Installation

Residential Generator Sets

Models:
15RESA
30RESA

TP-6725 11/09
 California Proposition 65

WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts. Controller Identification

Record the product identification numbers in the spaces
Record the controller description from the generator set
below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Controller Description
kits.
Engine Identification
Generator Set Identification Numbers
Record the product identification information from the
Record the product identification numbers from the engine nameplate.
generator set nameplate(s).
Manufacturer
Model Designation
Model Designation
Specification Number
Serial Number
Serial Number

Accessory Number Accessory Description

2 TP-6725 11/09
 Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 Enclosed Generator Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Unit-Mounted Radiator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.1 Cooling System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3.2 Recommended Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.2 Gas Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.1 Line Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.3 Load Lead Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.4 Ground and Neutral Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.5 Terminal Connector Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.6 Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.7 Alternator Factory Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5.8 Automatic Transfer Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 2 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.1 Location Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.2 Mounting Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.3 Vibration Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.4 Lifting Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.1 Prepare Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.2 Mount and Ground Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.3 Connect AC and DC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.4 Install Engine Starting Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.5 Install and Connect Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.6 Fuel Conversion Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.7 Add Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.8 Operation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Common Fault and Run Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Remote Digital Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Block Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5 Oil Makeup Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 OnCue Home Generator Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 4 Controller ....................................................................... 27
4.1 Advanced Digital Control (ADC 2100) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 Code Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 Controller Automatic Power Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Controller Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5 Voltage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TP-6725 11/09 Table of Contents 3

Table of Contents, continued

Section 5 Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4 Table of Contents TP-6725 11/09

 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery gases. Explosion can cause
when reconnecting the battery. severe injury or death. Battery gases
DANGER can cause an explosion. Do not smoke
or permit flames or sparks to occur near
Disabling the generator set. a battery at any time, particularly when
Danger indicates the presence of a
Accidental starting can cause it is charging. Do not dispose of a
hazard that will cause severe
severe injury or death. Before battery in a fire. To prevent burns and
personal injury, death, or
working on the generator set or sparks that could cause an explosion,
substantial property damage.
connected equipment, disable the avoid touching the battery terminals
generator set as follows: (1) Move the with tools or other metal objects.
generator set master switch to the OFF Remove all jewelry before servicing the
WARNING
position. (2) Disconnect the power to equipment. Discharge static electricity
the battery charger. (3) Remove the from your body before touching
Warning indicates the presence of a battery cables, negative (--) lead first. batteries by first touching a grounded
hazard that can cause severe Reconnect the negative (--) lead last metal surface away from the battery. To
personal injury, death, or when reconnecting the battery. Follow avoid sparks, do not disturb the battery
substantial property damage. these precautions to prevent starting of charger connections while the battery
the generator set by an automatic is charging. Always turn the battery
transfer switch, remote start/stop charger off before disconnecting the
CAUTION switch, or engine start command from a battery connections. Ventilate the
remote computer. compartments containing batteries to
Caution indicates the presence of a prevent accumulation of explosive
hazard that will or can cause minor gases.
personal injury or property damage. Battery Battery electrolyte is a diluted
NOTICE sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
Notice communicates installation, WARNING can cause blindness and burn skin.
operation, or maintenance information
Always wear splashproof safety
that is safety related but not hazard
goggles, rubber gloves, and boots
related.
when servicing the battery. Do not
Safety decals affixed to the equipment open a sealed battery or mutilate the
in prominent places alert the operator battery case. If battery acid splashes in
or service technician to potential the eyes or on the skin, immediately
Sulfuric acid in batteries. flush the affected area for 15 minutes
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this with large quantities of clean water.
publication to improve operator Wear protective goggles and Seek immediate medical aid in the case
recognition. Replace missing or clothing. Battery acid may cause of eye contact. Never add acid to a
damaged decals. blindness and burn skin. battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.

TP-6725 11/09 Safety Precautions and Instructions 5

Battery short circuits. Explosion Combustible materials. A fire can Carbon monoxide symptoms.
can cause severe injury or death. cause severe injury or death. Carbon monoxide can cause severe
Short circuits can cause bodily injury Generator set engine fuels and fuel nausea, fainting, or death. Carbon
and/or equipment damage. vapors are flammable and explosive. monoxide is a poisonous gas present in
Disconnect the battery before Handle these materials carefully to exhaust gases. Carbon monoxide is an
generator set installation or minimize the risk of fire or explosion. odorless, colorless, tasteless,
maintenance. Remove all jewelry Equip the compartment or nearby area nonirritating gas that can cause death if
before servicing the equipment. Use with a fully charged fire extinguisher. inhaled for even a short time. Carbon
tools with insulated handles. Remove Select a fire extinguisher rated ABC or monoxide poisoning symptoms include
the negative (--) lead first when BC for electrical fires or as but are not limited to the following:
disconnecting the battery. Reconnect recommended by the local fire code or D Light-headedness, dizziness
the negative (--) lead last when an authorized agency. Train all D Physical fatigue, weakness in
reconnecting the battery. Never personnel on fire extinguisher joints and muscles
connect the negative (--) battery cable operation and fire prevention D Sleepiness, mental fatigue,
to the positive (+) connection terminal procedures. inability to concentrate
of the starter solenoid. Do not test the or speak clearly, blurred vision
battery condition by shorting the D Stomachache, vomiting, nausea
terminals together. Exhaust System If experiencing any of these symptoms
and carbon monoxide poisoning is
Battery acid cleanup. Battery acid possible, seek fresh air immediately
can cause severe injury or death. WARNING and remain active. Do not sit, lie down,
Battery acid is electrically conductive or fall asleep. Alert others to the
and corrosive. Add 500 g (1 lb.) of possibility of carbon monoxide
bicarbonate of soda (baking soda) to a poisoning. Seek medical attention if
container with 4 L (1 gal.) of water and the condition of affected persons does
mix the neutralizing solution. Pour the not improve within minutes of breathing
neutralizing solution on the spilled Carbon monoxide. fresh air.
battery acid and continue to add the Can cause severe nausea,
neutralizing solution to the spilled fainting, or death.
battery acid until all evidence of a Fuel System
chemical reaction (foaming) has The exhaust system must be
ceased. Flush the resulting liquid with leakproof and routinely inspected.
water and dry the area.
WARNING
Generator set operation. Carbon
monoxide can cause severe nausea,
Engine Backfire/Flash fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
Fire nonirritating gas that can cause death if
inhaled for even a short time. Avoid
WARNING Explosive fuel vapors.
breathing exhaust fumes when working
Can cause severe injury or death.
on or near the generator set. Never
operate the generator set inside a Use extreme care when handling,
building. Never operate the generator storing, and using fuels.
set where exhaust gas could seep
Fire. inside or be drawn into a potentially
The fuel system. Explosive fuel
Can cause severe injury or death. occupied building through windows, air vapors can cause severe injury or
intake vents, or other openings. death. Vaporized fuels are highly
Do not smoke or permit flames or
sparks near fuels or the fuel system. Carbon monoxide detectors. explosive. Use extreme care when
handling and storing fuels. Store fuels
Carbon monoxide can cause severe
in a well-ventilated area away from
Servicing the fuel system. A flash nausea, fainting, or death. Install
spark-producing equipment and out of
fire can cause severe injury or death. carbon monoxide detectors on each
the reach of children. Never add fuel to
Do not smoke or permit flames or level of any building adjacent to the the tank while the engine is running
sparks near the carburetor, fuel line, generator set. Locate the detectors to because spilled fuel may ignite on
fuel filter, fuel pump, or other potential adequately warn the building’s contact with hot parts or from sparks.
sources of spilled fuels or fuel vapors. occupants of the presence of carbon Do not smoke or permit flames or
Catch fuels in an approved container monoxide. Keep the detectors sparks to occur near sources of spilled
when removing the fuel line or operational at all times. Periodically fuel or fuel vapors. Keep the fuel lines
carburetor. test and replace the carbon monoxide and connections tight and in good
Servicing the air cleaner. A sudden detectors according to the condition. Do not replace flexible fuel
backfire can cause severe injury or manufacturer’s instructions.
death. Do not operate the generator
set with the air cleaner removed.

