Page 2 - WARNING; California Proposition 65; Product Identification Information; Generator Set Identification Numbers
Engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm. WARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts.Record the product identification...
Page 4 - Table of Contents, continued
Table of Contents, continued TP-5700 7/93 Table of Contents Section 7 Electrical Requirements 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Batteries 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - Safety Precautions and Instructions; Accidental Starting; Battery
TP-5700 7/93 I Safety Precautions and Instructions Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS . Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger when improperly installed...
Page 6 - Exhaust System; Fuel System
TP-5700 7/93 II Safety Precautions and Instructions Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injuryand/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove wristwatch, rings, and other jewelry ...
Page 7 - Hazardous Noise
TP-5700 7/93 III Safety Precautions and Instructions The fuel system. Explosive fuel vapors can cause severe injury ordeath. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe r...
Page 9 - Heavy Equipment
TP-5700 7/93 V Safety Precautions and Instructions Servicing the transfer switch controls and accessories within theenclosure. Hazardous voltage cancause severe injury or death. Disconnect the transfer switch controlsat the inline connector to deenergizethe circuit boards and logic circuitry butallo...
Page 10 - Notice
TP-5700 7/93 VI Safety Precautions and Instructions Notice NOTICE This generator set has been rewired from its nameplate voltageto 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnectingthe set to a voltage different from thevoltage on the nameplate. Order voltage ...
Page 11 - Introduction
TP-5700 7/93 i Introduction Introduction This manual provides installation instructions for20--2800 kW generator sets. Operation manuals andwiring diagram manuals are available separately. x:in:001:001 Information in this publication represents data availableat the time of print. Kohler Co. reserves...
Page 13 - Section 1 General
TP-5700 7/93 1 Section 1 General Section 1 General Industrial power systems give years of dependableservice if installed using the guidelines provided in thismanual and in applicable codes. Incorrect installationcan cause continuing problems. Figure 1-1 illustrates atypical installation. Your author...
Page 15 - Section 2 Load and Transport; Lifting the Generator Set
TP-5700 7/93 3 Section 2 Load and Transport Section 2 Load and Transport To ensure personal safety while preventing damage tothe product, we strongly recommend the followingguidelines be observed when loading and transportingstandby generator sets. Due to the different designs,dimensions and weights...
Page 17 - Weather Housing; Subbase Fuel Tank; Transporting the Generator Set
TP-5700 7/93 5 Section 2 Load and Transport D Do not attach lifting hooks to outside reinforcing plate on skid. Attach lifting hooks to skid exactly as shown in Figure 2-4. This method utilizes thestrongest portion of the mounting skid and alsoprevents the lifting hooks from slipping. Generatorswith...
Page 18 - Notes
Page 19 - Section 3 Location
TP-5700 7/93 7 Section 3 Location Section 3 Location 3.1 Location Factors Location is the key to a proper installation. The followingsections will deal with the factors to consider in a properinstallation. Before final plans are made for locating agenerator set, the following questions should be rai...
Page 21 - Vibration Isolation
TP-5700 7/93 9 Section 3 Location The composition of the mounting pad should followstandard practice for the required loading. Commonspecifications call for 2500-3000 psi (176-211 kg/cm 2 ) concrete reinforced with eight-gauge wire mesh ornumber 6 reinforcing bars on 12-inch (30-cm) centers.The tota...
Page 23 - Section 4 Air Requirements
TP-5700 7/93 11 Section 4 Air Requirements Section 4 Air Requirements 4.1 General An ample flow of clean, cool air is required to supportcombustion and dissipate heat. Approximately 70% ofthe heat value of fuel consumed by an engine will berejected to the cooling system and exhaust. Battery compartm...
Page 26 - Cooling System
TP-5700 7/93 14 Section 4 Air Requirements 4.4 Air-Vac Cooling System The air flow direction with the Air-Vac system is the opposite of the conventional forced air cooling system.Use the Air-Vac system in confined areas since it includes a blower scroll which easily connects to theductwork. Fo...
Page 29 - Remote Radiator Cooling
TP-5700 7/93 17 Section 4 Air Requirements The connection from the radiator duct flange to theductwork should be heavy canvas, silicone or similarflexible material to prevent noise and vibrationtransmission. Sheet metal ductwork should be self-supporting. In general, the outlet duct should havean un...
Page 30 - City Water Cooling
TP-5700 7/93 18 Section 4 Air Requirements The engine water pump can be used to circulate waterthrough the remote radiator providing that the verticaldistance from the engine water pump does not exceed theengine manufacturer’s recommendations. The allowablestatic head may range from 17-50 feet (5.2-...
