Installation Manual, 7ER (TP-6034)
Contents
1. 5 3 Fuel Pump Lift and Fuel Consumption See Figure 5 2 for the fuel pump lift capability Consult the current generator set specification sheet for the generator set fuel consumption rates Do not exceed 3 1 2 psi fuel pump pressure to the carburetor Note Fuel system alterations may adversely affect emissions levels Fines resulting from higher than allowable emissions levels are the responsibility of the user Fuel Pump Lift Model m ft 7ER 0 9 3 Figure 5 2 Fuel Pump Lift Capability Max 5 4 Fuel Filters or Strainers These generator sets are shipped with a fuel filter No additional fuel filter or strainer is required ADV 6450 E 1 Fuel filter Figure 5 3 Fuel Filter Location TP 6034 10 02 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 Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building campground electrical system only through an approved device and after the building campground main switch is opened Backfeed connections can cause severe injury or death to utility personnel work2. Circuit Protection 120 V Outside Power 120 Volt Figure 6 1 12 Electrical System Transfer Switch Connections 3 Wire AC Circuit Note For standby service connect output of the generator to a suitably rated transfer switch in accordance with the Canadian Electrical Code Part 1 AC Vehicle Circuit Ground Fault Circuit Protection LO 240 V Outside 120 240 Volt TP 6034 10 02 6 3 Circuit Protection The AC circuit breakers protect the generator set from extreme overload AC circuit breakers trip when they detect a fault in the output circuit For application and selection information contact an authorized distributor dealer After correcting the fault reset the circuit breaker s by placing them in the ON position Restartthe unit See an authorized service distributor dealer for AC circuit breaker ratings The units voltage configuration determines the circuit breaker selection Note Circuit breaker ampere rating and availability are subject to change 6 3 1 Circuit Breaker Considerations Mounting location Mount the circuit breakers in the generator set controller Sizing Use the generator set voltage frequency configuration to determine the circuit breaker amperage If the circuit breaker was sized for one voltage configuration and later the generator set is reconnected to a different voltage change the circuit breaker accordingly to provide optimum protection Have a qualified el
3. Section 7 of this manual for generator set dimensions and weights For angular operating limits consult the operation manual TP 6034 10 02 Section 2 Location and Mounting 2 3 Vehicle Floor Mounting Install the Kohler 7ER mobile generator set on an open vehicle s floor or truck bed Follow the guidelines below Contact an authorized Kohler service distributor dealer with your specific application questions Minimum clearance Allow clearance for vibration and cooling during operation Minimum clearance for vibration top front rear and sides is 38 mm 1 1 2 in Keep the radiator end unobstructed for proper air flow Additional clearance Generator set service requires more clearance than 38 mm 1 1 2 in Design the mounting location to allow for sufficient room to easily remove the generator set to perform major service Mounting tray Ensure that the structural members for mounting can support the generator set s weight and withstand vibration The generator set includes vibration mounts and a mounting tray if desired install additional vibration isolating pads underneath the generator set s base Use the four mounting holes in the mounting tray to mount the generator set securely to the vehicle to avoid unwanted movement from vibration and road shock Location and Mounting 3 2 4 Extended Shaft Mounting If the mobile generator set includes an extended shaft allow adequate space atthe generator end ofthe setfo
4. The exhaust gases must discharge freely to prevent carbon monoxide from deflecting into the vehicle Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas present in exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness 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 and remain active Do not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention ifthe condition of affected persons does not improve within minutes of breathing fresh air TP 6034 10 02 Installing the exhaust tail pipe Carbon monoxide can cause severe nausea fainting or death Install the exhaust system tail pipe to preventthe drawing of discharged exhaust gases into the vehicle interior through windows doors air conditioners and other openings Do not use flexible tail piping because it could crack and allow lethal exhaust fumes to enter the vehicle Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the vehicle s occupants install a carbon monoxide detector Consult the coach buil
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6. and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water oronwetground because these conditions increase the risk of electrocution 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 Connect the generator set to the building campground electrical system only through an approved device and after the building campground main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a transfer switch to prevent interconnection of the generator set power and other sources of power Electrical System 13 Note Wire material Note Wire protection 6 3 2 Circuit Breaker Installation Only Required for Changing from Factory Installed and Wired 120 Volt 2 Wire Use stranded copper for all wiring Use wire gauges insulation conductor temperature ratings sheath stripping conductor support and protection
