Operation and Installation Residential/Commercial Generator Sets » Models: 8.5RMY 11RMY ww Controller: Relay d 99001 KOHLER. we POWER SYSTEMS____Table of Contents Safety Precautions and instructions 1 38 Batery ...... 4 381 Cleaning... IIs Introduction i 382 Checking the Elecroiyie Level 00... 18 3.83 Checking the Specific Gravity 0... 1. 18 Service Assistance . ii 39° Storage Procedure 16 39:1" Engine Of ceeecaces Section 1. Specifications 392 Fuel... eres ig 11 tnfroduction . 393. Oylinder Lubrication - 16 412 Generator. 3.94 Exterior Preparation 16 fae Section 4, Troubleshooting . “7 18 Service View Section 5. Generator Reconnection . -19 Section 2. Operation 5.1 Voltage Reconnection serene 18 1 1 1 1 1 2 3 3 3 3 120/240 Volt 60 Hz 4 4 4 4 5 5 ot ra Coie 22 farloasnperac) Gaara 18 HL Staite 22 Fae mec a ono 23 Siok et ‘8 22 Sila opin 22 teem Cred 4 ae section. Wing Disarm. 2 B13. Palouse oe coms “a os Ghaanemen 82 ana iin a is 2 Se ee oa Fe 5 Sibi taty Sagan ers 2008 26 Controlier Resetting Procedure a (otowing faut shutdown) 5 TA General........ Section 3. Scheduled Maintenance ............ 7 72. AirRequirements 34 Service Schedule . 73. Exhaust Requirements 2 82 Lubrication System 10 74 Weight . 28 3.21 LowOl Pressure Shutdown S197 Generater Sot spocton 28 322 Ol\Check «...- COUEEE Eo 76 Meuning UIEIINIIII ge 828 Engine Ol Recommendation «ss... 10 77 FuelSystem fea 324 _Olland Fiter Change - SIG10. 78 Electical Connections eas a8 Spark Plugs oon 781 Accessory Electrical Connections |... 29 34 Ar Cleaner Element and Predeaner . iz 782 AC Load Lead Connections ..+... ss... 29 84.1 Precleanet Senvce veces... 12 7.8 Presta Intataion Check 20 342 Raper Element Service eee 7.84 Battery 30 Bey pees corcvecs 8 appendix A. Glossary of Abbreviations ...... At 87 Exhaust System %8Safety Precautions and 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 manualhas severaltypes of safety precautions and instructions: Danger, Warning, Caution, and Notice, A pancen Danger indicates the presence of a hazard that will cause severe personal injury, death, ot substantial property damage. A warnine 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 for service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator fecognition. Replace missing or damaged decals, Accidental Starting A_WARNING A WARNING D a% Accidental starting. Can cause severe injury or death Disconnect the battery cables before working on the generator set. Flemove the negative (-) lead tit 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. Betore 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 fist 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 star'stop switch, orengine start command from a remote computer Battery A WARNING ‘Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and Glothing. Battery acid may cause blindness and bur skin [Explosion [Can cause severe injury or death, Relays in the battery charger| Jcause arcs or sparks. Locate the battery in awell ventilated area, Isolate the battery charger from explosive fumes Battery acid. Sulfuric acid in batteries can cause severe injury or death, Sulfuric acid in the battery can ccause blindness and burn skin. Always wear splashproot safety goggles when working near the battery. I battery acia splashes in the eyes or on the skin, immediately fush the affected area for 1Sminutes 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. ‘Saety Precautions and instructions 1Battery gases. Explosion can cause severe injury or death. Battery gases, ‘can cause an explosion. Do notsmoke ‘or permtflames or sparksto occur near ‘a battery at any time, particularly when itis charging. To prevent bums and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove wristwatch, rings, and other jewelry before handing the battery. Never connect the negative (-) battery cable to the positive (+) connection terminal ofthe starter solenoid. Do not ‘test the battery condition by shorting ‘the terminals together. Sparks could ignite the battery gases or fuel vapors. Ventilate the compartments containing batteries to prevent accumulation of ‘explosive gases. To avoid sparks, do rot disturb the battery charger connections while the battery is charging, Always turn the battery ccharger off before disconnecting the battery connections. Remove the negative (-) lead first’ when ‘disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery. Engine Backfire/Flash Fire & WARNING i [Can cause severe injury or death. Do nat smoke or permit flames of} sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury ordeath, Do not smoke or permit flames or sparks near the carburetor, fuel line, ‘uel fiter, 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. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator ‘set with the air cleaner removed, 1 Safety Preceutions and instructions Exhaust System Fuel System ‘Carbon monoxide. Can cause severe nausea, fainting, lor death. The exhaust system must be leakproof and routinely inspected. & WARNING “« Explosive fuel vapors. ‘Can cause severe injury or death. { Use extreme care when handling, storing, and using fuels. Generator set operation. Carbon monoxide can cause severe nausea, tainting, or death. Carbon monoxide is an odorless, colotiess, tasteless, nonintating gas that can cause death it inhaled for even a short time. Avoid breathing exhaust fumes when working (on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas ‘could accumulate and seepbackinside ‘a potentially occupied building. Carbon monoxide symptoms. Carbon monoxide can cause severe ‘nausea, fainting, or death. Carbon ‘monoxideis a poisonous gas presentin exhaust gases. Carbon monoxide poisoning symptoms include but are ot imited to the following: ‘¢ Light-headedness, dizziness ‘© Physical fatigue, weakness in joints and muscles. ‘© Sleepiness, mental fatigue, inabilty to concentrate or speak cleaty, blurred vision ‘© Stomachache, vomiting, nausea ‘experiencing any of these symptoms ‘and carbon monoxide poisoning is possible, seek fresh air immediately ‘and remain active, Do nots, ie down, cr fall asleep. Alert others to the possibilty of carbon monoxide poisoning. Seek medicalattention tthe Condition of affected persons does not improve within minutes of breathing fresh air. 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 ofchildren, Neveraddtuelto. the tank while the engine is running because spilled fuel may ignte on ‘contact with hot parts or from sparks. Do not smoke or permit flames or ‘sparks to occur near sources of spilled fue! or fuel vapors. Keep the fuel ines land connections tight and in good condition. Do not replace flexible fuel fines with rigid fines. Use flexible ¢ sections to avoid fuel line breakage causedby vibration. Do notoperate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Explosive fuel vapors can cause ‘severe injury or death. Take addtional precautions when using the following fue. Propane (LP}—Adequate ventiation is mandatory. Because propane is heavier than air, instal propane gas detectors low in a room. Inspect the detectors per the manufacturer's instructions, Natural Gas—Adequate ventiation is mandatory. Because natural gas rises, install natural gas detectors high in a room, Inspect the detectors per the ‘manufacturer's instructions.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 andwatersolution withthe fuel system test pressurized to 6-Bounces per square inch (10-14 inches water column). Do not Use a soap solution containing either ‘ammonia or chlorine because both prevent bubble formation. A successful test depends on the abiity of the solution to bubble, LP liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage ccan cause an explosion. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90psi (621 kPa). Do not use a soap solution containing either ammonia or chiorine because both prevent bubble formation. A successful test depends fn the abilty of the solution to bubble. Hazardous Noise & CAUTION Hazardous noist Can cause hearing loss. Never operate the generator set without a muffer 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 tonoise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set. Hazardous Voltage/ Electrical Shock A_WARNING Hazardous voltage.! Moving rotor. JCan cause severe injury or death. (Operate the generator set only when all guards and electrical enclosures. are in place, A WARNING [Hazardous voltage. Backteed to the utility system can| Jcause property damage, severe injury, or death. It the generator set is used for standby power, install an automatic Itanster 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. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electricaly ground the generator set, transfer switch, and related equipment and electrical ‘circuits to comply wih applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditons increase the fisk of electrocution. High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing highvotage tests on the fotor or stator. AN improper test procedure can damage equipment or lead to generator set failure. Installing the battery charger. Hazardous voltage can cause severe injury or death. An Uungrounded battery charger. may ‘cause electrical shock. Connect the battery charger enclosure tothe ground of a permanent wiring system. As an attemative, 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 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(es). Have a qualified electrician install the battery(es). Short circuits. Hazardous voltage/current can cause severe Injury or death. Short circuits can ‘cause bodily injury andior equipment damage. Do not contact electrical Connections with toots or jewelry while making adjustments or repairs. Remove wristwatch, rings, and jewelry before servicing the equipment. Testing the voltage regulator. Hazardous voltage can cause ‘severe injury ordeath. High vottageis present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink ‘when testing the voltage regulator. (PowerBoost™, PowerBoost™ Il, and PowerBoost™ V voltage regulator ‘models only) Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. installa transfer switch in standby power installations to prevent the connection, ofstandby and other sources of power. Electrical baokieed into a utity electrical system can cause serious injury or death to utility personne! working on power lines. Safety Precautons and Instructions IHeavy Equipment Moving Parts Notice A_WARNING ‘A_WARNING NOTICE [This generator sot has been rewired from its nameplate voltage| to Hazardous voltage, Moving rator. Unbalanced weight, ‘Can cause severe injury or death. improper lifting can cause severe| injury or death and equipment} ama Do not use titing eyes. Liftthe generator set using ling bars| inserted through the liting holes on| the skid Hot Parts A WARNING Hot engine and exhaust system. ‘Can cause severe injury or death. Do not work on the generator set unt it cools, Servicing the generator. Hot parts, ‘can cause severe injury or death. ‘Avoid touching the generator setfeld or exciter armature. When shorted, the ‘generator set field and exciter armature become hot enough to cause severe burns. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine pars. The engine and exhaust system components become extremely het during operation, IV Safety Precautions and Instructions ]Operate the generator set only when all guards and electrical enclosures are in place. A WARNING ay Rotating parts. (Can cause severe injury or death. (Operate the generator set only when| all guards, screens, and covers are in place. Tightening the hardware. Flying projectiles can cause severe Injury ‘or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can ‘cause personal injury. Retorque all crankshatt and rotor hardware after ‘servicing. Donotloosen the crankshaft hardware or rotor thruboltwhen making adjustments or servicing the generator ‘set. Rotate the crankshaft manually in a clockwise direction only, Turing the crankshaft bot or rotor thrubott counterclockwise can loosen the hardware, Servicing the generator setwhen itis, ‘operating. Exposed moving parts ‘can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and Covers before operating the generator set 2ae242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the vottage on the nameplate. Order vottage reconnection decal 246242 from an authorized service distributor/dealer, NOTICE Hardware damage. The engine and ‘generator set may use both American ‘Standard and metric hardware. Use the comect size tools to prevent rounding of the bot heads and nuts NOTICE When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in diferent hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses ‘numeric system. Check the markings fon the bott heads and nuts for identification, 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.Introduction ‘All information in this publication represents data available at time of print. Kohler Co. reservesthe rightto change this literature and the products represented without incurring obligation. Read through this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this, ‘manual with equipment for future reference. Equipment service requirements are minimal but are very important to safe and efficient operation; therefore, inspect parts often and perform required service at the prescribed intervals. An authorized service distributor/dealer should perform required service to keep equipment in top condition, California Emission Certification If your engine/generator has the identification label, itis certified for operation in the state of California. (_IMPORTane ENGINE RiFORWATION “ThaS ENGINE CONFORMS TOUS. EpnPrage 1ANO. cisem: CCALIFOPBIA EMISSION CONTROL REGULATIONS FOR ULGE ENGINES. DISPLACEMENT: FAMILY. = BULD OATET | REFER TO OWNERS MANUAL FOR | SAFETY, MANTENANGE SPECS AND ya a Gra ae This engine/generator is certified to operate on natural {gas or propane fuel. This engine is certtied with engine modifications. Introduetion |Service Assistance Please contact a local authorized distributor or dealer for sales, service, or other information about Kohler Generator Division products. Tolocatealocal authorized distributor or dealer © Look on the product or the information included with the product ‘© Consultthe Yellow Pages under the heading Generators—Electric © Visitthe Kohler Generator Division web site at ‘www. kohlergenerators.com © Call 1-800-544-2444 (inside the U.S.A. and Canada) 0° 920-565-3381 (outside the U.S.A. and Canada) 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 instaling the kits, 5 Introduction Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate(s). Model Number ‘Specification Number ‘Serial Number ‘Accessory Number ‘Accessory Description Engine Identification Record the product identification information from the ‘engine nameplate. Manufacturer Model Number Serial Number& Section 1. Specifications 1.1 Introduction ‘The spec sheets for each generator set provide specific generator and engine information. Refer to the respective spec sheet for data not supplied in this manual. Consult the generator set service manual, installation manual, engine operation manual, and engine service manual for additional specifications. 1.2 Generator The generator has Kohler's PowerBoost™ voltage regulation system, which provides instant response to load changes. PowerBoost™ is a unique system that ensures reliable ‘motor starting and consistent voltage level. PowerBoost™ utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage. 1.3 Engine The generator set has a four-cycle, twin cylinder, air-cooled Kohler engine. Engine features include: ‘Efficient overhead valve design and full pressure lubrication for maximum power, torque, and reliabilty under all operating conditions. ‘© Dependable, maintenance-free electronic ignition. ‘© Parts subjected to the most wear and tear made from precision-formulated cast iron. 1.4 Controller ‘The generator set has a relay controller. For a specific description ofthe controller, see Section 2—Operation. Controller features include the following: «© Fautt shutdowns © Overcrank © Overspeed © Pressure, low oil © Running time meter © Switches and standard features © Switch, run/reset-oft/auto (engine start) © Cranking, cyclic, ‘Specifeations 11.5 Service View ‘Ar cleanot 39. Onfter Figure 1-1. Generator Set Service View 2 Specifiations& Section 2. Operation 2.1 Prestart Checklist ‘To ensure continued satistactory operation, check the following items before each startup and at regular intervals. Refer to the engine service manual for specific service procedures. ‘Air Cleaner. Keepthe aircleaner element clean. Install the element to keep unfitered air from entering the engine. Battery. Ensure tight battery connections. Maintain a full battery electrolyte level. Exhaust System. Keep the exhaust outlet clear. Keep, the silencer and piping tight and in good condition. Inspect exhaust system components for cracks and corrosion (exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe). © Check for corroded or broken metal parts and replace as needed. '* Check for loose, corroded, or missing clamps and hangers. Tighten or replace clamps and/or hangers as needed, © Check that the exhaust outlet is clear. Oil Level. Maintain the oil level at or near the full mark ‘on the dipstick but not over the full mark. 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. 2.2 Exercising the Generator Run the generator set under load once each week for one hour. Perform this exercise in the presence of an operator f the generator set does not have an automatic, transfer switch with an exercise option. The operator should perform all prestart checks before startingthe exercise procedure. While the generator set is running, listen for a smooth-running engine and visually inspect the generator set o ensure there areno fluid or exhaust leaks. Start the generator set according to the starting procedure in the controller section of this manual. 