6 Safety Precautions and Instructions TP-6725 11/09

lines with rigid lines. Use flexible Hazardous Voltage/ Grounding electrical equipment.
sections to avoid fuel line breakage Hazardous voltage can cause
caused by vibration. Do not operate the Moving Parts severe injury or death. Electrocution
generator set in the presence of fuel is possible whenever electricity is
leaks, fuel accumulation, or sparks. DANGER present. Ensure you comply with all
Repair fuel systems before resuming applicable codes and standards.
generator set operation. Electrically ground the generator set,
transfer switch, and related equipment
Explosive fuel vapors can cause and electrical circuits. Turn off the main
severe injury or death. Take circuit breakers of all power sources
additional precautions when using the before servicing the equipment. Never
following fuels: Hazardous voltage.
Will cause severe injury or death. contact electrical leads or appliances
Propane (LP)—Adequate ventilation when standing in water or on wet
is mandatory. Because propane is Disconnect all power sources before ground because these conditions
heavier than air, install propane gas opening the enclosure. increase the risk of electrocution.
detectors low in a room. Inspect the Disconnecting the electrical load.
detectors per the manufacturer’s Hazardous voltage can cause
instructions. WARNING severe injury or death. Disconnect
Natural Gas—Adequate ventilation is the generator set from the load by
mandatory. Because natural gas rises, turning off the line circuit breaker or by
install natural gas detectors high in a disconnecting the generator set output
room. Inspect the detectors per the leads from the transfer switch and
manufacturer’s instructions. heavily taping the ends of the leads.
Hazardous voltage. Moving parts. High voltage transferred to the load
Gas fuel leaks. Explosive fuel Can cause severe injury or death. during testing may cause personal
vapors can cause severe injury or Operate the generator set only when injury and equipment damage. Do not
death. Fuel leakage can cause an all guards and electrical enclosures use the safeguard circuit breaker in
explosion. Check the LP vapor gas or are in place. place of the line circuit breaker. The
natural gas fuel system for leakage by safeguard circuit breaker does not
using a soap and water solution with disconnect the generator set from the
the fuel system test pressurized to load.
6--8 ounces per square inch WARNING
(10--14 inches water column). Do not Welding on the generator set. Can
use a soap solution containing either cause severe electrical equipment
ammonia or chlorine because both damage. Before welding on the
prevent bubble formation. A successful generator set perform the following
test depends on the ability of the steps: (1) Remove the battery cables,
solution to bubble. Hazardous voltage. negative (--) lead first. (2) Disconnect
Backfeed to the utility system can all engine electronic control module
cause property damage, severe (ECM) connectors. (3) Disconnect all
Hazardous Noise injury, or death. generator set controller and voltage
regulator circuit board connectors.
If the generator set is used for (4) Disconnect the engine battery-
CAUTION standby power, install an automatic charging alternator connections.
transfer switch to prevent inadvertent (5) Attach the weld ground connection
interconnection of standby and close to the weld location.
normal sources of supply.
Installing the battery charger.
Hazardous voltage can cause
severe injury or death. An
Hazardous noise. CAUTION ungrounded battery charger may
Can cause hearing loss. cause electrical shock. Connect the
battery charger enclosure to the ground
Never operate the generator set of a permanent wiring system. As an
without a muffler or with a faulty alternative, install an equipment
exhaust system. grounding conductor with circuit
Welding the generator set. conductors and connect it to the
Engine noise. Hazardous noise can Can cause severe electrical equip- equipment grounding terminal or the
cause hearing loss. Generator sets ment damage. lead on the battery charger. Install the
not equipped with sound enclosures battery charger as prescribed in the
can produce noise levels greater than Never weld components of the equipment manual. Install the battery
105 dBA. Prolonged exposure to noise generator set without first discon- charger in compliance with local codes
levels greater than 85 dBA can cause necting the battery, controller wiring and ordinances.
permanent hearing loss. Wear hearing harness, and engine electronic con-
protection when near an operating trol module (ECM).
generator set.

TP-6725 11/09 Safety Precautions and Instructions 7

Connecting the battery and the Hot Parts
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly, WARNING
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Hot coolant and steam.
Short circuits. Hazardous Can cause severe injury or death.
voltage/current can cause severe
injury or death. Short circuits can Before removing the pressure cap,
cause bodily injury and/or equipment stop the generator set and allow it to
damage. Do not contact electrical cool. Then loosen the pressure cap
connections with tools or jewelry while to relieve pressure.
making adjustments or repairs.
Remove all jewelry before servicing the
equipment. WARNING
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the Hot engine and exhaust system.
electrical outlet before working on the Can cause severe injury or death.
block heater electrical connections.
Do not work on the generator set until
Electrical backfeed to the utility. it cools.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection WARNING
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines. Hot engine oil.
Can cause severe injury or death.
Heavy Equipment Avoid skin contact with hot oil. Do not
start or operate the generator set with
the engine oil filler cap removed, as
WARNING hot oil can spray out. Ensure that the
lubrication system is not under pres-
sure when servicing. Do not work on
the generator set until it cools.

Servicing the exhaust system. Hot

Unbalanced weight.
parts can cause severe injury or
Improper lifting can cause severe
death. Do not touch hot engine parts.
injury or death and equipment
The engine and exhaust system
damage.
components become extremely hot
Do not use lifting eyes. during operation.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid. Notice
NOTICE
Canadian installations only. For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

8 Safety Precautions and Instructions TP-6725 11/09

 Introduction

This manual provides installation instructions for 15 and Literature Type Part Number
30 kW residential generator set models listed on the
Operation Manual (Generator) TP-6726
front cover. Operation manuals are available
separately. Parts Catalog* TP-6319
Service Manual (Engine) TP-6724
Information in this publication represents data available
Service Manual (Generator Set) TP-6198
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented Wiring Diagram Manual (Generator Set) TP-6719
without notice and without any obligation or liability * One Parts Catalog combines generator and engine
whatsoever. information.

Read this manual and carefully follow all procedures Figure 1 Related Literature
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
Warranty Registration
beginning of this manual. Keep this manual with the
equipment for future reference. Complete the startup and installation checklists
supplied with the startup notification form. Complete
and sign the startup notification form and return copies
List of Related Materials to an authorized Kohler distributor/dealer as instructed
on the form.
Figure 1 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.

TP-6725 11/09 Introduction 9

Service Assistance

For professional advice on generator power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest authorized Kohler distributor/dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 Phone: (863) 619-7568
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

10 Service Assistance TP-6725 11/09

 Section 1 General

1.1 Introduction 1.4 Fuel Supply

Review this section and the Safety Precautions before Gas fuel systems operate on either LP (liquefied
starting the installation procedure. The generator set petroleum) or natural gas. Refer to the generator set
specification sheet also contains data that may be specification sheet and Section 2.2.5 for more detailed
required during the installation process. information on fuel requirements.

The generator set and accessories must be installed by Note: Design and install gas fuel systems in
an authorized Kohler distributor/dealer or authorized accordance with NFPA-54, National Fuel Gas
representative. The installation must comply with all Code, and applicable local codes.
applicable national and local codes.
1.4.1 Fuel Lines
1.2 Enclosed Generator Sets Gas lines. Never use fuel piping to ground electrical
Install the generator set outdoors. Enclosed generator equipment. The gas supplier is responsible for
sets include a factory-supplied sound enclosure. The installation, repair, and alteration to gas piping.
exhaust systems of enclosed units are complete for
Use Schedule 40 black-iron pipe for gas piping. Copper
outdoor installations. Review Section 1 and then refer to
tubing may be used if the fuel does not contain hydrogen
Section 2 for the outdoor installation of enclosed units.
sulfide or other ingredients that react chemically with
Note: DO NOT install enclosed units inside a copper.
building.
Line size. Size piping according to the requirements of
the equipment. Refer to the the instructions in
1.3 Unit-Mounted Radiator Cooling Section 2.2.5. In addition to actual fuel consumption,
consider the following pressure loss factors:
The generator set is equipped with a unit-mounted D Pipe length
radiator common cooling system.
D Other appliances on the same fuel supply
D Number of fittings
1.3.1 Cooling System Features
Flexible connections. Rigid mount the piping but
The system’s major components include an engine- protect it from vibration. Use flexible connections
driven fan and circulating water pump, a radiator, and a spanning a minimum of 152 mm (6 in.) between the
thermostat. The pump circulates water through the stationary piping and the engine fuel inlet connection.
engine until it reaches operating temperature. Then the
engine thermostat opens, allowing water circulation
through the radiator. The thermostat restricts water flow
as necessary to prevent overcooling. The fan blows air
from the engine side of the radiator across the cooling
surface.

1.3.2 Recommended Coolant

Add antifreeze before starting the generator set or
energizing the block heater.

The generator set manufacturer recommends a solution

of 50% ethylene glycol and 50% clean, softened water to
provide freezing protection to --37_C (--34_F) and
boiling protection to 129_C (256_F). A 50/50 solution
also inhibits corrosion. Consult the engine manufacturer’s
instructions for engine coolant specifications. See the
List of Related Materials in the Introduction.

TP-6725 11/09 Section 1 General 11

1.4.2 Gas Regulators 1.5.2 Electrical Connections
Gas regulators reduce high incoming fuel pressures to Several electrical connections must be made between
lower levels acceptable for engines. See the generator the generator set and other components of the system
set specification sheet for fuel supply pressure for proper operation. Most field-installed accessory kits
requirements. include installation instructions. Comply with applicable
national and local codes when installing a wiring system.
Primary gas regulator. The primary regulator reduces
the high pressure from a tank or transmission line to the Size the wire according to the length of run and 115% of
lower pressure required by the secondary regulator on the circuit current (amperage) as directed by the
the engine. The fuel supplier provides the primary National Electrical Coder (NEC) in ANSI/NFPA 70.
regulator. The fuel supplier is also responsible for
providing sufficient gas pressure to operate the primary For Canadian installations, refer to the Canadian
regulator. Electrical Code (CEC).

