Kohler 8.5RMY, 11RMY Installation Manual

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Page 1

Operation and

Installation

Residential/Commercial Generator Sets

Models:

8.5RMY 11RMY

with Sound Enclosure

Controller:

Decision-Makert 1

TP-6049 9/02f

Page 2

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. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator set operation manual, spec sheet, or sales invoice.

Controller Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

Page 3

Table of Contents

Product Identification Information Inside front cover............................................

Safety Precautions and Instructions I........................................................

Introduction i...............................................................................

Service Assistance ii........................................................................

Section 1 Features 1........................................................................

1.1 Specifications 1.........................................................

1.2 Generator 1............................................................

1.3 Engine 1...............................................................

1.4 Controller 1............................................................

1.5 Service Views 2........................................................

Section 2 Operation 5.......................................................................

2.1 Prestart Checklist 5.....................................................

2.2 Exercising the Generator Set 5...........................................

2.3 Decision-Maker 1 Controller Operation 6...................................

2.3.1 Controls and Indicators 6........................................

2.3.2 Starting the Generator Set 6......................................

2.3.3 Stopping the Generator Set 6.....................................

2.3.4 Fault Shutdowns 7..............................................

2.3.5 Resetting the Controller after a Fault Shutdown 7....................

2.4 Circuit Protection 7......................................................

Section 3 Scheduled Maintenance 9..........................................................

3.1 Routine Maintenance 9..................................................

3.2 Service Schedule 9.....................................................

3.3 Lubrication System 11....................................................

3.3.1 Low Oil Pressure Shutdown 11....................................

3.3.2 Oil Check 11....................................................

3.3.3 Engine Oil Recommendation 11....................................

3.3.4 Oil Change Procedure 11.........................................

3.4 Spark Plugs 12..........................................................

3.5 Air Cleaner Element and Precleaner 12.....................................

3.5.1 Precleaner Service 12............................................

3.5.2 Paper Element Service 13.........................................

3.6 Cooling System 14.......................................................

3.7 Exhaust System 14......................................................

3.8 Battery 14...............................................................

3.8.1 Cleaning the Battery 15...........................................

3.8.2 Checking Battery Electrolyte Level 15...............................

3.8.3 Checking Electrolyte Specific Gravity 16............................

3.8.4 Charging 16.....................................................

3.9 Storage Procedure 17....................................................

3.9.1 Lubricating System 17............................................

3.9.2 Fuel System 17..................................................

3.9.3 Cylinder Lubrication 17...........................................

3.9.4 Exterior Preparation 17...........................................

3.9.5 Battery 17.......................................................

Section 4 Troubleshooting 19.................................................................

Section 5 Wiring Diagrams 21................................................................

5.1 Specification Numbers 21.................................................

5.2 Controller Wiring Diagram Reference 21....................................

TPMP-6049 9/02 Table of Contents

Page 4

Table of Contents, continued

Section 6 Installation 27......................................................................

6.1 General 27..............................................................

6.2 Air Requirements 27.....................................................

6.3 Exhaust Requirements 27.................................................

6.4 Weight 27...............................................................

6.5 Generator Set Inspection 27...............................................

6.6 Mounting 27.............................................................

6.7 Fuel System 29..........................................................

6.7.1 Fuel Supply 29..................................................

6.7.2 Fuel Pipe Size 29................................................

6.7.3 Single-Fuel Systems 29...........................................

6.7.4 Multi-Fuel Systems 30............................................

6.7.5 Fuel Conversion (multi-fuel models only) 30.........................

6.8 Electrical Connections 31.................................................

6.8.1 Accessory Electrical Connections 31...............................

6.8.2 AC Load Lead Connections 32.....................................

6.8.3 Battery 32.......................................................

6.8.4 Battery Charger 33...............................................

6.8.5 Carburetor Heater 34.............................................

6.9 Generator Reconnection 35...............................................

6.9.1 Voltage Reconnection 35..........................................

6.9.2 Factory Connections, 110/220 Volt 50 Hz or 120/240 Volt 60 Hz 36.....

6.9.3 Reconnection Options 36.........................................

110 and 120 Volt Configurations 36.................................

220 and 240 Volt Configuration 37..................................

6.10 Prestart Installation Check 37..............................................

Appendix A Abbreviations A-1..................................................................

TPMP-6049 9/02Table of Contents

Page 5

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

This manual has severaltypesofsafety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe

personal injury,death,orsubstantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe

personal injury,death,or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set. Accidental starting can cause severe injury or death. Before

working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Battery

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

WARNING

Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolatethe battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid

can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a containerwith4L(1gal.)ofwaterand mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

TP-6049 9/02 ISafety Precautions and Instructions

Page 6

Battery gases. Explosion can cause severe injury or death. Battery gases

can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash Fire

WARNING

Fire. Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator

set with the air cleaner removed.

Exhaust System

WARNING

Carbon monoxide. Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide

is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly

explosive. Use extreme care when handling and storing fuels. Store fuels inawell-ventilatedareaawayfrom spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Donot operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

Explosive fuel vapors can cause severe injury or death. Tak e

additional precautions when using the following fuels:

Propane (LP)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions.

Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer’s instructions.

TP-6049 9/02II Safety Precautions and Instructions

Page 7

Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an

explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

Hazardous Noise

CAUTION

Hazardous noise. Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can cause hearing loss. Generator sets

not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Electrical Shock

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

WARNING

Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death.

If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the

test equipment manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure.

Moving rotor.

Installing the battery charger. Hazardous voltage can cause severe injury or death. An

ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.

Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies).

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can

cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage

is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.

(PowerBoostt, PowerBoostt III, and PowerBoostt V voltage regulator models only)

Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install

a transfer switch in standby power installations to prevent the connection 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.

TP-6049 9/02 IIISafety Precautions and Instructions

Page 8

Heavy Equipment

Moving Parts

Notice

WARNING

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.

Hot Parts

WARNING

Hot engine and exhaust system. Can cause severe injury or death.

Do not work on the generator set until it cools.