2.3 Controller Features Refer to Figure 2-1 and the following descriptions to identity controller components. Hourmeter. The hourmeter records generator set operating hours for reference in maintenance scheduling. AC Circuit Breaker. The circuit breaker trips when a faut is detected in the AC output circuit, See Section 4—Troubleshooting to determine the cause of the fault. After correcting the fault, place the AC circuit breaker in the ON position to reset it. Controller Input Fuse (10. amp). The fuse protects the generator set controller circuitry. Ifthe generator set will ‘not crank and the battery and/or connections are intact, the controller fuse may be blown. Contact an authorized Kohler service distributor/dealer it the fuse blows repeatedly. Voltage Regulator Fuse (10 amp). The fuse protects the voltage regulator circuitry. The generator set shuts down if this fuse blows. See Section 2.5.1. Generator Master Switch (Run/Rest-Off/Auto). The ‘switch functions as the controller reset and generator ‘set operation switch. Refer to the Starting, Stopping, and Controller Resetting procedure in this section. 3 A.2580764-A\ 7 Hourmeter 2. AC areal breaker 3, Votage regular fuse 3. Conte fuse 5. Generator master switch Figure 2-1. Controller Features Operation 32.4 Controller Operation 2.4.4 Starting Place the controller or remote Start/Stop switch in the RUN position untilthe engine starts. Ifthe engine failsto start after three 8-second attempts, the generator set stops cranking because of overcrank fault shutdown. ‘Wait for the engine to come to a complete stop before attempting a restart. Place the switch in the RESET/OFF position and then to the RUN position. ‘After a fault shutdown, leave the generator master switch in the RESET/OFF position for 3 to 5 seconds before attempting to restart the generator set. NOTE Do not crank the engine continuously for more than 30 seconds at a time. Allow a 60-second cooldown period between cranking attempts ifthe engine does not start. If the generator set does not start after three attempts, see Section 4—Troubleshooting for possible causes. 2.4.3 Fault Shutdowns ‘The generator set shuts down automatically under the following fault conditions and cannot be restarted until the fault condition is corrected. Do not attempt restart Until the fault has been corrected. Do not attempt to restart the generator set until the fault has been corrected. The shutdown switches automatically reset when the problemis corrected or the generator set cools (if overheating was the faut). After a fault shutdown, leave the generator master switch in the RESET/OFF position for a couple of seconds before attempting to restart the generator set. Overcrank. Shutdown occurs after 30 to 60 seconds of continuous cranking, Overspeed. The generator set shuts down immediately if governed frequency exceeds 70 Hz (2100 rpm) on 50 and 60 Hz models. Low Oil Pressure. Shutdown occurs approximately 8 seconds after fault. Fault ocours when the engine cil pressure drops below the specified limit, 2.4.2 Stopping 4. Disconnect the load from the generator set by opening the line circuit breaker and allow the generator set to run without load for 5 minutes. NOTE Run the generator set at no load for § minutes prior to stopping to ensure adequate cooling of the set. 2. Place the controller or remote start/stop switch in the RESET/OFF position. The generator set shuts down. 4 Operation NOTE Low oll pressure shutdown does not protect against low Gil level. Check the engine oil level NOTE If the cause of a low oil pressure shutdown is not corrected, the generator set can be restarted (after controller reset) and will run approximately 8 seconds before shutting down again. See the Resetting Fault ‘Shutdown procedure following.2.5 Circuit Protection Aline circuit breaker sized for the generator output interrupts the generator output in the event of an overload or short circuit in the wiring between the alternator and components. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. With the breaker in the OFF position, the ‘generator set runs but there is no output voltage. See Figure 2-2 for the circuit breaker ratings. NOTE Hf the generator set circuit breaker trips repeatedly, see ‘Section 4—Troubleshooting for possible causes. Wodel 5/1RMY CB Rating _| 50 amp Figure 2-2. Controller Circuit Breaker Rating ‘A replaceable 10-amp fuse protects the controller circuitry. Check the controller fuse ifthe generator set will nt crank and the battery and/or connections appear correct. Replace the fuse. If the fuse blows again, see Section 4—Troubleshooting for possible causes. 2.5.1 Voltage Regulator Fuse ‘A replaceable 10-amp fuse protects the voltage regulator circuitry. The generator set shuts down ifthe fuse blows. Typically with this condition, the generator set starts and then shuts down in 8 seconds. Hf this fuse blows again after_— replacement, see Section 4—Troubleshooting for possible causes. See Figure 2-1 forthe location of the voltage regulator fuse. 2.6 Controller Resetting Procedure (following fault shutdown) Use the following procedure to restart the generator set after a fault shutdown. Reset the controller and correct the fault before resetting the generator set. NOTE Hf the fault is not corrected, the generator set will start and then shut down in 8 seconds. 