7. begins to drop When set to these specifications the generator attempts to maintain normal output until the engine speed drops below the frequency set in step 5 as load is applied Readjust the engine speed to normal 63 Hz 1890 RPM for 60 Hz Readjust the voltage adjustment pot if necessary Readjust the stability pot if necessary Use the remote rheostat if equipped to make final voltage adjustments Stop the generator set TP 6034 10 02 Appendix A Generator Selection and Wattage Requirements General Wattage Requirements Consider the total wattage requirements lights motors appliances when selecting a generator set or when sizing wattage usage in which available space and construction limit the size of the generator set Motor Loads When figuring generator set capacity requirements for loads that include electric motors consider the high current demanded by the motors during startup The inrush or starting current is typically 2 to 3 times higher than that required when the motor reaches normal operating speed Allow a reserve for inrush demands plus other loads that could be on the line as the electric motor starts Use Figure 1 as a guide when selecting generator set capacity requirements involving motor loads Starting Inrush Watts Running Watts Figure 1 Motor Requirements Appliance Loads Generator sets often furnish AC for appliances such as TVs stereos a
8. conductor terminals and splices and overcurrent protection circuit breakers fuses that conform to standards and codes Use rubber grommets and cable ties as necessary to protect and secure the wiring from sharp objects the exhaust system and any moving parts Turn the generator set off and disconnect the generator set engine starting battery the negative lead first Remove the controller cover screws and remove the controller access cover Remove the screws and nuts to remove the circuit breaker cover plate Save the mounting hardware Install the circuit breaker from the inside of the cutout panel and mount it using the existing screws Position the circuit breaker with ON in the normal upright position or to the left side Cover the cutout opening if applicable with the circuit breaker coverplate Use the existing screws and nuts See Section 8 for voltage reconnection Install insulation boots over the stator lead terminals if the kit includes insulation boots Note See Section 8 for wiring instructions 14 Electrical System 7 10 11 Make the recommended connections for the following three reconnection systems using circuit breakers Two pole circuit breaker with a single voltage system example 120 volt 3 wire Attach stator leads marked 2 and 4 to the side ofthe circuit breaker marked LINE Install the jumper lead across the LINE side of the circuit breaker terminals see S
9. 20 240 Volt 2 Wire Configuration TP 6034 10 02 8 2 Voltage Regulator Adjustment A 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 Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is present atthe voltage regulator heat sink To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator PowerBoost PowerBoost Ill and PowerBoost V voltage regulator models only The controller typically contains the voltage regulator Voltage regulator adjustments are possible without removing the voltage regulator The voltage regulator adjustment procedure applies to the PowerBoost Figure 8 5 voltage regulator Note The following adjustment procedure is for readjustment of the voltage regulator and governor for broadrange generator sets with mechanical governors Note Special Tools Frequency meter 50 60 Hz TP 6034 10 02 TT 875 11 1 Voltage adjustment potentiometer 2 Stability adjustment potentiometer 3 Volts Hz adjustment potentiometer Figure 8 5 PowerBoost Voltage Regulator Note A customer provided rheostat may be connected across regulator leads terminals 33 and 66 to adjust the generator output voltage from a location remote from the set The rheostat 10k Ohm 1 2 watt minimum pr
10. 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 thatcan 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 unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas couldaccumulate and seep back inside a potentially occupied building or vehicle Do not obstruct the exhaust outlet when parking your vehicle The exhaust gases must discharge freely to prevent carbon monoxide from deflecting into the vehicle Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness 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 Ifexperiencing any ofthese symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possib
11. Installation Commercial Mobile Generator Sets Model ISO KOHLER POWER SYSTEMS NATIONALLY REGISTERED Table of Contents Safety Precautions and Instructions nennen nennen hh nnn Section 1 Introduction iia a a a ana 1 1 1 Installation Standards nern een nenn 1 1 2 Generator Set Specifications esee 1 1 3 Generator Set Operation nennen 1 Section 2 Location and Mounting nenn nennen een nennen nenne 3 2 1 General Considerations 3 NEM Educ D DL 3 2 3 Vehicle Floor Mounting IIR Ih 3 2 4 Extended Shaft Mounting esee 4 Section 3 Cooling System enhn hh ehh nnn 5 Sil Air Requirements der EMERGED Raw cia E 5 3 2 High Water Temperature Switch 5 Section 4 Exhaust System eher hh nnn 7 4d Planning iia LESION xen er ita de 8 4 2 Clearance Requirements 8 4 3 Exhaust Piping If Used Ih 8 Section 5 Fuel System ir zen aac noce d wei A A Raa 9 51 Fuel Tank oue voe RR tu bo aru eite eg 9 A Ines ee een ra 10 5 3 Fuel Pump Lift and Fuel Consumption 10 5 4 Fuel Filters or Strainers 10 Section 6 Electri