Page 32 - Recommended Coolant
TP-5700 7/93 20 Section 4 Air Requirements 4.11 Block Heaters Block heaters are recommended on all standbyapplications where the generator is subject to temperatures below 60 ° F (16 ° C) and are available as installed accessories on all generator sets. The blockheater should be connected to a sourc...
Page 33 - Section 5 Exhaust System
TP-5700 7/93 21 Section 5 Exhaust System Section 5 Exhaust System Proper installation of the exhaust system is essential toobtain satisfactory performance from a generator set.The most important factor is that the installed systemmust not exceed the engine manufacturer’s maximumexhaust back pressure...
Page 37 - Section 6 Fuel Systems; Diesel Fuel Systems
TP-5700 7/93 25 Section 6 Fuel Systems Section 6 Fuel Systems When planning an installation, check state and localregulations regarding fuel storage and handling. Piping andfuel system components must conform to these regulations. 6.1 Diesel Fuel Systems Since diesel fuel is less volatile than gas o...
Page 40 - Auxiliary Fuel Pumps
TP-5700 7/93 28 Section 6 Fuel Systems 6.5 Auxiliary Fuel Pumps Engine-driven fuel transfer pumps usually develop amaximum of 7 psi (48 kPa) pressure and have a liftcapacity of 4-6 feet (1.2-1.8 m). Even if the engine pumpcan draw fuel a greater distance, a more reliable systemresults if a transfer ...
Page 41 - Gasoline Fuel Systems
TP-5700 7/93 29 Section 6 Fuel Systems 6.6 Gasoline Fuel Systems Due to code restrictions which do not allow storage ofmore than one gallon (3.8 L) of gasoline inside abuilding, gasoline fuel systems are usually limited tohoused generator sets installed outdoors or portabletrailer-mounted units. Gas...
Page 42 - Natural or LP Gas Fuel
TP-5700 7/93 30 Section 6 Fuel Systems 6.7 Natural or LP Gas Fuel Systems Natural and LP (liquified petroleum) gas fuel systemsshould be designed and installed in accordance with therequirements of NFPA 54, National Fuel Gas Code, andall applicable local codes. Various types of gas fuelsystems are a...
Page 44 - Flexible Connector
TP-5700 7/93 32 Section 6 Fuel Systems 6.8 Flexible Connector An approved flexible connector should always be usedbetween stationary gas piping and the engine-mountedfuel system components. It should be at least six inches(15.3 cm) long or as recommended by the generatorsupplier based upon engine sp...
Page 45 - LP Gas Fuel Characteristics; Liquid Withdrawal Systems
TP-5700 7/93 33 Section 6 Fuel Systems 6.11 LP Gas Fuel Characteristics LP gas is supplied as a liquid in pressure tanks. It iseasily adaptable to stationary applications wherecomplete independence of an outside fuel supply isrequired. Since LP gas does not deteriorate in longperiods of storage as g...
Page 48 - Electrical Connections; Load Lead Connections
TP-5700 7/93 36 Section 7 Electrical Requirements 7.2 Electrical Connections Several electrical connections must be made betweenthe generator set and other components of the systemfor proper operation. Because of the large number ofaccessories and possible combinations, this manualdoes not address s...
Page 49 - Terminal Connector Torque
TP-5700 7/93 37 Section 7 Electrical Requirements 7.4 Terminal Connector Torque Use the torque values shown in Figure 7-4 or Figure 7-5for terminal connectors. Refer to UL-486A, UL-486B,and UL-486E for information on terminal connectors foraluminum and/or copper conductors. See Section 7.2,Electrica...
Page 50 - Automatic Transfer Switches
TP-5700 7/93 38 Section 7 Electrical Requirements 7.5 Automatic Transfer Switches A typical standby system has at least one automatictransfer switch connected to the generator set output toautomatically transfer the electrical load to thegenerator set if the normal source fails. When normalpower ret...
Page 51 - Remote Emergency Stop
TP-5700 7/93 39 Section 7 Electrical Requirements 7.9 Remote Emergency Stop Switch The emergency stop switch allows immediate shutdownof the generator from a remote location. If theemergency stop switch is activated, the emergency stoplamp on the generator controller lights and the unit shutsdown im...
Page 53 - Appendix A Abbreviations
TP-5700 7/93 Appendix A-1 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimension...