Servicing the generator. Hot parts can cause severe injury or death.

Avoid touching the generator set field or exciter armature. When shorted, the generator set field and exciter armature become hot enough to cause severe burns.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Moving rotor.

WARNING

Rotating parts. Can cause severe injury or death.

Operate the generator set only when all guards, screens, and covers are in place.

Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause

the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.

Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

NOTICE

This generator set has been rewired from its nameplate voltage to

246242

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

NOTICE

Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are

available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Canadian installations only.For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.

TP-6049 9/02IV Safety Precautions and Instructions

Page 9

Introduction

This manual provides operation and installation instructions for model 8.5RMY and 11RMY generator sets equipped with sound enclosures. This manual covers both single-fuel systems and multi-fuel systems. To identify the generator set’s fuel system, see Section

1.5, Service Views, and Section 6.7, Fuel Systems.

Information in this publication represents data available at the time of print. The manufacturer may provide this manual for models not listed on the front cover. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Obtain service from an authorized service distributor/ dealer to keep equipment in top condition.

EPA and California Emission Certification

An engine or generator set with one of the following identification labels is certified to meet Small Off-Road Engine (SORE) emission standards for EPA/CARB.

Nameplate

The following illustration shows a typical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual. See Section 1.5, Service Views, for the nameplate location.

* Spark-Ignited Small Off-Road Engines

This engine/generator is certified to operate using natural gas or propane fuel.

This engine is certified with engine modifications made by the generator set manufacturer.

TP-6049 9/02 iIntroduction

Page 10

IMPORTANT ENGINE INFORMATION

THIS ENGINE MEETS U.S. EPA PHASE 1 AND CALIFORNIA 2006 AND LATER EMISSION CONTROL REGULATIONS FOR SI SORE

FAMILY DISPL (CC) MODEL NO. SPEC. NO. SERIAL NO.

EMISSION COMPLIANCE PERIOD: EPA: CARB: EXTENDED

THIS ENGINE IS CERTIFIED TO OPERATE ON: PROPANE / NATURAL GAS

REFER TO OWNER’S MANUAL FOR SAFETY, MAINTENANCE SPECS AND ADJUSTMENTS.

FOR SALES AND SERVICE IN US/CANADA, CALL:

1--800 --544--2444

WWW.KOHLERENGINES.COM

N11236

The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown

Service Assistance

to meet CARB emission requirements. The following table provides the engine compliance period (in hours) associated with the category descriptor found on the certification label.

Emission Compliance Period (hours)

CARB

Moderate,

125

Intermediate,

250

Extended,

500

Refer to the certification label for engine displacement.

The exhaust emission control system for the 8.5RMY and 11RMY (CH25) is EM.

Look for the identification label shown above to determine whether generator sets with single-fuel systems are emission-certified. All model 8.5RMY and 11RMY generator sets with multi-fuel systems are emission-certified and include one of the identification labels shown above.

For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric

D Visit the Kohler Power Systems website at

KohlerPowerSystems.com

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents included with the product

D Call toll free in the US and Canada 1-800-544-2444

D Outside the US and Canada, call the nearest regional

office

Africa, Europe, Middle East

London Regional Office Langley, Slough, England Phone: (44) 1753-580-771 Fax: (44) 1753-580-036

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 264-6422 Fax: (65) 264-6455

China

North China Regional Office, Beijing Phone: (86) 10 6518 7950

(86) 10 6518 7951 (86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

Latin America

Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

X:in:008:001a

TP-6049 9/02ii Service Assistance

Page 11

Section 1 Features

1.1 Specifications

The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications. Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local distributor/dealer.

1.2 Generator

The generator uses Kohler’s unique PowerBoostt voltage regulation system, which provides instant response to load changes.

PowerBoostt ensures reliable motor starting and consistent voltage levels. PowerBoostt utilizes a voltage excitation system that employs a winding independent of the main output windings to provide excitation voltage.

1.3 Engine

The generator set has a four-cycle, twin cylinder, air-cooled Kohlerr engine. The engine operates on clean-burning natural gas or propane (LP) vapor. Engine features include:

D Efficient overhead valve design and full pressure

lubrication for maximum power, torque, and reliability under all operating conditions.

D Dependable, maintenance-free electronic ignition.

D Precision-formulated cast iron construction of parts

subjected to the most wear and tear.

D Field-convertible multi-fuel systems that allow fuel

changeover from natural gas to LP vapor (and vice-versa) while maintaining CARB emission certification.

1.4 Controller

The generator set has a Decision-Makert 1 relay controller. For a specific description of the controller, see Section 2, Operation. Controller features include the following:

D Fault shutdowns

D Overcrank D Overspeed D Low oil pressure

D High engine temperature D Running-time meter D Switches and standard features

D Switch, run/reset-off/auto (engine start)

D Cranking, cyclic D Line circuit breaker:

D 8.5RMY: 40 amps

D 11RMY: 50 amps D Common fault lamp (on some controllers)

TP-6049 9/02 1Section 1 Features

Page 12

1.5 Service Views

This section includes two generator set service views. See Figure 1-1 and the descriptions below to determine which service view applies to your generator set.

Figure 1-2 shows single-fuel generator sets, which can be identified in two ways:

D Single-fuel model specification numbers begin with

PA-. See the generator set nameplate for the spec number.

D Single-fuel models have the fuel valve shown in

Figure1-2,item8.

Figure 1-3 Shows multi-fuel generator sets, which can be identified in two ways:

D Multi-fuel model specification numbers begin with

GM. See the generator set nameplate for the spec number.

D Multi-fuel models have the multi-fuel block shown in

Figure 1-3, item 10.