12. and the green lead is the hazard ground See Section 8 forthe AC load lead connections Route the load leads directly from the junction box to the vehicle AC circuit or transfer switch connection Route the load leads of all installations through flexible conduit from the generator end bracket to the junction box Keep the load lead junction box accessible for service and inspection Note Keep the load lead circuit away from the generator fuel and exhaust system components Note Use field supplied wiring capable of withstanding temperatures of 75 C 167 F Connectthe neutral ofthe AC circuit in the vehicle to the lead LO white or gray Ifthe vehicle uses equipment ground type plugs and receptacles 3 pronged connectthe green wire to the U shaped pin On vehicles that also have provisions for using an outside AC power source completely isolate the neutral as well as the hot black leads from the generator set when switching power to the outside source See Figure 6 1 Electrical System 11 Note Transfer switch Use atriple pole double throw transfer switch rated for the calculated load ofthe vehicle to transfer the load from one source to the other Install a ground fault circuit interrupter in the wiring system to protect all branch circuits Note AC load circuit protection Protectthe AC load circuit ofthe generator set against overloading or short circuiting with a circuit breaker s AC Vehicle Circuit Ground Fault
13. cal ehh heh hn 11 6 1 Electrical Connections e n 11 6 2 AC Load Lead lt 11 6 39 Circuit Protectioni rt ARA LR A reden 13 6 3 1 Circuit Breaker Considerations 13 6 3 2 Circuit Breaker Installation 14 6 4 Battery and Connections rer nennen 15 6 5 Remote Switch Connection 16 Section 7 Installation Drawing sseeeeeeee een nennen nennen mnn 17 Section 8 Reconnection Adjustments nennen nennen nnn 19 8 1 Four Lead Reconnection 19 8 2 Voltage Regulation Adjustment 21 Appendix A Generator Selection and Wattage Requirements A 1 Appendix B Glossary of Abbreviations Hmm nenn A 2 TP 6034 10 02 Table of Contents Notes Table of Contents TP 6034 10 02 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and a
14. cal 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 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 pint positive temperature coefficient power takeoff polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier S sec second SI Systeme international d unites International System
15. ct 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 WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage 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 6034 10 02 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 when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment con
16. da phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 264 6422 Fax 65 264 6455
17. der or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times A WARNING 7 Re are 4 Hot engine exhaust system Can cause severe injury or death Do not work on the generator set until it cools Combustible materials Fire can cause severe injury or death A hot exhaust system can ignite adjacent combustible materials Do not locate electrical wiring fuel lines or combustible materials above the exhaust muffler Exercise caution when parking your vehicle to prevent the exhaust system and hot exhaust gases from starting grass fires Exhaust System 7 4 1 Planning Carefully planthe generator exhaust system to ensure a safe quiet installation Verify that the installation complies with all state and local requirements and applicable articles of the codes listed at the beginning of this manual 4 2 Clearance Requirements Kohler Co recommends a clearance of 38 mm 1 1 2 in between the exhaust system parts and the fuel system the electrical system and all combustible components to protect the generator set components and to avoid igniting adjacent combustible materials 8 Exhaust System 4 3 Exhaust Piping If Used Route the exhaust piping to maintain minimum clearances and to m
18. e Canadian Standards Association current transformer copper 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 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 data interchange emergency frequency relay for example exempli gratia electronic governor 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 estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft Ibs ft min 9 gal gen genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute g