Secondary gas regulator. The secondary regulator is

factory-installed on the generator set engine and
1.5.3 Load Lead Connections
controls the inlet pressure to the engine. The models Feed load leads to the generator set junction box
covered by this manual use an electronic pressure through the nonservice side of the box. See Figure 1-1.
regulator. See Section 2.2.6. Route DC leads in separate conduit from AC
conductors.
Note: The Integrated Electronic Pressure Regulator
(IEPR) and air/fuel mixer are specially calibrated
emission-control devices. Do not adjust the IEPR
or the air/fuel mixer.

1.5 Electrical System 1

2
Before installing the generator set, provide for electrical
connections through conduit to the transfer switch and
other accessories for the generator set. Route DC leads
in separate conduit from AC conductors. Carefully
ADV-7692
install the selected generator set accessories. Route
wiring to the generator set through flexible connections. 1. Customer interface connector
2. Load lead access
Comply with all applicable codes when installing a wiring
system.
Figure 1-1 Load Lead Access (enclosure not
shown)
1.5.1 Line Circuit Breakers
AC circuit protection. All AC circuits must include
circuit breaker or fuse protection. If the generator set is
not equipped with a factory-installed circuit breaker,
select a circuit breaker for up to 125% of the rated
generator set output current. The circuit breaker must
open all ungrounded connectors. The circuit breaker or
fuse must be mounted within 7.6 m (25 ft.) of the
alternator output terminals.

The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.

12 Section 1 General TP-6725 11/09

1.5.4 Ground and Neutral Connections applicable national and local codes when installing a
wiring system.
Ground the generator set. The grounding method must
Note: If a connector has a clamp screw such as a
comply with NEC and local codes. Connect the
slotted, hexagonal head screw with more than
grounding strap to the generator set ground lug. See
one means of tightening, test the connector using
Section 2.2.2 for the ground lug location.
both applicable torque values provided in
Various regulations and site configurations including the Figure 1-3.
National Electrical Code (NEC), local codes, and the
type of transfer switch used in the application determine Socket Size Across Tightening Torque,
the grounding of the neutral at the generator. NEC 2002 Flats, mm (in.) Nm (in. lb.)
Section 250.20 is one example that has a very good 3.2 (1/8) 5.1 (45)
explanation of the neutral grounding requirements for 4.0 (5/32) 11.4 (100)
generators.
4.8 (3/16) 13.8 (120)
Generator sets are shipped with the generator neutral 5.6 (7/32) 17.0 (150)
attached to the generator in the junction box. At 6.4 (1/4) 22.6 (200)
installation, the neutral can be grounded at the 7.9 (5/16) 31.1 (275)
generator set or lifted from the ground stud and isolated 9.5 (3/8) 42.4 (375)
if the installation requires an ungrounded neutral 12.7 (1/2) 56.5 (500)
connection at the generator. The generator set will
14.3 (9/16) 67.8 (600)
operate properly with the neutral either bonded to
ground or isolated from ground at the generator. Note: For values of slot width or length not corresponding to
those specified, select the largest torque value
associated with the conductor size. Slot width is the
1.5.5 Terminal Connector Torque nominal design value. Slot length is to be measured at
the bottom of the slot.
Use the torque values shown in Figure 1-2 or Figure 1-3
for terminal connectors. Refer to UL-486A, UL-486B, Figure 1-2 Tightening Torque for Pressure Wire
and UL-486E for information on terminal connectors for Connectors with Internal-Drive
aluminum and/or copper conductors. Comply with Socket-Head Screws

Tightening Torque, Nm (in. lb.)

Wire Size for Unit Hexagonal Head—External
Connection Slot Head 4.7 mm (No. 10) or Larger* Drive Socket Wrench
Slot Width <1.2 mm (0.047 in.) Slot Width >1.2 mm (0.047 in.) Split-Bolt Other
AWG, kcmil (mm2) Slot Length <6.4 mm (0.25 in.) Slot Length >6.4 mm (0.25 in.) Connectors Connections
18--10 (0.82--5.3) 2.3 (20) 4.0 (35) 9.0 (80) 8.5 (75)
8 (8.4) 2.8 (25) 4.5 (40) 9.0 (80) 8.5 (75)
6--4 (13.3--21.2) 4.0 (35) 5.1 (45) 18.6 (165) 12.4 (110)
3 (26.7) 4.0 (35) 5.6 (50) 31.1 (275) 16.9 (150)
2 (33.6) 4.5 (40) 5.6 (50) 31.1 (275) 16.9 (150)
1 (42.4) — 5.6 (50) 31.1 (275) 16.9 (150)
1/0--2/0 (53.5--67.4) — 5.6 (50) 43.5 (385) 20.3 (180)
3/0--4/0 (85.0--107.2) — 5.6 (50) 56.5 (500) 28.2 (250)
250--350 (127--177) — 5.6 (50) 73.4 (650) 36.7 (325)
400 (203) — 5.6 (50) 93.2 (825) 36.7 (325)
500 (253) — 5.6 (50) 93.2 (825) 42.4 (375)
600--750 (304--380) — 5.6 (50) 113.0 (1000) 42.4 (375)
800--1000 (406--508) — 5.6 (50) 124.3 (1100) 56.5 (500)
1250--2000 (635--1016) — — 124.3 (1100) 67.8 (600)
* For values of slot width or length not corresponding to those specified, select the largest torque value associated with the conductor size.
Slot width is the nominal design value. Slot length is to be measured at the bottom of the slot.
Note: If a connector has a clamp screw such as a slotted, hexagonal head screw with more than one means of tightening, test the
connector using both applicable torque values.

Figure 1-3 Tightening Torque for Screw-Type Pressure Wire Connectors

TP-6725 11/09 Section 1 General 13

1.5.6 Battery Chargers 1.5.8 Automatic Transfer Switches
An engine-driven, battery-charging alternator charges A typical standby system has at least one automatic
the battery whenever the generator set operates. transfer switch connected to the generator set output to
Engine-driven systems can quickly restore the charge automatically transfer the electrical load to the
used in a normal cranking cycle. generator set if the normal source fails. When normal
power returns, the switch transfers the load back to the
When the engine is not operating, a very low charge rate normal power source and then signals the generator set
from an AC-powered battery charger is usually sufficient to stop.
to maintain a full charge on the batteries. Select an
automatic float/equalize battery charger with a 3 amp or The transfer switch uses a set of contacts to signal the
greater rating. engine/generator to start. When the normal source fails
and the generator set master switch is in the AUTO
Use separate, self-contained battery chargers or units position, the transfer switch contacts close to start the
built into the automatic transfer switch. Run leads from a generator set.
transfer switch-mounted battery charger in conduit
separate from the conduit that holds the generator load The engine start terminals are usually located near the
cables or remote engine-start circuits. transfer switch contactor with an engine start decal
identifying the terminals. Use the transfer switch wiring
diagrams to identify the engine start terminals prior to
1.5.7 Alternator Factory Connection making connections.
Figure 1-4 shows the factory connection for the
single-phase 120/240 V 60 Hz generator set. The Connect the transfer switch engine-start contacts or a
remote manual engine-start switch to the engine start
generator set is not reconnectable.
connectors on the generator set. Use the remote
harness with pigtail to connect to leads 3 and 4 from the
100--120/200--240V, 60Hz ADC 2100 generator set controller to the engine-start
leads from the ATS. Size the wire according to the
transfer switch connection and the length of run. Use
separate conduit for the DC engine-start leads and the
AC generator set load cables and battery charger leads.

ADV-5875A--

Figure 1-4 Single-Phase Factory Connection,

120/240 V 60 Hz

14 Section 1 General TP-6725 11/09

 Section 2 Installation Instructions

2.1 Introduction Grounding electrical equipment. Hazardous voltage can

cause severe injury or death. Electrocution is possible
Have the generator set installed by an authorized Kohler whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
distributor/dealer or authorized representative. Install
generator set, transfer switch, and related equipment and
the equipment in compliance with the National Electrical electrical circuits. Turn off the main circuit breakers of all
Code (NEC) and local codes. For Canadian power sources before servicing the equipment. Never contact
installations, refer to the Canadian Electrical Code electrical leads or appliances when standing in water or on wet
(CEC). ground because these conditions increase the risk of
electrocution.
Note: These instructions outline one procedure for
installing the generator set. Local codes may WARNING
require different procedures.

The generator set must be installed outdoors. The

exhaust systems on enclosed units are designed for
outdoor installation only. Review the information in
Section 1, General, before beginning the installation Carbon monoxide.
procedure. Can cause severe nausea,
fainting, or death.
Note: DO NOT install enclosed generator sets inside a
The exhaust system must be
building. leakproof and routinely inspected.