Spec Number

Format

Fuel System Service View

PA-xxxxxx Single-fuel Figure 1-2 GMxxxxx Multi-fuel Figure 1-3

Figure 1-1 Service View Identification

123 679 11

84 10

OFF

RESET/

AUTOOFF

RUN

F210 AMP

F110 AMP

TYPEABCTYPEABC

1. Generator set sound enclosure

2. Muffler

3. Oil check

4. Oil drain hose

5. Oil fill

6. Spark plugs

7. Air cleaner

8. Fuel valve (Do not adjust on emission-certifed models.)

9. Controller

10. Nameplate

Figure 1-2 Generator Set Service View, Single-Fuel Systems (spec numbers PA-)

1617

11. Gas regulator assembly

12. Rodent screens

13. Engine starting battery location

14. Engine oil cooler

15. Engine battery charge regulator

16. Oil drain valve

17. Oil filter

18. Rodent plugs

19. Spark arrestor

1415

P-358000-C

TP-6049 9/022 Section 1 Features

Page 13

123 678 11

4 9 12

1718

1516

GM24829A-A

1. Generator set sound enclosure

2. Muffler

3. Oil check

4. Oil drain hose

5. Oil fill

6. Spark plugs

7. Air cleaner

8. Controller

9. Nameplate

10. Multi-fuel block

11. Gas regulator assembly

12. Fuel solenoid valve

13. Rodent screens

14. Engine starting battery location

15. Engine oil cooler

16. Engine battery charge regulator

17. Oil drain valve

18. Oil filter

19. Rodent plugs

20. Spark arrestor

Figure 1-3 Generator Set Service View, Multi-Fuel Systems (spec numbers GMxxxxx)

TP-6049 9/02 3Section 1 Features

Page 14

Notes

TP-6049 9/024 Section 1 Features

Page 15

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

the battery manufacturer’s instructions regarding battery care and maintenance.

Exhaust System. Check for exhaust leaks and blockages. Check the muffler and piping condition and check for tight exhaust system connections.

Inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, muffler, and outlet pipe) for cracks, leaks, and corrosion.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace the exhaust clamps and/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Check

for carbon or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.

Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.

Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.

x:op:001:002

2.2 Exercising the Generator Set

Operate the generator set under load once each week for one hour. If the generator set does not have a programmed exercise mode or an automatic transfer switch (ATS) with an exercise option, exercise the unit in the presence of an operator.

During the exercise period apply a minimum of 35% load based on the nameplate standby rating.

The operator should perform all of the prestart checks before starting the exercise procedure. Start the generator set according to the starting procedure in the controller section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks. Check the air inlets and outlets and remove any items restricting the air flow.

TP-6049 9/02 5Section 2 Operation

Page 16

2.3 Decision-Maker 1 Controller Operation

For identification of the Decision-Makert 1 controller’s indicators and controls and their functions, refer to Figure 2-1.

RUN

F1 10 AMP

1. Hourmeter

2. AC circuit breaker

3. Fault lamp

4. Voltage regulator fuse

5. 10-amp controller fuse

6. Generator set master switch

Figure 2-1 Decision-Makert 1 Controller (with Fault

2.3.1 Controls and Indicators

RESET/

AUTOOFF

F2 10 AMP TYPE ABCTYPE ABC

Lamp)

OFF

FAULT

GM10615

Note: The controller provides up to 30 seconds of cyclic

cranking before the overcrank shutdown occurs.

Name Description

Generator set master switch

Hourmeter Hourmeter records the generator set

Voltage regulator fuse, 10-amp

Controller fuse, 10-amp Fuse protects the controller circuitry

AC circuit breaker Circuit breaker trips when a fault is

Fault lamp Lamp lights when a fault shuts the

Switch functions as the controller reset and generator set operation switch.

total operating hours for reference in maintenance scheduling.

Fuse protects the voltage regulator circuitry.

from short circuits and overloads.

detected in the AC output circuit.

generator set down and remains lit until the generator set master switch is moved to the OFF/RESET position. See Section 2.3.4 for fault shutdown information.

Figure 2-2 Decision-Makert 1 Controls and

Indicators

2.3.3 Stopping the Generator Set

The following procedures describe the actions required to stop the generator set.

Automatic Stopping

1. The ATS or other device disconnects the load from the generator set.

2. The generator set continues to run for a preset cooldown time if the ATS is equipped with an engine cooldown time delay.

The table in Figure 2-2 describes the controls and indicators located on the controller.

2.3.2 Starting the Generator Set

The following procedures describe the actions required to start the generator set.

Local Starting. Move the generator set to the RUN position to immediately start the generator set.

Auto (Automatic) Starting. Move the generator set master switch to the AUTO position to allow startup by the ATS or the remote start/stop switch (connected to controller terminals TB1-3 and TB1-4).

3. The ATS or other device opens the connection between controller terminals TB1-3 and TB1-4. The generator set shuts down if the generator set master switch is in the AUTO position.

Local Stopping

1. Cooldown. Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown.

2. Stopping. Move the generator set master switch to the OFF/RESET position. The engine stops.

TP-6049 9/026 Section 2 Operation

Page 17

2.3.4 Fault Shutdowns

The generator set shuts down automatically under the fault conditions listed in Figure 2-3 and cannot be restarted until the fault condition is corrected. The generator set shutdown switches automatically reset when the problem is corrected. The high engine temperature switch automatically resets when the generator set cools.

After a fault shutdown leave the generator set master switch in the RESET/OFF position for a couple of seconds before attempting to restart the generator set.

3. Start the generator set by moving the generator set master switch to RESET/OFF and then to RUN.

4. Verify that the cause of the shutdown has been corrected by test operating the generator set.

5. Reconnect the generator set to the load using the line circuit breaker or ATS.

6. Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start/stop switch.

2.4 Circuit Protection

Fault Description

High engine temperature

Low oil pressure Shutdown occurs 5 seconds after the fault.

Overcrank Shutdown occurs after 30 seconds of cyclic

Overspeed Shutdown occurs immediately when the

Shutdown occurs 5 seconds after the fault. The high engine temperature shutdown does not function during the first 5 seconds after startup.

The low oil pressure shutdown does not function during the first 5 seconds after startup.

Note: The low oil pressure shutdown does not protect against low oil level. Check the oil level at the engine.

cranking. The factory sets the circuit board for three starting attempts of 8 seconds each (crank 8 seconds, wait 3 seconds, crank 8 seconds, wait 3 seconds, crank 8 seconds).