19. ection 8 Attach stator leads 1 and 3 to LO Two pole circuit breaker with a dual voltage system example 120 240 volt 3 wire Attach stator leads marked 1 and 4 to the side of the circuit breaker marked LINE Do not use a jumper lead see Section 8 Attach stator leads 2 and 3 to LO Single pole circuit breaker with a single voltage system example 240 volt 2 wire Attach the stator lead marked 2 to the side of the circuit breaker marked LINE see Section 8 Bolt together leads 1 and 4 and tape the leads to insulate them from ground Attach the stator lead marked 3 to LO Connect the stator lead s used for neutral connection to the LO stud See illustrations in Section 8 Connect the side of the circuit breaker marked LOAD to the transfer switch or vehicle Attach insulation boots to the black leads if the kit includes insulation boots With a single pole circuit breaker use one black lead L1 With a two pole circuit breaker use two black leads L1 and L2 Connect the neutral white lead to the LO stud Connect the equipment ground green lead to the GRD stud Replace the controller cover or circuit breaker box access panel Reconnect the generator set engine starting battery negative lead last For voltage or frequency adjustments refer to the procedure in Section 8 2 TP 6034 10 02 6 4 Battery and Connections A WARNING Sulfuric acid in batteries Can cause severe injury or death Use pro
20. ectrician or technician install circuit breakers and reconnect the generator set Comply with all governing standards and codes WARNING Qe AS x 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 TP 6034 10 02 Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator setasfollows 1 Placethe generator set start stop switch in the STOP position 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch A 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 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 electrically ground the generator set transfer switch
21. en Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system TP 6034 10 02 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 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
22. enerator set operational e Attach the exhaust system e Add radiator coolant e Add oil to the engine crankcase until the dipstick indicates full e Connect the fuel line e Connect the remote switch if equipped e Connect the load leads e Connect the battery terminals Introduction 1 Notes 2 Introduction TP 6034 10 02 2 1 General Considerations Consider the following items concerning the generator set and Section 2 2 for the proposed location 1 Selecta generator set having adequate capacity to handle the electrical load 2 Design the fuel system to prevent fuel starvation of the main or generator set engine 3 Ensure that the exhaust system meets all safety requirements after installation 4 Ensure compatibility of all electrical systems battery load and remote switch with the vehicle s electrical systems 2 2 Location Note This generator set is not designed for installation a compartment or enclosure Before making final plans for locating the generator set ensure the following 1 The location has sufficient room to maintain required minimum clearances 2 The location provides enough air flow to allow required cooling and combustion 3 The location can support the generator set weight 4 The location provides ample room for routine service of the generator set s engine controller cooling system and fuel system components See the current generator set specification sheet or
23. ent 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 Ill and PowerBoost V voltage regulator models only Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building campground electrical system only through an approved device and after the building campground main switch is opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a transfer switch to prevent interconnection of the generator set power and other sources of power Safety Precautions and Instructions III Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes andfollowthe instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to
24. essure gauge if equipped e Water temperature gauge if equipped e Battery voltage e Hourmeter e Start Stop switch including run light Available panels e Start Stop switch with hourmeter e Start Stop switch with hourmeter and battery voltage e Start Stop switch with hourmeter battery voltage water temperature and oil pressure One end ofthe 38 1 cm 15 in P3 wiring harness plugs directly into the controller The pigtail leads on the remaining end of the harness connect to the remote panel terminals via customer supplied wiring Connect the remote operating controls to the P3 wire harness lead See the wiring diagram in the operation manual to identify the P3 harness connections TP 6034 10 02 Section 7 Installation Drawing 3S0H o l 19219 437NDI3NI 9911 ezi Am BRO Q9 x6 As Juil 4TIOHINOO 40 NO HO LOSNNOO H313W ONY dOLS LYVLS 310N3H NOLLV907 LINDY 1vNOlLdO 43TIOYLNOO JO NO YOLOANNOD QV31 GVOT YINOLSNO HOLIMS dOLS LUVLS NOLLYT Y LSNI H3 13V TYNOL4O ISOH a l 827 01 10 110 M93H9 Ne LI7LNO LSNYHX3 892 96 92 eei ste NOLLO3NNO9 Adallva 3ALLVO3N 311109 LNVIOOO logar 0576 voc oot soc loozi soe 3NION3 40
