Kohler 20--2800 kW User Manual

Industrial/Commercial/ResidentialGenerator SetsModels:20--2800 kWTP-5700 7/93dInstallation

TP-5700 7/93VI Safety Precautions and InstructionsNoticeNOTICEThis generator set has beenrewired from its nameplate voltageto246242NOTICEVoltage recon

TP-5700 7/93 iIntroductionIntroductionThis manual provides installation instructions for20--2800 kW generator sets. Operation manuals andwiring diagra

TP-5700 7/93 1Section 1 GeneralSection 1 GeneralIndustrial power systems give years of dependableservice if installed using the guidelines provided in

TP-5700 7/932 Section 1 GeneralTP-5700-11. Exhaust thimble (for wall or ceiling)2. Silencer3. Supports4. Flexible sections5. Duct work for cooling air

TP-5700 7/93 3Section 2 Load and TransportSection 2 Load and TransportTo ensure personal safety while preventing damage tothe product, we strongly rec

TP-5700 7/934 Section 2 Load and TransportD A four-point lifting method is necessary to lift thegenerator set. To maintain generator balance duringlif

TP-5700 7/93 5Section 2 Load and TransportD Do not attach lifting hooks to outside reinforcingplate on skid. Attach lifting hooks to skid exactly assh

TP-5700 7/936 Section 2 Load and TransportNotes

TP-5700 7/93 7Section 3 LocationSection 3 Location3.1 Location FactorsLocation is the key to a proper installation. The followingsections will deal wi

Engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm.WARNINGC

TP-5700 7/938 Section 3 Location3.3 MountingTypical mounting surface details and dimensions areshown in Figure 3-1. The recommended mountingsurface is

TP-5700 7/93 9Section 3 LocationThe composition of the mounting pad should followstandard practice for the required loading. Commonspecifications call

TP-5700 7/9310 Section 3 LocationNotes

TP-5700 7/93 11Section 4 Air RequirementsSection 4 Air Requirements4.1 GeneralAn ample flow of clean, cool air is required to supportcombustion and di

TP-5700 7/9312 Section 4 Air RequirementsIn many installations it may be desirable to installlouvers in the inlet and outlet openings. Louvers may bee

TP-5700 7/93 13Section 4 Air Requirements4.3 Forced AirWith the forced-air system, cooling air is drawn inthrough the front of the engine, circulated

TP-5700 7/9314 Section 4 Air Requirements4.4 Air-Vac Cooling SystemThe air flow direction with the Air-Vac system is theopposite of the conventional

TP-5700 7/93 15Section 4 Air Requirements4.5 Air VentThe air vent system is used on some air-cooled gas andhas been used on some diesel models. It inc

TP-5700 7/9316 Section 4 Air Requirements4.6 Liquid-Cooled ModelsThe three most common liquid cooling systems used forgenerator sets are unit-mounted

TP-5700 7/93 17Section 4 Air RequirementsThe connection from the radiator duct flange to theductwork should be heavy canvas, silicone or similarflexib

Table of ContentsTP-5700 7/93 Table of ContentsProduct Identification Information Inside front cover...Safety

TP-5700 7/9318 Section 4 Air RequirementsThe engine water pump can be used to circulate waterthrough the remote radiator providing that the verticaldi

TP-5700 7/93 19Section 4 Air Requirements71234651. Ventilation fan (for heat rejected from exhaust and engine)2. City water in3. Flexible section4. Ma

TP-5700 7/9320 Section 4 Air Requirements4.11 Block HeatersBlock heaters are recommended on all standbyapplications where the generator is subject tot

TP-5700 7/93 21Section 5 Exhaust SystemSection 5 Exhaust SystemProper installation of the exhaust system is essential toobtain satisfactory performanc

TP-5700 7/9322 Section 5 Exhaust System5.1 Flexible SectionA section of flexible exhaust line should be installedwithin 2 feet (51 mm) of the engine e

TP-5700 7/93 23Section 5 Exhaust System5.4 Double-Sleeve ThimblesIf the exhaust pipe should need to pass through a wall orroof, an exhaust thimble mus