The generator set also shuts down if the output line voltage is lost. Shuts down 1 second after the fault is detected.

governed frequency on 50 and 60 Hz models exceeds 70 Hz.

Figure 2-3 Fault Shutdowns

2.3.5 Resetting the Controller after a Fault Shutdown

Use the following procedure to restart the generator set after a fault shutdown.

See Figure 2-1 for the line circuit breaker, controller fuse, and voltage regulator fuse locations.

Note: If the generator set circuit breaker trips or the

fuses blow repeatedly, see Section 4, Troubleshooting, for possible causes.

Line Circuit Breaker. A line circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. See Figure 2-4 for the circuit breaker ratings. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. With the breaker in the OFF position the generator set runs but the generator output is disconnected from the load.

Circuit Breaker

Model

8.5RMY 40

11R M Y 50

Rating, Amps

Figure 2-4 Line Circuit Breakers

Controller Fuse. A replaceable 10-amp fuse protects

the controller circuitry. If the generator set does not crank, check the battery and battery connections and then check the controller fuse. Replace the fuse if it is blown.

1. Disconnect the generator set from the load using the line circuit breaker or ATS. See the safety precautions at the beginning of this section before proceeding.

2. Correct the cause of the fault shutdown. See the safety precautions at the beginning of this section before proceeding.

TP-6049 9/02 7Section 2 Operation

Voltage Regulator Fuse. A replaceable 10-amp fuse protects the voltage regulator circuitry. The generator set shuts down if the fuse blows. When the operator starts a generator set with a blown voltage regulator fuse, the generator set typically starts and then shuts down in 8 seconds.

x:op:007:001

Page 18

Notes

TP-6049 9/028 Section 2 Operation

Page 19

Section 3 Scheduled Maintenance

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep

hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

Moving rotor.

3.1 Routine Maintenance

Refer to the service schedule following and the hourmeter located on the generator set controller to schedule routine maintenance. Have an authorized distributor/ dealer perform all generator set service. Perform maintenance on each item in the service schedule at the designated interval for the life of the generator set. Service units subject to extreme weather, long operating hours, or dusty or dirty conditions more frequently.

Hot engine and exhaust system. Can cause severe injury or death.

Do not work on the generator set until it cools.

3.2 Service Schedule

Perform the items listed in the following service schedule at the designated intervals for the life of the generator set. For example, an item serviced every

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The

engine and exhaust system components become extremely hot during operation.

100 hours of operation or 3 months must also be serviced after 200 hours or 6 months, 300 hours or 9 months and so on. Rough operation, lack of power, and excessive oil use indicate serious generator set problems. Have an authorized distributor/ dealer perform all generator set service.

TP-6049 9/02 9Section 3 Scheduled Maintenance

Page 20

Procedure

Visually

Inspect

Check Change Clean Test

Frequency

System Component or Procedure

See

Section

Fuel

Flexible lines and connections X R Quarterly

Main tank supply level X Weekly

Fuel piping X Yearly

Lubrication

Oil level X X Daily or before use

Crankcase breather* X X Yearly or 500 hours

Change oil X Yearly or 100 hours

Replace filter* X Yearly or 200 hours

Cooling

Air ducts, louvers X X Yearly

Exhaust Line

Leakage X X Weekly

Insulation, fire hazards X Yearly

Hangers and supports X Yearly

DC Electrical System

Battery charger operation, charge rate (if equipped) X Monthly

Remove corrosion, clean and dry battery and rack X X Yearly

Clean and tighten battery terminals X X Yearly

Battery electrolyte level and specific gravity[

3.3

3.6

3.7

3.8

X Yearly

AC Electrical System

Visible wear or damage X Quarterly

Wire abrasions where subject to motion X X Six Months

Tighten control and power wiring connections X Yearly

Wire-cable insulation breakdown* X 3 Years or 500 hours

Engine And Mounting

Visible wear or damage X Weekly

Air cleaner service 3.5 R Yearly or 100 hours

Spark plugs 3.4 X Yearly or 300 hours

Remote Control System

Compartment condition X X Weekly

Remote control X Monthly

Run generator set X Weekly

Generator

Visible wear or damage 2.1 X Quarterly

Exercise generator set 2.2 X Monthly

Rotor and stator* X X Yearly

Measure and record resistance readings of windings with insulation tester (Megger, with SCR assembly or rectifier disconnected)

X 3 Years

General Condition of Equipment

Evidence of vibration, leakage, excessive noise, temperature, or deterioration

Interior of sound shield housing X X Quarterly

* Consult your local distributor/dealer for parts or service. [ Not necessary for maintenance-free batteries.

X X X Weekly

XAction R Replace as necessary

Figure 3-1 Service Schedule

TP-6049 9/0210 Section 3 Scheduled Maintenance

Page 21

3.3 Lubrication System

3.3.4 Oil Change Procedure

See Section 3.2, Service Schedule, for oil change and oil filter replacement intervals. See Section 1.5, Service Views, for the oil drain, oil check, oil fill, and oil filter locations.

3.3.1 Low Oil Pressure Shutdown

The low oil pressure shutdown feature protects the engine against internal damage if the oil pressure drops below 24.1 kPa ±13.8 kPa (3.5 psi ±1.5 psi) because of oil pump failure or other malfunction. The shutdown feature does not protect against damage caused by operating with the oil level below the safe range; it is not a low oil level shutdown. Check the oil level regularly, and add oil as needed.

3.3.2 Oil Check

The generator set is shipped with oil. Before operating a new generator set, check the engine oil in the crankcase. See 1.5, Service Views. Verify that the oil level is at the F mark on the dipstick. Add oil that has a viscosity appropriate for the climate. See Section 3.3.3, Engine Oil Recommendation, for engine oil recommendations.

Drain the oil while it is still warm.