1. Place the generator set master switch in the RESET/OFF position. See the Safety Precautions and Instructions at the beginning of this manual before proceeding, 2. Disconnect the generator set from load using the line circuit breaker or automatic transfer switch. 3, Place the generator set master switch in the RUN position to restart the generator set. Refer to ‘Section 4—Troubleshooting for possible causes of fault shutdown. 4, Place the generator set master switch in the RESET/OFF position. 5. Correct the cause of the fault shutdown. 6. Place the generator set master switch in the RUN ‘or AUTO position for startup. Operation 5e Section 3. Scheduled Maintenance A WARNING Dar ‘Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (-) lead fist 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 tothe ‘OFF position. (2) Disconnect the power'to the battery charger. @) Remove the battery cables, negative (-) lead fist 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 startstop switch, or engine start command from a remote computer. 4_WARNING [Hot engine and exhaust system. [Can cause severe injury or death. Do not work on the generator set unt itcools. Servicing the exhaust system. Hotpartscan cause severe Injury or death. Do not touch hat engine parts. The engine and exhaust system components become extremely hot during operation. @_WARNING Hazardous voltage.! Moving rotor. \Can cause severe injury or death. (Operate the generator set only when, all guards and electrical enclosures are in place, ‘Servicing the generator set when itis operating. Exposed ‘moving parts can cause severe injury or death. Keep ‘hands, feet, hair clothing, and test leads away from the belts ‘and pulleys when the generator set is running. Replace ‘guards, screens, and covers before operating the generator set Alternator service. Under normal operating conditions the generator set alternator does not require scheduled service. Refer to the service schedule for items that require maintenance. Engine service. Perform generator set engine service at the intervals specified by the engine service literature. Contact an authorized Kohler service distributor/dealer to obtain engine service literature. Generator set service. If the generator set operates under dusty or dirty conditions, use dry compressed air to blow dust out of the generator. Withthe generator set running, direct the stream of air in through the cooling slots at the generator end. Generator set service. See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized Kohler service distributor/dealer perform all generator service. Routine maintenance. Refer to the service schedule following and the hourmeter located on the generator set controller to schedule routine maintenance. Service units subject to extreme weather, long operating hours, or dusty or dirty conditions more frequently. ‘Service schedule. Perform maintenance on each item inthe service schedule at the designated interval for the life of the generator set. Tools. Tools and instruments used to perform some maintenance items are not generally available to the generator set owner. Therefore, have service performed by an authorized distributor/dealer. Tune-ups. Have the generator set tuned-up by an authorized distributor/dealer. Tune-ups improve performance and ensure continuous satisfactory ‘operation during a long, trouble-free service life. All generator sets have emission-certiied engine. Emission-certified engines are fitted with carburetors that have no possible adjustments, ‘Scheduled Maintenance 73.1 Service Schedule Perform the items listed in the service schedule at the designated intervais for the life of the generator set. For ‘example, an item serviced every 100 hours or 3 months must also be serviced after 200 hours or 6 months, 300 hours or 9 months and so on. Rough operation, lack of power, and excessive oil use indicate serious generator set problems. ‘System—Component Procedure @ Follow procedures and frequencies indicated n the ‘engine manufacturer's maintenance manual. lf not indicated, follow this service schedule, Some items may ‘not pertain to specific generator sets. X Action FL_ Replace as necessary Visually Inspect | Check Clean | Tost Change FUEL labo ines and connecbons Tain tank supply Tevet Fue piping TUBRICATION Olllevel Grankcase breather Yar 00 Change of x| Yor t00 place ite™ x Yor 200 COOLING ‘Ar leaner to roomjenciosure Tir dacs, iouvers <= EXHAUST LINE Toakage insulation, We hazards Flexible constants) Hangers