 7 2 7 7 11 Fuel Consumption at Rated Load Natural Gas m hr cfh 100 75 50 25 LP Vapor m3 hr cfh 100 75 50 25 LP vapor conversion factors 8 58 13 1 Ib 0 535 m 1 kg 36 39 ft 3 1 gal Nominal fuel rating Natural gas LP vapor 37 MJ m 1000 Btu ft 3 93 MJ m 2500 Btu ft 3 Figure 1 11 Fuel Consumption 12 kW Models Fuel Consumption at Rated Load Natural Gas m3 hr cfh Fuel flow rate Btu hr 12 kW 193000 203000 Fuel flow rate Btu hr 17 18 kW 242000 280000 Nominal Fuel Rating Btu ft3 Natural gas 1000 LP vapor 2500 Figure 1 10 Fuel Supply Verify that the output pressure from the primary gas utility or LP tank pressure regulator is within the range shown in Figure 1 10 and that the utility gas meter flow rate is sufficient to supply the generator set at rated load plus all other gas consuming appliances See Figure 1 11 or Figure 1 12 for fuel consumption Contact the fuel supplier for flow rate information or a gas meter upgrade See Figure 1 2 or Figure 1 4 for the location of the fuel inlet connection Use flexible sections to prevent fuel line breakage caused by vibration Hold the fuel solenoid valve with a wrench when tightening the fuel connections Protect all fuel lines from machinery or
47. retor heater prevents condensation and carburetor icing The heater turns on when the temperature at the thermostat falls below approximately 4 C 40 F and turns off when the temperature rises above approximately 16 C 60 F See Figure 1 23 through Figure 1 26 The heater thermostat is instaled in the cord Figure 1 26 shows the location of the thermostat on the power cord tp6195 1 Carburetor heater air cleaner removed to show heater 2 Carburetor heater power cord Figure 1 23 Carburetor Heater Location 12 kW The heater requires a continuous source of 120 VAC power The heater power cord and thermostat are located in the generator set housing air intake area 26 Section 1 Installation battery compartment See Figure 1 22 and Figure 1 24 Plug the carburetor heater into an outlet that supplies continuous 120 VAC power Note Do not place the heater thermostat inside the generator set engine compartment The thermostat must be exposed to the ambient air Thermostat will shut off power to the heater when ambient temperature reaches approximately 16 C 60 F Figure 1 25 shows the location of the carburetor heater on the 17 18 kW generator set engine for reference The engine has been removed from the generator set in this photo for a clear view
48. rr rr rss rna 13 1 4 Location and Mounting rer rr rer rr tte eee 13 1 4 1 Exhaust Requirements 18 1 4 2 lt 18 1 5 Power Supply Av HS EI I MEUS 18 1 6 Fuel Requirements n 19 1 6 1 Fuel Supply 2 2 ri ee 19 1 6 2 Fuel Pipe SiZe ac pa una es 20 1 7 Fuel Conversion e n 20 1 7 1 Fuel Conversion ou serm ede haha e eR 20 1 8 Electrical Connections ee 22 1 8 1 AG Connections 2 2 ts Suyu Caches en af SQ ek 22 1 8 2 Remote Start 23 1 8 3 Gro nding z spese ea Saree hited ia ea tele bare 23 1 84 Battery 23 19 Batey csr oy E een nee 24 1 10 Carburetor Heater optional 26 1 11 Prestart Installation Check 27 1 12 Startup Notification 27 Section 2 Wiring Diagrams su v Ie eek vba rues dee wee uw e Rad een 29 Appendix A Abbreviations oooocoocnccconnc eh hh mehr 35 TP 6516 4 09 Table of Contents 3 Notes TP 6516 4 09 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and acce
49. ry acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area 24 Section 1 Installation Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconn
50. s Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING Gh Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 6 Safety Precautions and Instructions Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Combustible materials A fire can cause severe injury or death Generator set engine
51. s from terminals 3 and 4 to the automatic transfer switch s engine start terminals or to an optional remote start stop switch Route the engine start leads through separate conduit from the AC power and load leads 1 8 3 Grounding Ground the generator set The grounding method must comply with NEC and local codes Connect the grounding strap to the generator set ground lug terminal GND inside the controller compartment Kohler generator sets are shipped with the generator neutral attached to the generator in the junction box At installation the neutral can be grounded at the generator set or lifted from the ground stud and isolated if the installation requires an ungrounded neutral connection at the generator The generator set will operate properly with the neutral either bonded to ground or isolated from ground at the generator Various regulations and site configurations including the National Electrical Code NEC local codes and the type of transfer switch used in the application determine the grounding of the neutral atthe generator NEC 2002 Section 250 20 is one example that has a very good explanation of the neutral grounding requirements for generators 1 8 4 Battery Charger A 6 amp battery charger is factory installed in the battery compartment to keep the starting battery fully charged The battery charger s DC leads are factory connected Plug the battery charger s power cord into the receptacle on the bottom of