TP-5700 7/9324 Section 5 Exhaust SystemNotes

TP-5700 7/93 25Section 6 Fuel SystemsSection 6 Fuel SystemsWhen planning an installation, check state and localregulations regarding fuel storage and

TP-5700 7/9326 Section 6 Fuel Systems1234TP-5700-61. Generator set skid2. Side view3. Subbase fuel tank4. End viewFigure 6-2 Subbase Fuel Tank6.2 Main

TP-5700 7/93 27Section 6 Fuel SystemsFlexible connections must be used wherever there maybe relative motion between piping and suppliedequipment. Alwa

Table of Contents, continuedTP-5700 7/93Table of ContentsSection 7 Electrical Requirements 35...

TP-5700 7/9328 Section 6 Fuel Systems6.5 Auxiliary Fuel PumpsEngine-driven fuel transfer pumps usually develop amaximum of 7 psi (48 kPa) pressure and

TP-5700 7/93 29Section 6 Fuel Systems6.6 Gasoline Fuel SystemsDue to code restrictions which do not allow storage ofmore than one gallon (3.8 L) of ga

TP-5700 7/9330 Section 6 Fuel Systems6.7 Natural or LP Gas FuelSystemsNatural and LP (liquified petroleum) gas fuel systemsshould be designed and inst

TP-5700 7/93 31Section 6 Fuel Systems1 2 35TP-5700-649108761. Carburetor2. Load adjustment valve3. Converter (vaporizer)4. Solenoid valve5. LP gas fil

TP-5700 7/9332 Section 6 Fuel Systems6.8 Flexible ConnectorAn approved flexible connector should always be usedbetween stationary gas piping and the e

TP-5700 7/93 33Section 6 Fuel Systems6.11 LP Gas Fuel CharacteristicsLP gas is supplied as a liquid in pressure tanks. It iseasily adaptable to statio

TP-5700 7/9334 Section 6 Fuel Systems6.15 Natural GasNatural gas is in a vapor state as supplied from the utility.This fuel system, therefore, consist

TP-5700 7/93 35Section 7 Electrical RequirementsSection 7 Electrical RequirementsBefore installing the generator set, provide for electricalconnection

TP-5700 7/9336 Section 7 Electrical Requirements7.2 Electrical ConnectionsSeveral electrical connections must be made betweenthe generator set and oth

TP-5700 7/93 37Section 7 Electrical Requirements7.4 Terminal Connector TorqueUse the torque values shown in Figure 7-4 or Figure 7-5for terminal conne

TP-5700 7/93 ISafety Precautions and InstructionsSafety Precautions and InstructionsIMPORTANT SAFETY INSTRUCTIONS.Electromechanical equipment,includin

TP-5700 7/9338 Section 7 Electrical Requirements7.5 Automatic Transfer SwitchesA typical standby system has at least one automatictransfer switch conn

TP-5700 7/93 39Section 7 Electrical Requirements7.9 Remote Emergency StopSwitchThe emergency stop switch allows immediate shutdownof the generator fro

TP-5700 7/9340Section 7 Electrical RequirementsTP-5700 7/93GENERATOR JUNCTION BOXSAFEGUARDCIRCUIT BREAKERTERMINAL STRIP(IN JUNCTION BOX)RUN RELAYKITBA

TP-5700 7/93 Appendix A-1Appendix A AbbreviationsThe following list contains abbreviations that may appear in this publication.A, amp ampereABDC after

TP-5700 7/93A-2 Appendixkg kilogramkg/cm2kilograms per squarecentimeterkgm kilogram-meterkg/m3kilograms per cubic meterkHz kilohertzkJ kilojoulekm kil

E 1993, 2001, 2003 by Kohler Co. All rights reserved.TP-5700 7/93dKOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Web site www.kohlergenerators.

TP-5700 7/93II Safety Precautions and InstructionsBattery short circuits. Explosioncan cause severe injury or death.Short circuits can cause bodily in

TP-5700 7/93 IIISafety Precautions and InstructionsThe fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyex

TP-5700 7/93IV Safety Precautions and InstructionsHazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.If

TP-5700 7/93 VSafety Precautions and InstructionsServicing the transfer switchcontrols and accessories within theenclosure. Hazardous voltage cancause