Note: Install carbon monoxide (CO) detector(s) on

Generator set operation. Carbon monoxide can cause
each level of any building adjacent to a generator
severe nausea, fainting, or death. Carbon monoxide is an
set. Locate the detectors to adequately warn the
odorless, colorless, tasteless, nonirritating gas that can cause
building’s occupants of the presence of carbon
death if inhaled for even a short time. Avoid breathing exhaust
monoxide. fumes when working on or near the generator set. Never
operate the generator set inside a building. Never operate the
Read and follow the safety precautions in this manual generator set where exhaust gas could seep inside or be
and observe the decals on the equipment. Refer to the drawn into a potentially occupied building through windows, air
diagrams and drawings in Section 5 for dimensions and intake vents, or other openings.
electrical connections during the installation procedure.
Read the entire installation procedure and obtain the Carbon monoxide detectors. Carbon monoxide can
accessories and tools needed before beginning cause severe nausea, fainting, or death. Install carbon
installation. Perform the steps in the order shown. monoxide detectors on each level of any building adjacent to
the generator set. Locate the detectors to adequately warn the
To install optional accessories, follow the instructions building’s occupants of the presence of carbon monoxide.
provided with each kit. Keep the detectors operational at all times. Periodically test
and replace the carbon monoxide detectors according to the
manufacturer’s instructions.
WARNING
2.1.1 Location Factors
Ideally, the generator set should be mounted on
concrete at ground level. For above-ground installations,
Hazardous voltage. including roof installations, weight considerations are
Backfeed to the utility system can especially important. The building engineer must
cause property damage, severe determine whether the structure can support the weight
injury, or death. of the generator set.
If the generator set is used for
standby power, install an automatic The location of the generator set must:
transfer switch to prevent inadvertent
interconnection of standby and D Support the weight of the generator set and related
normal sources of supply. equipment such as batteries, radiators, and mounting
pad(s). Keep in mind that the mounting pad weight
may exceed the weight of the generator set.

TP-6725 11/09 Section 2 Installation Instructions 15

D Meet applicable fire rating codes and standards. 2.1.4 Lifting Generator Set
D Position the generator set over a noncombustible
surface. DO NOT allow accumulation of combustible
WARNING
materials under or around the generator set.

D Permit vibration isolation to reduce noise and prevent

damage.

D Not be subject to flooding. Unbalanced weight.

Improper lifting can cause severe
D Provide clearance for cooling air flow and access for injury or death and equipment
service. See Section 2.2 for required clearances from damage.
obstructions and combustible materials.
Do not use lifting eyes.
D Allow safe expulsion of exhaust. Lift the generator set using lifting bars
inserted through the lifting holes on
D Minimize the risk of public or unauthorized access. the skid.

Enclosed units weigh approximately 500 kg (1100 lb.).

Notice Use equipment that is rated for the generator set’s
DO NOT locate the generator set near patios, weight to lift the unit into place. Lift the enclosure and
decks, play areas, or animal shelters. Keep items generator set together as one unit.
such as lawn furniture, toys, sports equipment,
and all combustible materials away from the DO NOT lift the generator set using the lifting eyes
generator set exhaust outlet. attached to the engine and/or alternator. These eyes
cannot support the generator set’s weight. Instead,
Remind family members, children, and visitors to insert lifting hooks or lifting bars through the four holes in
use caution near the generator set. Generator the mounting skid. The placement of the holes
sets connected to automatic transfer switches maintains balance during lifting.
start automatically during exercise periods and
power outages. Some generator set components
become hot when the generator set is running and 2.2 Installation Procedure
remain hot for a time after the generator set shuts
down. Tools Required:
D Multimeter (for measuring voltage and current)
2.1.2 Mounting Surface D Frequency meter (may be part of multimeter)
D Manometer (for measuring fuel pressure)
The manufacturer recommends a single, level concrete
D Torque wrench
mounting pad. This method provides maximum stability
for the generator set. The recommended mounting pad D Wrenches
dimensions are shown in the dimension drawings in D Screwdrivers
Section 5. D Socket wrenches or nut drivers
D Pliers
Refer to the generator set dimension drawings for
conduit and fuel-line placement. The drawings give D Safety glasses or goggles
dimensions for electrical and fuel connection rough-ins D Drill with bits and hole saw
and stub-ups.

2.1.3 Vibration Isolation

The generator set is equipped with neoprene vibration
isolators. Connections between the generator set or its
mounting base and any conduits or fuel lines must
include flexible sections to prevent breakage and to
isolate vibration.

16 Section 2 Installation Instructions TP-6725 11/09

Installer/Customer-Supplied Items: b. Spread a 76 mm (3 in.) thick layer of gravel to
D One 12-volt battery with a minimum rating of 525 cold support the concrete mounting pad. For the
cranking amps (CCA) at 0_F. mounting pad dimensions, see Figure 5-2 or
for weather enclosures or Figure 5-4 for sound
D Remote harness with pigtail connector
enclosures.
(to connect ATS engine start, if used)
D Gravel or crushed stone c. Lay a 100 mm (4 in.) thick concrete pad on the
D Concrete mounting pad gravel layer. Include mounting bolts and stub-
D Cables and conduit ups for the fuel supply and electrical conduit.
See Figure 5-2 or Figure 5-4 for the mounting
D Fuel supply line with shutoff valve and pipe sealant
pad dimensions, mounting bolts, and stub-up
(provided by fuel supplier)
locations.
D Carbon monoxide (CO) detector(s)

2.2.2 Mount and Ground Generator Set

Available Accessories:
D Air cleaner restriction indicator
1. Place the generator set on the concrete mounting
pad. Secure the generator set with mounting bolts
D Battery
anchored in the concrete pad.
D Battery charger
D Battery heater 2. Remove the enclosure doors and alternator-end
D Block heater panel to gain access to the junction box and other
generator set components during installation.
D Flexible fuel lines
D Maintenance kit (includes filters and belt) 3. Ground the generator set. The grounding method
D Natural gas strainer must comply with NEC and local codes. Connect
D Relay kit, includes common fault and auxiliary run
the grounding strap to the generator set ground
relays lug, terminal GRD inside the junction box. See
Figure 2-1.
D Remote digital gauge
D Remote harnesses
3
D Rodent guards 2

2.2.1 Prepare Site

1
Choose a location that is at least 0.9 m (3 ft.) from any
building or structure and near the incoming gas service.
Allow a minimum of 2.4 m (8 ft.) clearance beyond the 4
exhaust end of the generator set. Plan the installation so
that the exhaust end of the generator set is not directed 6
toward the building or any openings where exhaust gas
could be drawn into the building.

Install carbon monoxide detectors on each level of any

building adjacent to the generator set. Locate the 5 GM69195
detectors to adequately warn the building’s occupants of
the presence of carbon monoxide.
1. Neutral (L0) connection
1. Obtain a building permit and contact your local 2. Ground (GRD) connection
utility companies to mark the locations of 3. Relay interface board (RIB; standard 3--relay board shown)
underground pipes and cables. 4. Line circuit breaker location
5. Load lead access opening
2. Prepare an area for mounting the generator set. 6. Customer interface connector location

a. Clear all combustible materials, including Figure 2-1 Generator Set Junction Box
plants and shrubs, building materials, and lawn
furniture, from an area at least 2.4 m (8 ft.)
beyond the exhaust end of the generator set.

TP-6725 11/09 Section 2 Installation Instructions 17

 Generator sets are shipped with the generator set 3. Use separate conduit for the power cables and the
neutral attached to the generator set in the junction low voltage engine start leads. Local codes and the
box. At installation, the neutral can be grounded at length of run as well as the transfer switch wire size
the generator set or lifted from the ground stud and requirements will determine the wire size needed
isolated if the installation requires an ungrounded for the AC leads. Route the load leads into the
neutral connection at the generator set. The junction box through the access opening in the
generator set will operate properly with the neutral back of the box.
either bonded to ground or isolated from ground at
the generator set. 4. Connect the load leads from the line circuit breaker
in the generator set junction box to the transfer
Various regulations and site configurations switch emergency power connection points. See
including the National Electrical Code (NEC), local Figure 2-1 and refer to transfer switch installation
codes, and the type of transfer switch used in the manual for ATS connection instructions.
application determine the grounding of the neutral
at the generator set. NEC 2002 Section 250.20 is 5. Use the remote harness with pigtail connector at
one example that has a very good explanation of the customer interface connector to connect
the neutral grounding requirements for generator engine start leads 3 and 4 to the engine start
sets. terminals on the transfer switch. Refer to the
transfer switch installation manual for ATS
connection instructions.
2.2.3 Connect AC and DC Wiring
6. If an auxiliary fault switch is used, connect it to
Note: Have a licensed electrician make the following leads 30 and N at the customer interface
electrical connections. All connections must
connector.
comply with state and local codes.

Size the wire according to the length of run and 115% of Optional Run/Common Fault Relay Interface
the circuit current (amperage) as directed by the Board (RIB)
National Electrical Coder (NEC) in ANSI/NFPA 70. See
The optional Run/Common Fault Relay interface board
Figure 2-1 and refer to the wiring diagrams in Section 5,
(RIB) has five relays and a customer connection
Diagrams and Drawings.
harness. The standard RIB has three relays with no
Refer to Section 1.5 for additional information about customer connections required. See Figure 2-1 for the
connecting the electrical system. RIB location.

The common fault relay is energized on a fault. The

Load Lead and Engine Start Connections auxiliary run relay is energized when the generator set is
running. When a relay is energized, the normally open
1. Install a 120 VAC receptacle for the generator set
battery charger and block heater, if equipped. contacts close and the normally closed contacts open.
Supply power to the receptacle through a circuit
that is powered at all times, by the utility and by the
generator set during utility power outages.

2. Some codes require the use of a disconnect switch.

Check the code requirements for your location and
install a disconnect switch, if required.