1. Drain the oil.

a. Place the generator set master switch in the

OFF position.

b. Disconnect the power to the battery charger, if

equipped.

c. Disconnect the generator set engine starting

battery, negative (--) lead first.

d. Remove the housing side panel.

e. Remove the oil drain hose from its retaining

clip. Remove the cap from the oil drain hose and lower the hose into an oil collection container.

f. Open the oil drain valve on the engine.

g. Allow time for the engine oil to drain completely.

h. Close the oil drain valve.

i. Replace the cap on the oil drain hose. Replace

theoildrainhoseinitsretainingclip.

Do not check the oil level when the generator set is running. Shut down the generator set and wait several minutes before checking the oil level.

3.3.3 Engine Oil Recommendation

Use API (American Petroleum Institute) Service Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner. Select the viscosity based on the air temperature at the time of operation. SeeFigure3-2.

10W-30

5W-20, 5W-30

-- 2 0

°C°F-- 3 0 Temperature Range Expected Before Next Oil Change

-- 2 0

01020

-- 1 0

Figure 3-2 Engine Oil Selection

32 60 80 100

02040

2. Replace the oil filter.

a. Remove the oil filter by rotating it

counterclockwise with an oil filter wrench.

b. Clean the gasket sealing surface of the oil filter

adapter.

c. Apply a light coat of clean oil to the rubber seal

of the new oil filter.

d. Install the new oil filter following the instructions

provided with the filter.

Note: Dispose of all waste materials (engine

oil, fuel, filter, etc.) in an environmentally safe manner.

3. Fill with oil.

a. Remove the oil fill cap and fill the engine to the F

mark on the dipstick. The engine oil capacity is

1.9 L (2.0 qt.). See Section 3.3.3, Engine Oil Recommendation, for oil selection.

b. Reinstall the dipstick and the oil fill cap.

c. Check that the generator set master switch is in

the OFF position.

TP-6049 9/02 11Section 3 Scheduled Maintenance

Page 22

d. Reconnect the generator set engine starting

battery, negative (--) lead last.

e. Reconnect the power to the battery charger, if

equipped.

f. Start and run the generator set for a minute to

allow the oil pressure to reach the operating range.

g. Stop the generator set, wait 1 minute, and then

recheck the oil level. Add oil to bring the level up to the F mark on the dipstick.

4. Check for leaks.

a. Check for oil leaks.

b. Fix leaks and recheck the oil level.

c. Reinstall the housing side panel.

3.4 Spark Plugs

1--511

Figure 3-4 Adjusting the Spark Plug Gap

3.5 Air Cleaner Element and Precleaner

The engine has a replaceable high-density paper air cleaner element with an oiled foam precleaner. See Figure 3-5.

Check for a buildup of dirt and debris around the air cleaner system. Keep this area clean.

Reset the spark plug gap or replace the plugs with new plugs as necessary.

1. Clean the area around the base of the spark plug to keep dirt and debris out of the engine.

2. Remove the spark plug and check its condition. Replace the spark plug if it is worn or if its reuse is questionable.

3. Check the spark plug gap using a wire feeler gauge. Adjust the gap to 0.76 mm (0.030 in.) by carefully bending the ground electrode. See Figure 3-3 and Figure 3-4.

1--514

Figure 3-3 Checking the Spark Plug Gap

Note: Operating the engine with loose or damaged air

cleaner components could allow unfiltered air into the engine causing premature wear and failure.

3.5.1 Precleaner Service

Use the following procedure to wash and reoil the precleaner as indicated in the service schedule. Wash and reoil the precleaner more often under extremely dusty or dirty conditions.

1. Place the generator set master switch in the OFF/RESET position.

2. Disconnect the power to the battery charger, if equipped.

3. Disconnect the battery, negative (--) lead first.

4. Loosen the cover retaining knob and remove the cover. Remove the precleaner from the paper element. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out

TP-6049 9/0212 Section 3 Scheduled Maintenance

Page 23

excess water (do not wring). Allow the precleaner to air dry.

5. Saturate the precleaner with new engine oil. Squeeze out all of the excess oil.

6. Reinstall the precleaner over the paper element.

7. Reinstall the air cleaner cover. Secure the cover with the cover retaining knob.

8. Reconnect the power to the battery charger, if equipped.

9. Reconnect the generator set engine starting battery, negative (--) lead last.

3.5.2 Paper Element Service

Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions.

1. Place the generator set master switch in the OFF/RESET position.

2. Disconnect the power to the battery charger, if equipped.

3. Disconnect the generator set engine starting battery, negative (--) lead first.

4. Loosen the cover retaining knob and remove the cover.

5. Remove the element cover nut, element cover, and the paper element with precleaner.

6. Remove the precleaner from the paper element.

Note: Do not wash the paper element or clean it

with pressurized air, as this will damage the element.

1. Cover knob

2. Air cleaner cover

3. Element cover nut

4. Element cover

5. Foam precleaner

6. Air cleaner element

7. Air cleaner base

Figure 3-5 Air Cleaner Components

586536

7. Replace the element if it is dirty, bent, or damaged.

8. Check the air cleaner base. Make sure it is secure and not bent or damaged. Also check the element cover for damage and fit. Replace all damaged air cleaner components. Remove any loose dirt or debris from the air cleaner base. Wipe the base carefully so that no dirt drops into the intake throat. Check the condition of the rubber seal on the air cleaner stud and replace the seal if necessary.

9. Reinstall the paper element, precleaner, element cover, element cover nut, and the air cleaner cover. Secure the cover with the cover retaining knob.

10. Reconnect the power to the battery charger, if equipped.

11. Reconnect the generator set engine starting battery, negative (--) lead last.

TP-6049 9/02 13Section 3 Scheduled Maintenance

Page 24

3.6 Cooling System

3.8 Battery

The engine fan draws cooling air through the opening in the base next to the battery. The generator fan draws cooling air through an opening on the rear wall of the enclosure. The cooling air flows to the alternator at the far end of the unit and over the exhaust system. The air then mixes with the engine exhaust and is discharged at the cabinet outlet. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times. See Figure 3-6.

Note: Do not block the generator set cooling air inlet or

mount other equipment above it. Overheating and severe generator damage may occur.