25. gure 5 1 Two Dip Tubes in Fuel Tank Note Supply the fuel using a two dip tube arrangement if the generator shares the vehicle engine fuel tank Consult an authorized Kohler service distributor dealer for further fuel system installation information Fuel System 9 5 2 Fuel Lines Note Keep fuel lines away from the exhaust system Routing fuel lines Take care when routing the fuel line from the fuel tank to the generator set Keep the fuel lines as short as possible but maintain adequate clearance from the exhaust system Route the fuel lines along the frame or undercarriage never route the fuel lines inside the habitable area ofthe vehicle Locate the fuel lines with the entry point near the fuel pump See Section 5 3 for the fuel pump lift Sizing fuel lines Size the fuel line to handle the flow of fuel and to withstand road shock and year round climate conditions Use steel tubing as the codes require Use a 6 mm 1 4 in ID tubing with 230 mm 8 in minimum flexible section to allow free movement ofthe generator set Fuel line size Fuel inlet 6 mm 1 4 in ID Flexible hose sections If a metal fuel line draws fuel from the fuel tank install a flexible hose section to connect the metal line to the fuel pump The flexible section allows generator set vibrational motion during operation See Section 7 for the fuel inlet line connection point Note Gasoline fueled engines require a type A1 hose 10 Fuel System
26. hen 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 WARNING 4 d 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the 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 Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Il Safety Precautions and Instructions Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures
27. ility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes ofbreathing fresh air Installing the exhaust tail pipe Carbon monoxide can cause severe nausea fainting or death Install the exhaust system tail pipe to prevent the drawing of discharged exhaust gases into the vehicle interior through windows doors air conditioners and other openings Do not use flexible tail piping because it could crack and allow lethal exhaust fumes to enter the vehicle Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety ofthe vehicle s occupants install a carbon monoxide detector Consult the coach builder or dealer for approved detector location and installation Inspectthe detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times TP 6034 10 02 Fuel System WARNING er Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of childr
28. ine applications For marine installations use only generator sets specified for marine use USCG Regulation 33CFR183 requires that a generator set must be ignition protected when used in a gasoline fueled environment Safety Precautions and Instructions Notes VI Safety Precautions and Instructions TP 6034 10 02 All information in this publication represents data available atthe time of print Kohler Co reserves the right to change this literature and the products represented without incurring obligation The safe and successful operation of a mobile power system depends primarily on the installation Use this manual as a guide for installing the mobile generator set Refer to the operation manual for operating instructions 1 1 Mobile generator set installations must comply with the Kohler detailed installation instructions following and state and local requirements Installation Standards The installer is responsible for improper installations resulting in penalties from noncompliance with CARB or EPA emission standards 1 2 Generator Set Specifications Refer to the model s specification sheet for details Use the spec sheet as a guide for planning the installation Use the current dimension drawing and wiring diagrams TP 6034 10 02 Section 1 Introduction 1 3 Generator Set Operation After the installer attaches the generator set to the vehicle s frame and connects the hoses do the following to make the g
29. ing on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a transfer switch to prevent interconnection of the generator set power and other sources of power 6 1 Electrical Connections Have qualified electricians make connections Connections to the load leads battery and remote switch panel complete the installation To prevent unintentional starting make final connections to the battery only after making all other connections The following paragraphs provide details on each connection Refer also to the wiring diagram in the operation manual Securely support or harness all wiring to the generator set to prevent abrasion Provide additional support for the wiring to prevent exposure to the exhaust system and drippage of fuel oil or grease Allow at least a 51 mm 2 in clearance between the electrical wiring hot exhaust parts Do locate the wiring directly below or near the fuel system parts or the oil fill tube The following paragraphs cover some other points to consider when making AC load connections Note At the time of installation make the wiring connections accessible for inspection and service TP 6034 10 02 Section 6 Electrical System 6 2 AC Load Lead Connections Routing Each generator set has four color coded load leads The black leads L1 and L2 are hot the white lead LO is neutral
30. inimize exhaust piping bends Use a tail pipe as short as possible with as few bends as possible to reduce back pressure Design the exhaust piping to prevent excessive back pressure of the unit mounted muffler See Figure 4 1 for the allowable exhaust back pressure Do not apply weight or pressure to the unit mounted muffler otherwise premature exhaust system damage will occur Adding exhaust pipe extensions to the unit mounted muffler may cause excessive vibration and noise transmitted to the vehicle Allowable Exhaust Model Back Pressure 7ER lt 1 42 psi 1000 mm 20 Figure 4 1 Allowable Exhaust Back Pressure TP 6034 10 02 A WARNING HH W Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do notreplace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line b