and supports <|<|-|¢ DC ELECTRICAL SYSTEM Battery charger operation, charge rate emave corosion, clean and ary batary and rack ‘Giean and tghten bation terminals Tighten DC electrical consections x <|<| Gro ‘A umper lead is not used, After connection adjust the | oad u voltage regulator to obtain the desired voltage. Pe & boat 57S] LO (Neutral) ° f ce bt | actory ‘wor o—_—_> | f fscouge [ om cro ioh | Ci u > > Field installed bead S75] jury Side | O | O | , Factory two-pole | eee | rout breaker Line 4321 de 5 Stator Leads pr tele \ \ wr sone eto e tan Giese \L2 120 veh NO vo. 403 2 1 fromground | ‘AGvoltage measured fromLOto either L1 Stator Leads | ‘or 12 wil bein the 110120 vor range: wore Sone | & Tesest| Lor atove 20 vat Figure 5-3. 110 and 120 Volt, 3-Wire Soke came ok menaaeeey Configurations TP5691-5 oe Lo Figure 5-5. 220 and 240 Volt, 2-Wire Oponp = Gao Configurations Ground ut Load Side Field installed jumper lead Two-pole circu breaker 4324 Stator Leads o& 60 Hz 50 He LOLI 100-120 vot 110-120 vot AAC voltage measured from LO to Lt will be in the 100-120 vok range. NOTE The existing ammeter ower scale indicates half ofthe actual] [Lt'curtent, D0 NOT PUT THE CT ON Li. Either label the ammeter wih note indesting lower scale tes to, Purchase a new ammeter scaled twice the existing amet . nd install the new ammeter gale Figure 5-4. 110 and 120 Volt, 2-Wire Configurations Generator Reconnection 216.1 General ‘At the time of print, this manual applied to the model numbers and specification (spec) numbers following. (Onoccasion this manual may be applicable to specs not listed below, such as when similar new specs are created prior to the updated reprint or incases where the manual is deemed an acceptable substitute for a ‘manual under development. Use the Wiring Diagram Cross-Reference to determine the correct version number for a given model number ‘and spec number. Find that version number in the Controller Wiring Diagrams Reference and determine the wiring diagrams by choosing the type of controller on the unit. Wiring diagram pages are numbered and arranged in numerical sequence by the numeric part of the alphanumeric part number. Section 6. Wiring Diagrams 6.2 Wiring Diagram Cross-Reference Wiring Diagram Model No._|Spec. No. Version No. ‘BERMY —|195007, 195078 | 1 T1RMY _|195008, 195012 | 1 6.3 Controller Wiring Diagrams Reference Controller Description [version 1 [Pg Relay Controller Point-to-Point Wiring Diagram 1 phase ‘Schematic Diagram 1 phase 958098-E | 25 Av-s297-8 | 24 ‘wiring Diagrams 238-2629-AGY ‘eseud | ‘wesBeIG SeWOYDS ‘19I10:1U0D AION 24 Wing Diagrams.Wing Diagrams 25Section 7. Installation 7.1 General Installation must comply with the installation instructions. Install the generator set to comply with state and local requirements. Use the specifications and drawings provided here only in the intial planning. Use the respective spec sheets, dimension drawings, and wiring diagrams for installation. Contact an authorized service distributor/dealer for the most current information. 7.2 Air Requirements The generator set requires correct airflow for cooling and combustion. The louvers on the ends of the weather housing provide the cooling and combustion air. Do not block or otherwise interfere withthe function of these openings. Ifthe generator set is to be mounted indoors, maintain the air flow shown in the spec sheet. Install appropriately sized vents in the building. Use an air duct flange to provide the connection to duct the heated airto the outside of the building. Inspect the air inlet and outlet openings inside and ‘outside the weather housing to ensure that debris is not blocking the tree air flow. OH 4 I POWER SYSTEM Outer niet — l— - lo — l— ‘a-3580000-C Figure 7-1 Cooling Air intake and Exhaust 7.3 Exhaust Requirements ‘The exhaust system is complete for generator sets installed outdoors, For generator sets installed inside a building, pipe the exhaust outside. Use the available flexible exhaust kit and duct flange kit. See Figure 7-2. Correctly size any extension added to the exhaust outlet so it does not affect the maximum allowable back pressure of the engine. The total length and number of bends in the exhaust system may have an effect on the back pressure. Locate the exhaust outlet to prevent entry by rodents and birds. Use a rain cap when the exhaust outlet is directed upward. NOTE The flexible exhaust connector must be installed without any bends, 5 5 3s : 3 5 LEAL 750, 44 mm) Mutter cet ‘Glan, 125 in. (22 mm) Flouble exhaust connector ‘Air out ut ange Clamp, 2.0in. (1 mm) Figure 7-2. Exhaust Outlet—Alternator End Instatation 277.4 Weight ‘The weight of the generator set determines the type ot ‘base construction at the site. Most generator sets are mounted on concrete at the ground level. Small generator sets such as these can be installed on a ‘simple concrete slab, precast base, or other material as long as the generator set is secured and does not move while operating, 7.5 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 orwires. Repair or tighten prior to installation, 2. Check the engine oil. Fill, if necessary, with the recommended make and grade of oil. 7.6 Mounting See Figure 7-3 for the typical mounting surface details, and dimensions. A level concrete surface is recommended for mounting. if mounting the generator set on a structure, seal up the bottom of the unit using marine plywood to ensure design cooling air flow and restrict the entry of debris and/or wildlife through the bottom of the skid. _——— en |] some 3581978-8 1. Base mounting holes Figure 7-3. Generator Set Base—Top View 28 Instaiation 7.7 Fuel System ‘The generator set has an emission-certified engine. Emission-certified engines are fitted with carburetors ‘that have no possible adjustments. See Figure 7-4 for the location of the C.A.R.B. decal. ‘The fuel system of a emission certified generator set is sset at the factory for the specified fuel and sealed to prevent adjustments. A-3590008-C. Emission cert decal Emission exempt decal Decal ecaton igure 7-4. Emission Decal Location ‘The fuel system of a nonemission certified generator sets is adjustable to run on either LP gas or natural gas. Contact the local service distributor/dealer for fuel adjustments. ‘Comply with the local and state codes regarding the correct storage of fuel. Because of the scope of the topic involving variable climate conditions and ‘geographical considerations, contact an authorized service distributor/dealer for fuel system planning and installation. Protect al of the fuel lines from machinery or equipment contact, adverse weather conditions, and environmental damage.1. Fue inlet connection, 172 NPT 2. Fualline entry area Figure 7-5. Fuel Supply Line—Eni Ensure that the natural gas pipe size meets size specifications in the Figure 7-6 chart. Measure the pipe length from the gas utility pressure regulator (7-11 in, water column output pressure) to the end of the pipe where it connects to the fuel inlet. Compare the length with the chart in Figure 7-6. Replace piping longer than the listed maximum length with the specified pipe length before proceeding. NOTE ‘The utility gas meter flow rate (Btu/hr) must be sufficient to accommodate the generator set and other gas consuming appliances. Contact the natural gas utility for information or a gas meter upgrade. BSAMY Maximum | TIRMY Maximum PipeSize | Pipe Length Pipe Length Bain. NPT | 60ft (183m) ‘30f 2m) tin. NPT | 2008. (61 m) 95. (29.0 m) 1-1/4 in. NPT| 3008. (1.5m) | 2254. (68.6 m) Max. BTU/Hir 132,000 198,000 Figure 7-6. Maximum Natural Gas Pipe Length Contact the local LP provider for LP installation information. 7.8 Electrical Connections 7.8.1 Accessory Electrical Connections ‘Some accessories can be connected to the generator set, including a run relay and common faut relay. Contact an authorized service distributor/dealerfor alist of other accessories. ‘Most accessories operate on 12 volts DC and some may require AC line voltage. Follow the installation instructions provided with each kit. Use separate ‘conduit for AC and DC leads to reduce the possibilty 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 is done by a licensed electrician. Follow all applicable local and state codes. See Section 6—Wiring Diagrams for more information regarding generator set electrical connections. 7.8.2 AC Load Lead Connections Make the AC output lead connections in the controller ‘compartment where the AC circuit breaker is located. Route the building distribution panel or transfer switch leads through the bottom of the generator set or flexible conduit directly tothe AC circuit breaker box. Verity that ‘the leads and conduit do not interfere with the operation of the generator set or obstructthe service areas. Verity thatthe electrical installation complies with the National Electrical Code (NEC) and is done by a licensed electrician. Follow all applicable local and state codes. ‘See Figure 7-7 and Section 6—Wiring Diagrams forthe ‘generator set electrical connections. 1. Connect the L1/L2 black leads to the AC circuit breaker load side. 2. Connect the LO white leads to the neutral stud. 3. Connect the green lead to the equipment ground. NOTE 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 Installation 29