WARNING

Sulfuric acid in batteries. Can cause severe injury or death.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause

blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Neveradd acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Outlet

1. Air intake (on back; specs GM24829 and later)

Inlet

GM24829

Figure 3-6 Cooling Air Intake and Exhaust

3.7 Exhaust System

Remove all combustible materials from the exhaust location. Combustible materials include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a minimum of 0.3 m (1 ft.) from the exhaust outlet.

Periodically inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for cracks and corrosion.

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace clamps and/or hangers as needed.

Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and

corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke

or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

D Check for and remove loose insulation in the exhaust

duct.

D Check that the exhaust outlet is clear.

TP-6049 9/0214 Section 3 Scheduled Maintenance

Page 25

Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or

equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Refer to this section for general battery information and maintenance. All generator set models use a negative ground with a12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator spec sheet for battery capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information. See Figure 3-7 for typical battery connections, including multiple battery configurations.

3.8.1 Cleaning the Battery

To prevent dirt and grime buildup, occasionally wipe the battery with a damp cloth.

To prevent corrosion, maintain tight, dry electrical connections at the battery terminals. To remove corrosion from battery terminals, disconnect the cables from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water. Do not allow the cleaning solution to enter the battery’s cells. After cleaning, flush the battery and cables with clean water and wipe them with a dry, lint-free cloth.

After reconnecting the battery cables, coat the battery terminals with petroleum jelly, silicone grease, or other nonconductive grease.

3.8.2 Checking Battery Electrolyte Level

Check the electrolyte level and specific gravity of batteries with filler caps. Maintenance-free batteries do not require electrolyte level checking or specific gravity testing.

Clean the battery and cables and tighten battery terminals using the service schedule recommendations. Clean the battery by wiping it with a damp cloth. Keep the electrical connections dry and tight.

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

EZ-273000-J

Figure 3-7 12-Volt Engine Electrical System Single

Starter Motor, Typical Battery Connection

Check the battery electrolyte level before each startup. Remove the filler caps and verify that the electrolyte level reaches the bottoms of the filler holes; see Figure 3-8. Refill as necessary with distilled water or clean tap water. Do not add electrolyte. Install and tighten filler caps. After adding water to the battery in freezing temperatures, run the generator set 20--30 minutes to mix the added water and the battery electrolyte. Mixing the water and the electrolyte prevents the added water from freezing and damaging the battery.

TP-6049 9/02 15Section 3 Scheduled Maintenance

5810321

1. Filler caps

2. Electrolyte level

Figure 3-8 Checking Electrolyte Level

Page 26

3.8.3 Checking Electrolyte Specific Gravity

Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. Use the hydrometer’s test instructions, if available, or Figure 3-9 for bead-type testers.

Temperature affects specific gravity; correct the indicated hydrometer readings for temperature. If the hydrometer does not have a correction table, use Figure 3-10. A fully charged battery should have a specific gravity of 1.260 with the electrolyte at 26.7 _C (80_F). Charge the battery if the specific gravity from cell to cell varies by more than 0.01. Charge the battery if the specific gravity is less than 1.215 with the electrolyte at 26.7_C(80_F).

3.8.4 Charging

Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application. The engine battery-charging system charges the battery while the generator set is running.

Number of

Beads Floating

5 Overcharged

4 Full Charge

3 Adequate Charge

1, 2 Low Charge

0 Battery Dead

Battery

Condition

°C °F

71.1

65.6

60.0

54.4

48.9

43.3

37.8

32.2

26.7

21.1

15.6

4.4

-- 1 . 1

-- 6 . 7

-- 12.2

160

150

140

130

120

110

100

Correction

+ .032

+ .030

+ .028

Example 1:

+ .026

Temperature below 26.7

+ .024

+ .022

Hydrometer Reading 1.250

+ .020

Electrolyte Temperature

+ .018

+ .016

+ .014

+ .012

+ .010

+ .008

+ .006

+ .004

+ .002

-- .002

-- .004

--. 006

-- .008

-- .010

-- .012

-- .014

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

°C(20°F)

--6.7

Subtract .024 Specific Gravity Corrected Specific Gravity is 1.226

Example 2:

Temperature above 26.7

Hydrometer Reading 1.235

Electrolyte Temperature

°C (100°F)

37.8

Add .008 Specific Gravity Corrected Specific Gravity is

1.243

°C(80°F)

Figure 3-9 Electrolyte Testing Chart

The temperature correction amounts to about .004 (4 points) of specific gravity for each 5.5°C(10°F) change in electrolyte temperature.

5810322

Figure 3-10 Specific Gravity Temperature Correction

TP-6049 9/0216 Section 3 Scheduled Maintenance

Page 27

3.9 Storage Procedure

3.9.3 Cylinder Lubrication

Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer’s recommendations for storage, if available.

Note: Run the generator set monthly whenever

possible.

3.9.1 Lubricating System

1. Operate the generator set until it reaches operating temperature, or about 15 minutes.

2. Stop the generator set.

3. While the engine is still warm, drain the engine lubrication oil from the engine crankcase.

4. Refill the engine crankcase with oil. See Section

3.3.3 for oil recommendations.

5. Run the generator set for a few minutes to distribute the clean oil.

6. Stop the generator set.

3.9.2 Fuel System

1. Start the generator set.

1. Remove the spark plugs.

2. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the

plugs.

3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders.

3.9.4 Exterior Preparation

1. Clean the exterior surface of the generator set.

2. Seal all openings in the engine with nonabsorbent adhesive tape.

3. Mask all areas to be used for electrical contact.

4. Spread a light film of oil over unpainted metallic surfaces to prevent rust and corrosion.

3.9.5 Battery

Perform battery storage last.

1. Place the generator set master switch in the OFF/RESET position.

2. With the generator set running, shut off the gas supply.

3. Run the generator set until the engine stops.

4. Place the generator set master switch in the OFF/RESET position.

2. Disconnect the battery, negative (--) lead first.

3. Clean the battery. Refer to Section 3.8.1 for the cleaning procedure.

4. Place the battery in a warm, dry location.

5. Connect the battery to a float/equalize battery charger, or charge the battery monthly using a trickle charger. Follow the battery charger manufacturer’s recommendations.