31. ion 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 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permit flames 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 servicingthe 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 connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Safety Precautions and Instructions 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 w
32. it is 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 TP 6034 10 02 Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer TP 6034 10 02 NOTICE Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt 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 NOTICE This generator set does not comply with United States Coast Guard USCG requirements and must not be used for mar
33. n Cable Size AWG Generator Set At 18 C AtO C At 24 C and Battery m ft 0 F 32 F 75 F 12 2 40 0 1 9 1 7 6 6 1 4 6 3 0 15 0 8 Figure 6 3 Battery Cable Size Cable connections See Section 7 for the battery positive and negative connection points Refer to Figure 6 4 View A for cable connections Note that installers must connect a ground strap between the ground lug on the generator set and the frame of the vehicle with this arrangement For installations where the starting battery for the vehicle engine must also be used for starting the generator engine ground the negative battery terminal to the vehicle frame and connect a heavy gauge 4 ground strap to the ground lug on the generator set to the vehicle frame as illustrated in Figure 6 4 View Note Ensure a ground connection between the generator and the vehicle frame even if the battery used to startthe generator isnotthe same as the vehicle Electrical System 15 Using a Separate Battery for the Generator Set Battery Positive Vehicle Frame Using the Same Battery as the Vehicle Engine Battery Positive 12 Volt Battery View B Ground Strap Vehicle Frame Battery Negative to Vehicle Frame Figure 6 4 Battery Connection Details 16 Electrical System 6 5 Remote Switch Connection Controllers include an accessory plug P3 for easy connection of the remote switch to the following e Oil pr
34. nd electric water heaters Except for the resistance type loads such as the water heater the requirements for appliances are usually low Do not overlook such loads when figuring the total requirements Allow a reserve capacity for anticipated appliance loads to avoid overloading a generator set Lighting Load To calculate the lighting load add the wattage of each generator set operated lamp Note that not all of the lights or lamps are on the generator set AC circuit some are DC powered by a 12 volt battery Ensure that the calculated total wattage includes only lights actually on the generator set AC circuit Air Conditioners The starting characteristics of air conditioners vary greatly for example one 12 000 Btu unit has lower starting requirements than a 10 000 Btu unit of another variety When using only one unit there is usually no starting problem provided that the lighting and appliance load is not too high when starting the generator set Simultaneous starting of two air conditioning units however can present problems if the generator set capacity is marginal Because of the variation in starting characteristics among air conditioners this publication makes no statements regarding multiple motor starting capabilities of the generator set covered Consider delayed starting or the use of easy starting devices on air conditioner units whenever simultaneously starting more than one motor See Figure 2 for typical air co
35. nditioner requirements The requirements vary among different manufacturers Air Conditioner Size Btu 9 000 12 000 16 000 Voltage 115 230 115 230 115 230 Full load amps 9 9 5 0 11 8 6 3 16 3 8 0 Rated load amps 7 0 3 5 8 9 4 8 13 0 6 2 Locked rotor amps 50 0 31 0 75 0 36 0 Starting inrush watts 5750 7130 8630 8280 Running watts 1020 1100 1500 1430 Figure 2 Typical Air Conditioner Requirements 60 Hz TP 6034 10 02 Appendix A 1 Appendix B Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV AHWT AISI ALOP alt AI ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCW CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing 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 American Petroleum Institute approximate approximately as required as requested as supplied as stated as sugges
36. nected to the set disable the generator set as follows 1 Place the generator set start stop switch in the STOP position 2 Disconnectthe power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery 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 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 Seekimmediate medical aid inthe 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 solut
37. of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s Sq square 54 cm square centimeter Sq in square inch SS stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w with without wt weight xfmr transformer Appendix A 3 TP 6034 10 02a 1998 2001 and 2002 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 Cana