52. ssories 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 A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6516 4 09 Accidental Starting A WARNING Pa 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
53. the junction box to the terminal block for easier field wiring Refer to the decal near the terminal block for connections 1 Connect the leads from the transfer switch emergency source lugs to the L1 and L2 connections on the generator set terminal block 2 Connect the neutral LO and ground GRD leads from the ATS and the main panel to the corresponding connection points on the terminal block See Section 1 8 3 Grounding 3 The terminal block kit includes 120VAC receptacles for the battery charger and optional carburetor heater Connect utility power to the terminal block as shown Connectto a circuit that is supplied by the generator set if utility power is lost TP 6516 4 09 Db 1 7 1 8 kW ADV 7341 1 Junction box 2 Field connection terminal block location see Figure 1 20 3 Suggested electrical inlet Figure 1 19 Field Wiring OSO 0 05000030 G H LO L1 L2 N O 4 D T LOAD LEADS POWER START STOP TORQUE ALL SCREW TO MINIMUN OF 1 5 Nm 13 3 IN LBF WIRE GAUGE 6 20 AWG WIRE GAUGE 12 24 AWG GM54820 Figure 1 20 Field Connection Terminal Block TP 6516 4 09 1 8 2 Remote Start Connection Connect engine start lead
54. tions for 12 17 Information in this publication represents data available and 18kW residential commercial generator sets at the time of print Kohler Co reserves the right to equipped with the Kohler DC RET Digital Control change this publication and the products represented Refer to TP 6517 Operation Manual for generator set without notice and without any obligation or liability operation and maintenance instructions whatsoever The generator set is approved for use in stationary Read this manual and carefully follow all procedures applications in locations served by a reliable utility and safety precautions to ensure proper equipment power source operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the Have an authorized distributor dealer install the beginning of this manual generator set outdoors according to the instructions in this manual The generator set installation must comply See Figure 1 or Figure 2 for generator set component with the National Electrical Code NEC and local code locations requirements Do not install this generator set indoors ADV 7466 Muffler Oil filter Oil check Exhaust Oil fill Equipment ground Air cleaner Battery charger Fuses DSAI lead location RS 232 connector for application program updates LP fuel orifice locat
55. uilding Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied buildingthrough windows air intake vents or other openings The exhaust system is complete for generator sets installed outdoors Do not install this generator set indoors Figure 1 6 gives the exhaust flow and temperature at rated load The engine exhaust mixes with the generator set cooling air at the exhaust end of the enclosure Mount the generator set so that the hot exhaust does not blow on plants or other combustible materials Maintain the clearances shown in Figure 1 5 Exhaust System Exhaust flow at rated kW m3 min cfm 12 kW 17 18 kW 3 8 135 5 3 187 Exhaust gas temperature exiting the enclosure at rated kW C F 216 420 Figure 1 6 Exhaust Flow and Temperature 1 4 2 Air Requirements The generator set requires correct air flow for cooling and combustion The inlet and outlet openings in the sound enclosure provide the cooling and combustion air Figure 1 7 shows the locations of the cooling air intake and exhaust vents Inspect the air inlet and outlet openings inside and outside the housing to ensure that the air flow is not blocked 18 Section 1 Installation 1 Exhaust outlet 2 Alternator air intake both sides 3 Engine air intake GM51561 Figure 1 7 Cooling Air Intake and Exhaust Air
56. us service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler KohlerPower com Power Systems website at Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada callthe nearestregional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 TP 6516 4 09 Service Assistance Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Notes TP 6516 4 09 1 1 General Have an authorized distributor dealer install the generator set outdoors according to the instructions in this manual The generator set installation must comply with the Nationa
57. working on power lines A WARNING 2 Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Safety Precautions and Instructions 7 Hot Parts A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the engine heater Hot parts can cause minor personal injury or property damage Install the heater before connecting it to power Operating the heater before installation can cause burns and component damage Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts Notice NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 8 Safety Precautions and Instructions TP 6516 4 09 Introduction This manual provides installation instruc
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