TP-6049 9/02 17Section 3 Scheduled Maintenance

Page 28

Notes

TP-6049 9/0218 Section 3 Scheduled Maintenance

Page 29

Section 4 Troubleshooting

start,startshar

d,lacks

p,p

This section contains generator set troubleshooting, diagnostic, and repair information.

If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/ dealer. Maintain a record of repairs and adjustments

Use the following chart to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or an open circuit breaker. The

performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to the equipment.

chart includes a list of common problems, possible causes of the problem, and recommended corrective actions.

Note: Contact an authorized distributor/dealer if the

corrective actions described in the following chart do not solve the problem.

Problem Possible Cause Corrective Action

The generator set does not crank.

The generator set cranks but does not

power, or operates erratically.

No AC output. AC circuit breaker in the OFF position Place the circuit breaker in the ON position.

Low output or excessive drop in voltage.

Generator set stops suddenly.

Battery weak or dead Recharge or replace; check battery charger operation.

Battery connections reversed or poor Check the connections.

Controller fuse blown Replace the fuse.

Generator master switch in the OFF position Move the master switch to the RUN position.

Air cleaner clogged Clean and/or replace the air cleaner.

Battery weak or dead Recharge or replace the battery.

Battery connection poor Clean and tighten the battery connections.

Spark plug wire connection loose Check the spark plug wires.

Low oil pressure shutdown Check the oil level.

Fuel pressure insufficient Check the fuel supply and valves.

Engine malfunction Contact the distributor/dealer.

AC circuit breaker tripping because of overload Reduce the load on the generator set.

AC circuit breaker tripping because of short circuit Correct the cause of the short circuit. Contact the

Voltage regulator fuse blown Replace the fuse.

Generator set overloaded Reduce the load.

Low oil pressure shutdown Check the oil level.

Outoffuel Check fuel supply.

Overcrank shutdown Reset the controller. If the overcrank fault occurs again,

Controller fuse blown Replace the fuse. If the fuse blows again, contact the

Overspeed shutdown Reset the controller. If the overspeed fault occurs again,

Generator set master switch in the OFF/RESET position

Engine malfunction Contact the distributor/dealer.

Check battery charging circuit (circuit breaker, module, and wiring), if equipped.

distributor/dealer.

contact the distributor/dealer.

distributor/dealer.

contact the distributor/dealer.

Move the switch to the correct position (RUN or AUTO).

Figure 4-1 General Troubleshooting Chart

TP-6049 9/02 19Section 4 Troubleshooting

Page 30

Notes

TP-6049 9/0220 Section 4 Troubleshooting

Page 31

5.1 Specification Numbers

At the time of print, this manual applied to the model numbers and specification (spec) numbers in Figure 5-1. On occasion the manufacturer may provide this manual with units that are not listed below, such as when similar new specs are created prior to the updated reprint or in other cases when the manual is a suitable substitute for a manual under development.

Controller

Model No.

8.5RMY PA-195021 No

8.5RMY PA-195025 Yes

8.5RMY GM16902-GA1 Ye s

8.5RMY GM24829-GA1 Ye s

11RMY PA-195022 No 11RMY PA-195026 Yes 11RMY GM16902-GA2 Ye s 11RMY GM24829-GA2 Ye s

Figure 5-1 Generator Set Specification Numbers

Spec. No.

Fault Lamp

Section 5 Wiring Diagrams

RESET/

RUN

F1 10 AMP

1. Fault lamp (not included on early models)

AUTOOFF

F2 10 AMP TYPE ABCTYPE ABC

Figure 5-2 Controller

OFF

FAULT

GM10615

5.2 Controller Wiring Diagram Reference

Compare the front of the generator set controller with Figure 5-2. Use the version 1 diagrams for units that do not have a fault lamp on the front of the controller. Use the version 2 diagrams for units that have a fault lamp.

Figure 5-3 lists the wiring diagram numbers and locations.

Controllers

Without Fault Lamps

Wiring Diagram Description

Schematic Diagram ADV-6297-D 23 ADV-6524- 25

Point-to-Point Wiring Diagram GM10164-A 24 GM10619- 26

(Version 1)

Figure 5-3 Controller Wiring Diagrams

Controllers

With Fault Lamps

(Version 2)

TP-6049 9/02 21Section 5 Wiring Diagrams

Page 32

Notes

TP-6049 9/0222 Section 5 Wiring Diagrams

Page 33

TP-6049 9/02 23Section 5 Diagrams and Drawings

Relay Controller, Schematic Diagram, 1 Phase, ADV-6297-D

Page 34

TP-6049 9/0224 Section 5 Diagrams and Drawings

Relay Controller, Point-to-Point Wiring Diagram, 1 Phase, GM10164-A

Page 35

TP-6049 9/02 25Section 5 Diagrams and Drawings

Relay Controller, Schematic Diagram, ADV-6524-

Page 36

TP-6049 9/0226 Section 5 Diagrams and Drawings

Relay Controller, Point-to-Point Wiring Diagram, GM10619-

Page 37

Section 6 Installation

6.1 General

Installation must comply with these installation instructions. Install the generator set to comply with state and local code requirements.

Use the specifications provided here only in the initial planning. Use the respective spec sheets, dimension drawings, and wiring diagrams for installation. Contact an authorized service distributor/dealer for the most current information.

Provide a 110- or 120-volt outlet connected to the utility power supply for the carburetor heater and battery charger, if used.

6.2 Air Requirements

The generator set requires correct air flow for cooling and combustion. The inlet and outlet openings in the sound enclosure housing provide the cooling and combustion air. Figure 6-1 shows the locations of the cooling air intake and exhaust vents. Do not block or otherwise interfere with the airflow through these openings.