38. operate automatically 600 volts and under Hot Parts WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with athick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank ifthe generator set has a coolant recovery tank IV Safety Precautions and Instructions 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 Combustible materials Fire can cause severe injury or death A hot exhaust system can ignite adjacent combustible materials Do not locate electrical wiring fuel lines or combustible materials above the exhaust muffler Exercise caution when parking your vehicle to prevent the exhaust system and hot exhaust gases from starting grass fires Combu
39. operating generator set Hazardous Voltage Electrical Shock 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 WARNING Hazardous voltage Backfeed to the utility system can cause severe injury death or property damage Connect the generator set to the buildings electrical system only through an approved device and after the building s main switch is opened 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 electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution 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 repairs Remove all jewelry before servicing the equipment Testing the voltage regulator Hazardous voltage can cause severe injury or death High voltage is pres
40. ovides a 5 volt adjustment range Reconnection Adjustments 21 See Figure 8 5 to identify the potentiometers on the PowerBoost voltage regulator Stabilizer Potentiometer Pot Fine tunes the regulator circuitry to reduce light flicker Voltage Adjustment Potentiometer Pot Adjusts the generator voltage output within a range of approximately 100 130 volts Volts Hz Potentiometer Pot Determines the engine speed Hz at which the generator output voltage begins to drop Note For optimum results apply full load for voltage regulator adjustment Voltage Regulator Adjustment Procedure 1 With the generator set off turn the remote rheostat if equipped to midpoint 2 Turn voltage volts Hz and stability pots fully counterclockwise 3 Connectthe voltmeter and frequency meter to the AC circuit or an electrical outlet 4 Start the generator set 5 Rotate the voltage adjustment clockwise to increase the voltage counterclockwise to decrease the voltage to the desired output voltage 22 Reconnection Adjustments 10 11 12 13 14 Rotate the stability pot clockwise to minimize light flicker Readjust the voltage adjustment pot if necessary Adjust the engine speed to the desired cut in frequency factory setting 57 5 58 Hz for 60 Hz models as measured on the frequency meter Rotate the volts Hz adjustment pot clockwise until the voltage level as measured on voltmeter
41. per cubic feet LCB line circuit breaker LCD liquid crystal display Id shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 106 when used with SI units male m3 cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm MQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time between overhauls mtg mounting TP 6034 10 02 MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT pp PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electri
42. r an adapter flexible coupling and the operating equipment The mounting flange conforms to SAE J609a Flange B See Figure 2 1 for dimensions Note Customers must provide the adapter and flexible coupling for the extended shaft option Figure 2 2 Hydraulic Pump Note Adding a hydraulic pump drive lowers the engine horsepower available to drive the generator Therefore the engine can be overloaded Be aware of reduced generator output when powering external equipment 48 1 88 MOUNTING FLANGE TO END OF SHAFT 205 8 09 23 81 9375 0838 9365 SHAFT 1 256 KEYWAY 6 40 252 7 3 8 16 UNC 2B TAP 14 56 DEEP 4 HOLES 4146 08 45 751 0 146 02 02740 PILOT 165 06 500 ADV 6450 E Figure 2 1 Extended Shaft Dimensions Figure 2 2 shows a Kohler mobile generator set mounted to a hydraulic pump The generator set equipped with the extended shaft option can power external equipment to the limit of the engine s capacity Note The output shaft can pull max horsepower The extended shaft is designed for powering a direct driven hydraulic pump 4 Location and Mounting TP 6034 10 02 3 1 Air Requirements Air flow around the generator set is necessary for adequate cooling See the current generator set specification sheet for air requirements The air intake silencer cleaner p
43. rade gross equipment ground gross weight H x W x D 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 Ibs Inc ind int int ext 1 0 IP ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature 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 integrated 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 kilo 1000 kelvin kiloampere kilobyte 210 bytes TP 6034 10 02 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass
44. reakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system TP 6034 10 02 Section 5 Fuel System 5 1 Fuel Tank Fuel system design Design the generator set gasoline fuel system to operate independently of the vehicle engine fuel system if the operator may operate both engines simultaneously Kohler Co recommends using separate fuel tanks if possible using separate fuel tanks is usually impractical because of space restrictions In most installations both engines operate off a common tank with a separate dip tube arrangement as shown in Figure 5 1 The dip tube arrangement prevents the larger engine from starving the smaller engine of fuel The generator set dip tube is generally shorter than the vehicle dip tube to stop the generator set before the vehicle engine runs out of fuel With the dip tube arrangement the generator may not get fuel during a low fuel supply situation Tee arrangement Do not use the tee arrangement Do not tee into the fuel supply or return line of fuel injected systems 5605613 1 Fuel line to the generator set 2 Fuel line to the vehicle engine Fi