18 Section 2 Installation Instructions TP-6725 11/09

Connect customer equipment to connector P24 on the Battery gases. Explosion can cause severe injury or
optional relay board harness. Use 16 gauge or larger death. Battery gases can cause an explosion. Do not smoke
leads for the relay connections. Connect to each relay’s 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
normally open or normally closed contacts depending
fire. To prevent burns and sparks that could cause an
on the requirements for the connected equipment. See explosion, avoid touching the battery terminals with tools or
Figure 2-2 and the manufacturer’s instructions for the other metal objects. Remove all jewelry before servicing the
connected equipment. equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
Lead P24 Pin away from the battery. To avoid sparks, do not disturb the
Number Number Connection battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the
88 6 Common fault relay normally open battery connections. Ventilate the compartments containing
89 2 Common fault relay common batteries to prevent accumulation of explosive gases.
90 3 Common fault relay normally closed
Use a 12 VDC battery with a minimum rating of
91 4 Run relay normally open 525 CCA.
92 1 Run relay common
1. Verify that the generator set master switch is in the
93 5 Run relay normally closed
OFF/RESET position.
Figure 2-2 Optional Relay Connections
2. Ensure that the starting battery is fully charged
before placing the battery in service.
2.2.4 Install Engine Starting Battery
3. Clean the battery posts and/or adapters if
WARNING necessary.

4. Install battery post adapters, if needed.

5. See the dimension drawing in Section 5 for the

battery rack location. Place the battery on the
Explosion. battery rack on the skid.
Can cause severe injury or death.
Relays in the battery charger 6. Connect the red battery cable to the positive (+)
cause arcs or sparks. battery terminal.
Locate the battery in a well-ventilated 7. Connect the black battery cable to the negative (--)
area. Isolate the battery charger from
explosive fumes.
battery terminal.

8. Place the boots over the battery terminals.

9. Plug the battery charger, if equipped, into the 120

VAC power supply.

TP-6725 11/09 Section 2 Installation Instructions 19

2.2.5 Install and Connect Fuel Supply 3. Measure the pipe length from the primary gas
pressure regulator to the pipe connection on the
generator set fuel inlet. Add 2.4 m (8 ft.) to the
WARNING measured length for each 90 degree elbow. Use
the pipe size indicated in Figure 2-4 for the total
length of pipe.

Pipe Size
Maximum Pipe
Length, m (ft.) 15 kW 30 kW
Explosive fuel vapors.
Can cause severe injury or death. 6.1 m (20 ft.) 3/4 in. NPT 1 1/4 in. NPT
9.1 m (30 ft.) 1 in. NPT 1 1/4 in. NPT
Use extreme care when handling,
storing, and using fuels. 18.3 m (60 ft.) 1 in. NPT 1 1/2 in. NPT
30.5 m (100 ft.) 1 1/4 in. NPT 1 1/2 in. NPT
The fuel system. Explosive fuel vapors can cause severe 45.7 m (150 ft.) 1 1/4 in. NPT 2 in. NPT
injury or death. Vaporized fuels are highly explosive. Use 61.0 m (200 ft.) 1 1/4 in. NPT 2 in. NPT
extreme care when handling and storing fuels. Store fuels in a
well-ventilated area away from spark-producing equipment Figure 2-4 Fuel Pipe Sizes
and out of the reach of children. Never add fuel to the tank
while the engine is running because spilled fuel may ignite on 4. Have your fuel supplier install a manual fuel shutoff
contact with hot parts or from sparks. Do not smoke or permit valve and rigid gas piping. Bring the pipe to within
flames or sparks to occur near sources of spilled fuel or fuel 254 mm (10 in.) of the generator set fuel inlet
vapors. Keep the fuel lines and connections tight and in good
location. See Figure 2-5.
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.

Note: Have the fuel piping and regulator installed by the

fuel supplier. The fuel supply installation must
comply with NFPA and local codes.

1. See Figure 2-3 and the generator set spec sheet

for the fuel supply requirements. Add up the fuel
requirements for the generator set plus all other
gas-fired equipment fueled by the same supply.

2. Check that the primary regulator and gas meter

have sufficient capacity for the fuel requirements
for the generator set plus all other gas-fired
equipment. Have the fuel supplier install a larger
gas meter, if necessary.

Model Gas Flow Rate, Btu/hr.

15 kW 200000
30 kW 450000

Figure 2-3 Gas Flow Rate (natural gas and LP)

Figure 2-5 Manual Fuel Shutoff Valve (outdoor

installation shown)

20 Section 2 Installation Instructions TP-6725 11/09

 5. Remove the enclosure door on the service side of
the unit.

6. Connect the fuel supply:

a. Apply pipe sealant that is approved for fuel

connections to the threaded fuel connections.

b. Use a section of flexible fuel line to connect the

fuel supply to the fuel inlet connection on the
generator set. See Figure 2-6 and Figure 2-7
for the fuel inlet connection location.

c. Open the manual fuel valves and leak test all ADV-7692
1 2
fuel connections using soapy water. If a leak is
detected, close the fuel valves, disconnect the Note: UL 2200-listed units include a second fuel valve. See
Figure 2-7.
lines at the location of the leak, clean the
1. Fuel supply connection, 3/4 NPT
fittings, and apply fresh pipe sealant. 2. Fuel solenoid valve
Reconnect the lines and recheck for leaks.
Figure 2-6 Fuel Supply Connection Location
Note: After the system installation is complete,
(Generator set enclosure not shown)
you will be instructed to check for fuel
leaks with the generator set running.
See Section 2.2.8, Operation Tests. 1

7. Verify that the fuel system is set up for the fuel being
used (natural gas or LP). See Section 2.2.6.

GM39123

2
1. Fuel solenoid valves (qty. 2)
2. Fuel supply connection, 3/4 NPT

Figure 2-7 Fuel Supply Connection with Two Fuel

Valves

TP-6725 11/09 Section 2 Installation Instructions 21

2.2.6 Fuel Conversion Procedures
Note: The Integrated Electronic Pressure Regulator
(IEPR) and air/fuel mixer are specially calibrated
emission-control devices. Do not adjust the IEPR
or the air/fuel mixer.

Check the connections to the fuel solenoid valve to

verify that the fuel system is set up for the type of fuel that
will be used. See Figure 2-6 for the location of the fuel
solenoid valve.

To change the fuel type, change the connection to the

fuel solenoid valve as described below and shown in
Figure 2-8.

LP Connections:
D Disconnect lead 73A from the fuel valve.

D Connect lead 73B to the fuel valve.

D Connect lead 65 to lead N3 (ground).

Natural Gas Connections:

D Disconnect lead 65 from N3.

D Disconnect lead 73B from the fuel valve.

D Connect lead 73A to the fuel valve.

ADV-7602

Figure 2-8 Fuel Type Connections

22 Section 2 Installation Instructions TP-6725 11/09

2.2.7 Add Coolant 3. Check the oil level before operating the engine.

Follow the instructions below to fill the cooling system. 4. Operate the engine with the radiator’s pressure
cap removed until the thermostat opens and the
1. Close the radiator’s coolant drain valve and tighten radiator upper hose becomes hot.
the hose clamps.
5. Stop the engine and allow it to cool.
Note: Do not add coolant to a hot engine. Adding
coolant to a hot engine can cause the 6. Add coolant to the radiator to just below the
cylinder block or cylinder head to crack. overflow tube on the filler neck. See Figure 2-10 for
Wait until the engine has cooled. the overflow tube location.

2. Fill the radiator with the recommended coolant 7. Replace the radiator’s pressure cap.
mixture of 50% ethylene glycol and 50% clean,
softened water to inhibit rust/corrosion and prevent 8. Maintain the coolant level in the coolant overflow
freezing. See Figure 2-9 for coolant capacity. Do bottle between the High and Low markings. See
not replace the pressure cap at this time. Figure 2-10 for the coolant overflow bottle location.

Note: A coolant solution of 50% ethylene glycol 1

provides freezing protection to --37°C
(--34°F) and overheating protection to
129°C (265°F). A coolant solution with less 2
than 50% ethylene glycol may not provide
adequate freezing and overheating
protection. A coolant solution with more
than 50% ethylene glycol can cause engine
or component damage. Do not use alcohol
or methanol antifreeze or mix them with the
specified coolant.

Model Coolant Capacity, L (Gal.)

15 kW 11.5 (3.0)
30 kW 11.5 (3.0)

Figure 2-9 Coolant Capacity

3 ADV--7692

1. Pressure cap (engine coolant fill)

2. Coolant overflow tube
3. Coolant overflow bottle

Figure 2-10 Coolant Fill

TP-6725 11/09 Section 2 Installation Instructions 23

2.2.8 Operation Tests 4. Use a digital voltmeter (DVM) to check the output
voltage from the generator set. If voltage
WARNING adjustments are required, refer to Section 4.5 for
instructions to use the ADC 2100 voltage
adjustment menu.

5. Perform voltage checks as described in the ATS

operation and installation manual. Close the main
Hazardous voltage. Moving parts. circuit breaker on the main distribution panel when
Can cause severe injury or death. instructed to connect power in the test procedure.
Operate the generator set only when
all guards and electrical enclosures 6. Move the generator set master switch to OFF and
are in place. then to the AUTO position.