45. rovides combustion air to the engine See Figure 3 1 for allowable intake restriction The engine generator performance will be adversely affected ifthese guidelines are neglected Follow these guidelines to optimize generator set performance Model Normal Intake Restriction 7ER 0 03 psi 0 79 in H20 Figure 3 1 Intake Restriction TP 6034 10 02 Section 3 Cooling System 3 2 High Water Temperature Switch Each generator set includes a high water temperature shutdown switch that automatically shuts down the set if operating temperatures climb too high Follow the guidelines described in Section 3 1 to prevent shutdowns Cooling System 5 Notes 6 Cooling System TP 6034 10 02 Section 4 Exhaust System A WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building or vehicle Do not obstruct the exhaust outlet when parking your vehicle
46. stible materials Fire can cause severe injury or death A hot generator set can ignite debris in the compartment Keep the compartment and generator set clean and free of debris and combustible materials to minimize the possibility of fire Do not block the fuel oil drain opening in the generator set mounting tray Cut a corresponding hole in the subfloor if used for the drain opening Moving Parts A 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 A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place 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 Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator setengine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosenthe crankshaft hardware or rotorthruboltwhen making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware Servicing the generator set when
47. tective goggles and clothes Battery acid can cause permanent damage to eyes burn skin and eat holes in clothing 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 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 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 Starting battery A 12 volt separate battery is recommended for the generator set With a separate battery the battery can be installed closer to the generator set and the cable length can be minimized to eliminate voltage drop See Figure 6 2 for the minimum cold cranking amps CCA battery recommendation Model CCA 7ER 260 Figure 6 2 Battery Recommendation TP 6034 10 02 Lengths and sizes See Figure 6 3 for the lengths and recommended sizes of the battery cables Distance betwee
48. ted American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual 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 California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute A 2 Appendix CG CID CL cm CMOS cogen Com conn cont crit CRT CSA CT Cu cu in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tub
49. tion Adjustments 8 1 Four Lead Reconnection The following drawings illustrate the reconnection of four lead generator sets In all cases conform to the National Electrical Code NEC NOTICE Voltage reconnection Affix a noticetothe generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer 100 120 Volt Configurations If the installation requires a factory two pole circuit breaker do not connect the load side terminals of the circuit breaker See Figure 8 1 If the installation requires a 100 120 volt 2 wire system use a single pole circuit breaker See Figure 8 2 When connecting stator phase leads together size the output lead L1 to handle the amperage Use a jumper lead on the line side of the circuit breaker to balance the load of the generator set TP 6034 10 02 LO Neutral LO Ground 2 ORD gt gt 12 Load side O O Two Pole Line Circuit Side Breaker O E Jumper Lead Figure 8 1 100 120 Volt 3 Wire Configuration LO Neutral LO gt gt GRD Ground gt gt L1 Load Side Single Pole Circuit Breaker 4 3 2 1 Stator Leads 60 Hz 50 Hz 100 120 Volt 100 120 Volt LO L1 100 120 Volt LO L2 100 120 Volt Figure 8 2 100 120 Volt 2 Wire Config
50. uration Factory Installed and Wired Reconnection Adjustments 19 100 120 200 240 Volt Configurations The 100 120 200 240 volt configuration does not use ajumper lead Ifthe unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 8 1 for location Select a two pole circuit breaker Application of two single pole circuit breakers does not conform to NEC requirements for supplying a 200 240 volt load even if the breakers are mechanically attached Leads Li and 12 are for different phases never connect them LO Neutral LO Ground 2 GRD Load Side O Two Pole Line Circuit Side Breaker 100 120 200 240 Volt 4 3 2 1 3Wire Stator Leads 60 Hz 50 Hz LO L1 100 120 Volt 100 120 Volt LO L2 100 120 Volt 100 120 Volt L1 L2 200 240 Volt 200 240 Volt Figure 8 3 100 120 200 240 Volt 3 Wire Configuration 20 Reconnection Adjustments 200 240 Volt Configurations The 200 240 volt configuration does not use a jumper lead If the unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 8 1 for location LO Neutral LO OGround GRD gt 11 Load Side O Line Single Pole Side Circuit Breaker gt Tape to insulate from ground Sow er d 200 220 240 Volt Stator Leads 2 Wire 60 Hz 50 Hz LO L1 not used 200 220 240 Volt Figure 8 4 200 2
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