7. Install the enclosure’s service-side door. Verify that

1. Verify that all guards are in place. Install the all enclosure doors and panels are installed.
enclosure’s end panels and nonservice side door.
8. Test the system operation as described in the ATS
2. Check the items in the Prestart Checklist in the operation and installation manual.
generator set operation manual.
9. Set the exerciser on the transfer switch to exercise
3. Move the generator set master switch to the RUN the generator set weekly. Refer to the instructions
position to start the generator set. in the ATS operation and installation manual.

24 Section 2 Installation Instructions TP-6725 11/09

 Section 3 Accessories

3.1 Introduction The relay board location is shown in Figure 3-2.

Connect customer equipment to the relay board
Accessories are available factory-installed and/or harness. Figure 3-3 lists the customer connections.
shipped loose. Obtain the most current list of
accessories from the generator set specification sheet The common fault relay is energized on a fault. The
or by contacting an authorized Kohler distributor/ dealer. auxiliary run relay is energized when the generator set is
running. Connect to each relay’s normally open or
Have accessories installed by your local authorized normally closed contacts depending on the application.
Kohler distributor/dealer or authorized representative.
Follow the installation instructions provided with each kit.

Use separate conduit for AC and DC leads to reduce the 1

possibility of electrical interference. Use shielded cable 2
for all analog inputs. Verify that the leads and conduit do
not interfere with the operation of the generator set or
obstruct the service areas.
Verify that the accessory installation complies with the
National Electrical Code (NEC) and all applicable local
and state codes.
GM39949B--R

Accessory Wiring. To determine the appropriate size

for the customer-supplied wiring of engine battery-
powered accessories, use the guidelines in Figure 3-1.
Use 18--20 gauge wire for signal wires up to 305 m
(1000 ft.). 1. Relay board location 2. Relay board harness

Length, m (ft.) Wire Gauge Figure 3-2 Common Fault and Run Relay Board
30.5 (100) 18--20
152.4 (500) 14 Harness
304.8 (1000) 10 Lead Connector
Number Pin Number Connection
Figure 3-1 Wire Length and Size, Lead N and 42B 88 6 Common fault relay normally
open
Refer to the wiring diagram manual for more information
89 2 Common fault relay common
regarding generator set electrical connections.
90 3 Common fault relay normally
The following sections detail a few common accessories closed
and their functions. The instructions provided with the
91 4 Run relay normally open
accessory kit supersede these instructions, if different.
92 1 Run relay common
93 5 Run relay normally closed
3.2 Common Fault and Run Relay
Board
The optional relay board replaces the standard relay
interface board (RIB) and provides two additional relays GM50548A--

to control customer-provided equipment:

Figure 3-3 Common Fault and Run Relay Board
D Common fault relay Harness Connections
D Auxiliary run relay

TP-6725 11/09 Section 3 Accessories 25

3.3 Remote Digital Gauge 3.4 Block Heaters
The Remote Digital Gauge allows for remote Block heaters are available as installed accessories on
starting/stopping and monitoring of certain generator all generator sets. Use block heaters on all standby
set functions. See Figure 3-4. The Remote Digital applications where the generator set is subject to
Gauge connects to the 12-pin customer-interface temperatures below 16°C (60°F). Connect the block
connector. Refer to TT-1439 for instructions to install, heater to a power source that is energized when the
connect, and operate the gauge. generator set is not running.

Note: The Remote Digital Gauge will not display the oil Note: Block heater damage. The block heater will fail
pressure in this application. if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
1 on the block heater. Run the engine until it is
warm and refill the radiator to purge the air from
the system before energizing the block heater.

3.5 Oil Makeup Kit

The optional oil makeup kit, available for 30 kW
generator sets, provides an additional 2 quarts of oil for
extended run time. The kit also provides a large glass
sight gauge that allows quick and easy checks of the oil
level. Follow the instructions provided with the kit to add
oil, if necessary, and to check the height of the oil level
3 2 sight gauge during generator set installation.

1. SELECT button
2. UP arrow button 3.6 OnCue Home Generator
3. DOWN arrow button
Management System
Figure 3-4 Remote Digital Gauge
The OnCuet Home Generator Management System
The ADC 2100 communications parameter Cn must be allows monitoring and control of your generator set from
set to Cn01 or Cn06 to communicate with the gauge. a personal computer located in your home or at other
See Section 4.3 for important controller power down remote locations. OnCue can also be configured to
information. See Section 4.4 for more information on send email or text message notifications in the event of a
controller configuration. generator set fault.

Use one or more remote extension harness kits to The OnCue system is available separately as a loose kit.
connect the gauge to the generator set. Do not use Follow the instructions provided with the OnCue kit to
more than 3 remote harness kits and do not exceed install the network bridge inside the generator set
22.86 m (75 ft.) in harness length. See Figure 2 for kit junction box, connect to your ethernet router and cable
selection. or DSL modem, and configure the system for monitoring
and notification.
Remote Extension
Harness Kit Number Length, m (ft.)
GM32333-KP1 4.6 (15)
GM32333-KP2 7.6 (25)

Figure 2 Remote Extension Harness Kits

(for gauge to generator set)

26 Section 3 Accessories TP-6725 11/09

 Section 4 Controller

4.1 Advanced Digital Control down 48 hours after the generator stops. A remote start
signal from a transfer switch or remote switch connected
(ADC 2100) to engine start leads 3 and 4 will signal the controller to
The generator sets use the Advanced Digital Control power up and the generator set to start.
(ADC 2100). The ADC 2100 uses password-protected
menus for generator output adjustments and controller Continuous power mode. If the ADC 2100 is
configuration. configured for a CAN gauge (communications
parameter setting Cn01), the controller will not power
This section contains instructions for using the down. The ADC 2100 remains powered at all times to
controller’s password-protected menus to check and allow remote start commands from the remote CAN
adjust the generator output and controller configuration. gauge.
The controller configuration and generator set output
are factory-set and should not require field adjustment 1-hour power down. Setting the communications
under normal circumstances. Check and adjust the parameter to Cn06 will cause the controller to power
configuration and/or output when: down after 1 hour of no activity. In this mode, a remote
start/stop switch or the generator set master switch
D The controller has been replaced. must be used to activate the controller after it has
powered down. Controller application code version
D The voltage requires adjustment for a particular 1.21 or higher is required for the 1--hour power down
application. option.

D Troubleshooting generator set problems.

4.4 Controller Configuration
Have controller setup and adjustment performed only by
an authorized Kohler distributor/dealer or authorized The controller configuration for each generator model is
representative. set at the factory and should not normally require
changes. The controller’s configuration mode allows
adjustment of the system parameters listed in this
4.2 Code Version section. Use the instructions in this section to check the
configuration after installation and change them to
These models require ADC 2100 application code match the settings shown in Figure 4-1, if necessary.
version 3.25 or later. The code version is displayed as
you enter the controller configuration mode. See Note: If the controller is replaced, the new ADC 2100
Figure 4-2. will need to be configured to the settings for the
generator set as described in this section.

4.3 Controller Automatic Power Note: The controller will automatically exit the
Down configuration mode without saving any changes
after about 1 minute if no buttons are pressed.
With the generator set master switch in the AUTO Start the configuration procedure over again from
position, there are three possible controller power the beginning if the controller exits the
modes. configuration mode before the settings have
been saved.
48-hour power down. If the ADC 2100 controller is not
configured for a CAN gauge (communications
parameter setting Cn00, see Section 4.4), the controller
will power down after 48 hours of no activity. If the
generator set has been started, the controller will power

TP-6725 11/09 Section 4 Controller 27

Parameter Setting Definition
Unit’s system voltage and frequency Uu01 Single phase, 3 wire, 60 Hz, 120/240 VAC
Unit configuration Uc01 Standby
Engine type Ec11 15 and 30 kW
Engine data input types Ed01 15/30 kW
Battery Voltage Bt12 Battery voltage 12 VDC
Communications Cn00 No CAN communications, 48-hour power down (factory setting)
Cn01 J1939 (use for Remote Digital Gauge), no power down
Cn06 Enables J1939 communications and 1-hour ADC 2100 power
down after engine stop for either:
a. Remote start/stop switch
b. Automatic transfer switch
c. Remote Digital Gauge with remote start/stop switch and
replacement harness

Figure 4-1 Configuration Parameters

Follow the instructions in Figure 4-2 to enter the Advanced configuration mode (Adnc). The data
configuration mode while the engine is not running and input types, battery voltage, and communications
then step through the parameters. Use the up (∧) and setting can be changed in the advanced configuration
down (∨) arrow buttons to select the appropriate setting mode. Press the up arrow button when Adnc is
for the application. displayed to enter the advanced configuration mode.
See Figure 4-3.
Note: Be sure to save your settings before exiting the
configuration mode. See Figure 4-4. The Engine data input types (Ed). This setting defines the
controller reverts to the last saved settings when types of senders used on the generator set engine.
the master switch is moved to the OFF/RESET
position. Battery voltage (Bt). This setting toggles between 12
and 24 VDC for the engine starting battery voltage. The
Voltage/frequency setting (Uu). Set the system generator set uses a 12-volt battery, Bt12.
voltage and frequency to the value shown in Figure 4-1.
Communications setting (Cn). This setting allows the
Note: This parameter sets the nominal system voltage user to set the controller for communication with
and frequency. To adjust the output (measured) optional meters. The factory setting is Cn00, no CAN
voltage, see Section 4.5. communications. Change this setting to Cn01 or Cn06 if
an optional Remote Digital Gauge is used. See
Unit configuration (Uc). This parameter sets the Figure 4-1.
generator set type: marine, standby, or mobile.

Engine configuration (Ec). The engine configuration

must match the generator set engine type.

28 Section 4 Controller TP-6725 11/09

 Controller Configuration Mode:

Hold the Select button: Display:

Move the generator set master switch to the . 0
RUN position. (The generator set engine will
not start.)
Wait about 5 seconds until the display shows
the program version number. (The number 3. 2 5
may be different than the one shown here.)

Press the down arrow key and then the up

arrow key 3 times to enter the configuration
mode. (This is the controller “password.”)
Uu 0 1

Now release the Select button.

Press:

To set the voltage/frequency setting to Uu01. See Uu 0 1

or
Figure 4-1.

To step to the next parameter, unit configuration

Uc.

To change the unit configuration setting to Uc01, if

or
necessary.
Uc 0 1

To step to the next parameter, engine type Ec.

or To change the engine type to Ec11, if necessary. E c 1 1

To step to the next parameter, advanced Ad n c

configuration mode or save mode selection.

Now either save your settings or enter the Advanced Configuration Mode to
set the engine data inputs, battery voltage, and communications.

Press:
To enter advanced configuration mode. E d 0 1
Go to Figure 4-3.
or
or To proceed to the save mode without
entering the advanced configuration mode. S AV E
Go to Figure 4-4.

Note: Shaded boxes show which number in the controller display changes when the up or down arrow
key is pressed.

Figure 4-2 Configuration Mode (system voltage/frequency, unit configuration, and engine type parameters)
TP-6725 11/09 Section 4 Controller 29
 Pressing the up arrow key at the Adnc display (See Figure 4-2) puts you into
the Advanced Configuration Mode.
Press:

or To set the engine data input type to Ed01. E d 0 1

See Figure 4-1.

To enter battery voltage selection mode.

or To toggle between 12 and 24 VDC. Set this B t 1 2

parameter to 12 VDC.

To enter communications selection mode.

To set the communications parameter Cn. C n 0 0

or See Figure 4-1.

To enter SAVE mode. Go to Figure 4-4.

S AV E

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts
to the last saved settings when the master switch is moved to the OFF/RESET position.

Figure 4-3 Advanced Configuration Mode (engine data input type, battery voltage, and engine communications)

There are 3 options when the display says SAVE: S AV E

Press:
To return to the first parameter, system voltage/frequency
Uu, to check or change settings before saving. See Uu 0 1
Figure 4-2.
or

To save changes. Y E S
or
To discard changes without saving. n o

“Yes”or “no” flashes when the up or down arrow is pressed and then
the controller exits the configuration mode. The display returns to
the runtime hours.
x x x x

Now move the master switch to OFF/RESET.

* X in the runtime hours display above denotes any number from 0 to 9.

Figure 4-4 Save Mode (after configuring generator set parameters)

30 Section 4 Controller TP-6725 11/09

4.5 Voltage Adjustments Pressing the Select button when SAVE is displayed
returns to the first parameter, voltage adjust (1P).
WARNING
Note: Refer to the flowcharts in Figure 4-6 and
Figure 4-7 during the voltage adjustment
procedure.

Voltage Adjustment Procedure

Hazardous voltage. Moving parts.
Can cause severe injury or death. 1. With the generator set off, connect a digital
Operate the generator set only when multimeter to the output leads or an electrical outlet
all guards and electrical enclosures on the load side of the generator set. Set the meter
are in place. to measure AC voltage.

Short circuits. Hazardous voltage/current can cause 2. Start the generator set by moving the generator set
severe injury or death. Short circuits can cause bodily injury master switch to the RUN position.
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or 3. Use the ADC controller to adjust the voltage
repairs. Remove all jewelry before servicing the equipment. (parameter 1P) until the output voltage reaches the
desired value. See Figure 4-5 for the approximate
The controller’s adjustment mode allows adjustment of change in voltage per step in parameter 1P. See
the output voltage, if necessary. Have adjustments Figure 4-6 for adjustment instructions.
performed by an authorized Kohler distributor/ dealer or
service technician.
Measured Voltage Change per Step, VAC
Voltage, VAC
Note: A digital voltmeter is required for these Coarse Adjust Fine Adjust
adjustments. 85--132 5 0.5

Use a voltmeter to check the output voltage. If the output 180--251 7 0.7
voltage is not within specifications, use the ADC Figure 4-5 Voltage Adjustment (approximate)
controller to adjust the output voltage while the
generator set is running. The flowcharts in Figure 4-6 4. Adjust the voltage stability (gain, parameter 2P) to
and Figure 4-7 outline the adjustment procedures. minimize light flicker. See Figure 4-6 for
adjustment instructions.
Note: Be sure to save your settings before exiting the
configuration mode. 5. Readjust the voltage, if necessary.

Voltage changes are lost if they are not saved before the 6. Save the controller settings as described in
generator set shuts down. The generator set continues Figure 4-7.
to run with the new settings until it shuts down but then
reverts to the previous settings at the next startup if the 7. Stop the generator set.
changes have not been saved.

TP-6725 11/09 Section 4 Controller 31

 Output Voltage Adjustment Mode: Display :*
Move the generator set master switch to the RUN position. The generator set x x x x
engine starts and the controller display shows the engine runtime hours.
Hold:
Wait about 5 seconds until the display changes from runtime hours
to the program version number.
x. x x
Press the down arrow key and then the up arrow key 3 times to enter the
adjustment mode. (This is the controller “password.”)
1 P x x

The controller is now in the voltage coarse adjustment mode.

Press:

or
To raise or lower the voltage in large increments 1 P x x
(approximately 5--7 volts per step).

To enter fine voltage adjustment mode.

1 P x x
To raise or lower the voltage in smaller increments
or
(approximately 0.5--0.7 volts per step).

To enter coarse voltage stability (gain) adjustment mode.

2 P x x
To raise or lower the voltage stability (gain) in large
or increments.

To enter fine voltage stability (gain) adjustment mode.

2 P x x
or To raise or lower the voltage stability (gain) in smaller
increments.

To enter volts/Hz adjustment mode.

3 P 0 x
or To raise or lower the volts/Hz: 00=low; 09= high

Continued on Figure 4-7.

* Shaded boxes show which character in the controller display changes for each adjustment. X in the
examples above denotes any number from 0 to 9. The actual values may vary from model-to-model. TP6196

Figure 4-6 Output Voltage Adjustments

32 Section 4 Controller TP-6725 11/09

 Continued from Figure 4-6: Display : *

To enter SAVE mode. S AV E

Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to
the last saved settings when the master switch is moved to the OFF/RESET position.

There are 3 options when the display says SAVE: S AV E

Press:
To return to the first parameter, coarse voltage adjustment, to check 1 P x x
or change settings before saving. See Figure 4-6.
or

To save changes. Y E S
or
To discard changes without saving. n o

“Yes”or “no” flashes when the up or down arrow is pressed and then the
controller exits the configuration mode. The display returns to the x x x x
runtime hours.

Now move the master switch to OFF/RESET.

* X in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-
model.

Figure 4-7 Output Voltage Adjustments, Continued

TP-6725 11/09 Section 4 Controller 33

 Notes

34 Section 4 Controller TP-6725 11/09

 Section 5 Dimension Drawings

Figure 5-1 lists the drawing numbers and page

numbers.

Note: See TP-6719, Wiring Diagram Manual, for wiring

diagrams and schematics.

Dimension Drawing Description Drawing Number Page

Weather Housing with Sound Kit ADV-7694 Sheet 1 36
Sound Enclosure ADV-7694 Sheet 2 37
Installation Clearances ADV-7694 Sheet 3 38

Figure 5-1 Drawing Numbers and Locations

TP-6725 11/09 Section 5 Dimension Drawings 35

 Note: Dimensions are shown in mm [in.].

Figure 5-2 Dimension Drawing, Weather Housing with Sound Kit, ADV--7694 Sheet 1

36 Section 5 Dimension Drawings TP-6725 11/09

 Note: Dimensions are shown in mm [in.].

Figure 5-3 Dimension Draiwng, Sound Enclosure, ADV-7694, Sheet 2

TP-6725 11/09 Section 5 Dimension Drawings 37

 Note: Dimensions are shown in mm [in.].

Figure 5-4 Installation Clearances, ADV-7694, Sheet 3

38 Section 5 Dimension Drawings TP-6725 11/09

 Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute est. estimated
ABDC after bottom dead center CG center of gravity E-Stop emergency stop
AC alternating current CID cubic inch displacement etc. et cetera (and so forth)
A/D analog to digital CL centerline exh. exhaust
ADC advanced digital control; cm centimeter ext. external
analog to digital converter CMOS complementary metal oxide F Fahrenheit, female
adj. adjust, adjustment substrate (semiconductor) fglass. fiberglass
ADV advertising dimensional cogen. cogeneration FHM flat head machine (screw)
drawing com communications (port) fl. oz. fluid ounce
Ah amp-hour coml commercial flex. flexible
AHWT anticipatory high water Coml/Rec Commercial/Recreational freq. frequency
temperature conn. connection FS full scale
AISI American Iron and Steel cont. continued
Institute ft. foot, feet
CPVC chlorinated polyvinyl chloride ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure
crit. critical ft./min. feet per minute
alt. alternator
CRT cathode ray tube ftp file transfer protocol
Al aluminum
CSA Canadian Standards g gram
ANSI American National Standards Association
Institute (formerly American ga. gauge (meters, wire size)
Standards Association, ASA) CT current transformer gal. gallon
AO anticipatory only Cu copper gen. generator
APDC Air Pollution Control District cUL Canadian Underwriter’s genset generator set
Laboratories
API American Petroleum Institute GFI ground fault interrupter
CUL Canadian Underwriter’s
approx. approximate, approximately Laboratories GND, ground
AQMD Air Quality Management District cu. in. cubic inch gov. governor
AR as required, as requested cw. clockwise gph gallons per hour
AS as supplied, as stated, as CWC city water-cooled gpm gallons per minute
suggested
cyl. cylinder gr. grade, gross
ASE American Society of Engineers
D/A digital to analog GRD equipment ground
ASME American Society of
Mechanical Engineers DAC digital to analog converter gr. wt. gross weight
assy. assembly dB decibel HxWxD height by width by depth
ASTM American Society for Testing dB(A) decibel (A weighted) HC hex cap
Materials DC direct current HCHT high cylinder head temperature
ATDC after top dead center DCR direct current resistance HD heavy duty
ATS automatic transfer switch deg., ° degree HET high exhaust temp., high
auto. automatic dept. department engine temp.
aux. auxiliary DFMEA Design Failure Mode and hex hexagon
avg. average Effects Analysis Hg mercury (element)
AVR automatic voltage regulator dia. diameter HH hex head
AWG American Wire Gauge DI/EO dual inlet/end outlet HHC hex head cap
AWM appliance wiring material DIN Deutsches Institut fur Normung HP horsepower
e. V. (also Deutsche Industrie hr. hour
bat. battery Normenausschuss)
BBDC before bottom dead center HS heat shrink
DIP dual inline package hsg. housing
BC battery charger, battery DPDT double-pole, double-throw
charging HVAC heating, ventilation, and air
DPST double-pole, single-throw conditioning
BCA battery charging alternator
DS disconnect switch HWT high water temperature
BCI Battery Council International
DVR digital voltage regulator Hz hertz (cycles per second)
BDC before dead center
E, emer. emergency (power source) IC integrated circuit
BHP brake horsepower
ECM electronic control module, ID inside diameter, identification
blk. black (paint color), block engine control module
(engine) IEC International Electrotechnical
EDI electronic data interchange Commission
blk. htr. block heater
EFR emergency frequency relay IEEE Institute of Electrical and
BMEP brake mean effective pressure
e.g. for example (exempli gratia) Electronics Engineers
bps bits per second
EG electronic governor IMS improved motor starting
br. brass
EGSA Electrical Generating Systems in. inch
BTDC before top dead center Association in. H2O inches of water
Btu British thermal unit EIA Electronic Industries in. Hg inches of mercury
Btu/min. British thermal units per minute Association in. lb. inch pounds
C Celsius, centigrade EI/EO end inlet/end outlet Inc. incorporated
cal. calorie EMI electromagnetic interference ind. industrial
CAN controller area network emiss. emission int. internal
CARB California Air Resources Board eng. engine int./ext. internal/external
CB circuit breaker EPA Environmental Protection I/O input/output
cc cubic centimeter Agency
IP iron pipe
CCA cold cranking amps EPS emergency power system
ISO International Organization for
ccw. counterclockwise ER emergency relay Standardization
CEC Canadian Electrical Code ES engineering special, J joule
cert. certificate, certification, certified engineered special
JIS Japanese Industry Standard
cfh cubic feet per hour ESD electrostatic discharge

TP-6725 11/09 Appendix 39

k kilo (1000) MTBO mean time between overhauls rms root mean square
K kelvin mtg. mounting rnd. round
kA kiloampere MTU Motoren-und Turbinen-Union ROM read only memory
KB kilobyte (210 bytes) MW megawatt rot. rotate, rotating
KBus Kohler communication protocol mW milliwatt rpm revolutions per minute
kg kilogram μF microfarad RS right side
kg/cm2 kilograms per square N, norm. normal (power source) RTU remote terminal unit
centimeter NA not available, not applicable RTV room temperature vulcanization
kgm kilogram-meter nat. gas natural gas RW read/write
kg/m3 kilograms per cubic meter NBS National Bureau of Standards SAE Society of Automotive
kHz kilohertz NC normally closed Engineers
kJ kilojoule NEC National Electrical Code scfm standard cubic feet per minute
km kilometer NEMA National Electrical SCR silicon controlled rectifier
kOhm, kΩ kilo-ohm Manufacturers Association s, sec. second
kPa kilopascal NFPA National Fire Protection SI Systeme international d’unites,
kph kilometers per hour Association International System of Units
kV kilovolt Nm newton meter SI/EO side in/end out
kVA kilovolt ampere NO normally open sil. silencer
kVAR kilovolt ampere reactive no., nos. number, numbers SN serial number
kW kilowatt NPS National Pipe, Straight SNMP simple network management
kWh kilowatt-hour NPSC National Pipe, Straight-coupling protocol
kWm kilowatt mechanical NPT National Standard taper pipe SPDT single-pole, double-throw
kWth kilowatt-thermal thread per general use SPST single-pole, single-throw
L liter NPTF National Pipe, Taper-Fine spec specification
LAN local area network NR not required, normal relay specs specification(s)
L x W x H length by width by height ns nanosecond sq. square
lb. pound, pounds OC overcrank sq. cm square centimeter
lbm/ft3 pounds mass per cubic feet OD outside diameter sq. in. square inch
LCB line circuit breaker OEM original equipment SS stainless steel
manufacturer std. standard
LCD liquid crystal display
OF overfrequency stl. steel
ld. shd. load shed
opt. option, optional tach. tachometer
LED light emitting diode
OS oversize, overspeed TD time delay
Lph liters per hour
OSHA Occupational Safety and Health TDC top dead center
Lpm liters per minute Administration
LOP low oil pressure TDEC time delay engine cooldown
OV overvoltage TDEN time delay emergency to
LP liquefied petroleum oz. ounce normal
LPG liquefied petroleum gas p., pp. page, pages TDES time delay engine start
LS left side PC personal computer TDNE time delay normal to
Lwa sound power level, A weighted PCB printed circuit board emergency
LWL low water level pF picofarad TDOE time delay off to emergency
LWT low water temperature PF power factor TDON time delay off to normal
m meter, milli (1/1000) ph., ∅ phase temp. temperature
M mega (106 when used with SI PHC Phillipsr head Crimptiter term. terminal
units), male (screw) THD total harmonic distortion
m3 cubic meter PHH Phillipsr hex head (screw) TIF telephone influence factor
m3/hr. cubic meters per hour PHM pan head machine (screw) TIR total indicator reading
m3/min. cubic meters per minute PLC programmable logic control tol. tolerance
mA milliampere PMG permanent magnet generator turbo. turbocharger
man. manual pot potentiometer, potential typ. typical (same in multiple
max. maximum ppm parts per million locations)
MB megabyte (220 bytes) PROM programmable read-only UF underfrequency
MCCB molded-case circuit breaker memory UHF ultrahigh frequency
MCM one thousand circular mils psi pounds per square inch UL Underwriter’s Laboratories, Inc.
meggar megohmmeter psig pounds per square inch gauge UNC unified coarse thread (was NC)
MHz megahertz pt. pint UNF unified fine thread (was NF)
mi. mile PTC positive temperature coefficient univ. universal
mil one one-thousandth of an inch PTO power takeoff US undersize, underspeed
min. minimum, minute PVC polyvinyl chloride UV ultraviolet, undervoltage
misc. miscellaneous qt. quart, quarts V volt
MJ megajoule qty. quantity VAC volts alternating current
mJ millijoule R replacement (emergency) VAR voltampere reactive
mm millimeter power source VDC volts direct current
mOhm, mΩmilliohm rad. radiator, radius VFD vacuum fluorescent display
MOhm, MΩmegohm RAM random access memory VGA video graphics adapter
MOV metal oxide varistor RDO relay driver output VHF very high frequency
MPa megapascal ref. reference W watt
mpg miles per gallon rem. remote WCR withstand and closing rating
mph miles per hour Res/Coml Residential/Commercial w/ with
MS military standard RFI radio frequency interference w/o without
ms millisecond RH round head wt. weight
m/sec. meters per second RHM round head machine (screw) xfmr transformer
MTBF mean time between failure rly. relay

40 Appendix TP-6725 11/09

 Notes

TP-6725 11/09 41
 Notes

42 TP-6725 11/09
 KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6725 11/09 7 Jurong Pier Road
Singapore 619159
E 2009 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455