Inspect the air inlet and outlet openings inside and outside the housing to ensure that debris does not block the air flow. Mount the generator so that the hot exhaust does not blow on plants or shrubs. Maintain a minimum of 0.3 m (1 ft.) between the exhaust outlet and combustible materials.

6.3 Exhaust Requirements

6.4 Weight

WARNING

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.

The genertor set weighs approximately 182 kg (400 lbs.). Use lifting bars inserted through the holes in the skid to lift the unit. See Figure 6-2 for lifting hole locations.

6.5 Generator Set Inspection

Complete a thorough inspection of the generator set. Check for the following:

1. Inspect the generator set for loose or damaged parts or wires. Repair or tighten any loose parts before installation.

2. Check the engine oil. Fill, if necessary, with the recommended make and grade of oil. See Section 3.3.3 for engine oil recommendations.

The exhaust system is complete for generator sets installed outdoors. Do not install this generator set indoors.

1. Exhaust outlet

2. Alternator air intake (on back)

3. Engine air intake

Figure 6-1 Cooling Air Intake and Exhaust

TP-6049 9/02 27Section 6 Installation

GM24829

6.6 Mounting

Do not install the generator set directly on the ground. Mount the generator set on a level pad. Use a simple concrete slab, precast base, or other non-combustible, stable material. The mounting pad should be at least 1320 mm (52 in.) long and 800 mm (31.6 in.) wide. Center the unit on the mounting pad.

Figure 6-2 shows the generator set dimensions, mounting hole locations, and fuel and electric stub-up locations. The drawing dimensions are shown in mm with inches in parentheses.

Secure the generator set and ensure that it does not move while operating.

Page 38

METRIC CAD FILE

ADV-6788

Figure 6-2 Generator Set Mounting Details and Dimensions

TP-6049 9/0228 Section 6 Installation

Page 39

6.7 Fuel System

The generator set operates using natural gas or LP vapor fuel. The multi-fuel system allows conversion from natural gas to LP vapor (or vice-versa) in the field while maintaining emissions-standard compliance. A trained technician or authorized distributor/dealer can convert the fuel system. Generator sets with multi-fuel systems are CARB- and EPA-certified for both natural gas and LP vapor fuels.

6.7.1 Fuel Supply

Comply with local, state, and federal codes regarding the correct storage of fuel. Because of variable climates and geographical considerations, contact an authorized service distributor/dealer for fuel system planning and installation. Figure 6-2 shows the location of the fuel inlet connection, the fuel and electric stub-up area, and the rear panel access holes. Bring the fuel supply lines through either the bottom or the rear access openings. Protect all fuel lines from machinery or equipment contact, adverse weather conditions, and environmental damage.

Verify that the output pressure from the primary gas utility (or LP tank) pressure regulator is 1.7--2.7 kPa (7--11 in. water column) and that the utility gas meter flow rate is sufficient to supply the generator set plus all other gas-consuming appliances. Figure 6-3 shows the flow rate required for the generator set. Contact the natural gas utility for flow rate information or a gas meter upgrade.

Generator Set Model Gas Flow Rate, Btu/hr.

8.5RMY 132,000

11R MY 192,000

12RMY 202,000

Figure 6-3 Natural Gas Flow Rate

Maximum Pipe Length m (ft.)

Pipe Size

3/4 in. NPT 18.3 (60) 9.2 (30) 9.2 (30)

1 in. NPT 61 (200) 30 (100) 30 (100)

1 1/4 in. NPT 91.5 (300) 68.6 (225) 68.6 (225)

8.5RMY 11RMY 12RMY

Figure 6-4 Maximum Natural Gas Pipe Length

6.7.3 Single-Fuel Systems

Generator sets with single-fuel systems are equipped with the fuel valve shown in Figure 6-5 and have specification numbers starting with PA-.

Single-fuel generator sets that have the decal shown in the Introduction section are emission-certified. The fuel systems on emission-certified single-fuel generator sets are not field-convertible or adjustable. The factory sets the fuel system for the specified fuel and seals it to prevent adjustments.

Note: Do not adjust or convert the fuel system on an

emission-certified single-fuel generator set. Changing the fuel or adjusting the fuel systems on these units may violate federal or state laws.

6.7.2 Fuel Pipe Size

Ensure that the natural gas pipe size and length meet

RUN

TYPEABC

F110 AMP

OFF

RESET/

AUTOOFF

F210 AMP TYPEABC

the specifications in Figure 6-4. 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 measured length for each 90 degree elbow. Compare the pipe size and length with the chart in Figure 6-4. If the piping is longer than the maximum length shown for that size, replace it with the specified size before proceeding.

Contact the local LP provider for LP installation information.

P-358000-C

1. Fuel valve

Figure 6-5 Single-Fuel Generator Set Fuel Valve

Location

TP-6049 9/02 29Section 6 Installation

Page 40

Single-fuel generator sets that are not emission-certified do not have the emission decal. An authorized distributor/dealer can convert the fuel system from natural gas to LP vapor (or vice-versa) on a non-certified unit. Converting the fuel system includes adjusting the fuel metering valve and checking the exhaust emissions. The generator set service manual explains the adjustment procedures.

6.7.4 Multi-Fuel Systems

Generator sets with multi-fuel systems are CARB- and EPA-certified for both natural gas and LP vapor fuels. Multi-fuel units are equipped with the fuel block shown in Figure 6-6 and have specification numbers beginning with GM. The multi-fuel system allows conversion from natural gas to LP vapor (or vice-versa) in the field while maintaining emissions-standard compliance. A trained technician or authorized distributor/dealer can convert the fuel system.

6.7.5 Fuel Conversion (multi-fuel models only)

Two fuel connections on the fuel block allow fieldconversion between natural gas and LP vapor. The fuel metering valves are factory-set and sealed to comply with applicable emission standards and to provide the best possible hot and cold starting.

Note: Do not adjust the factory-sealed fuel-metering

adjustments on the fuel block. Changing the fuel-metering adjustments on multi-fuel units may violate federal or state laws.

The manufacturer ships the generator set with the fuel system connected for natural gas. To convert to LP gas, use the following procedure to move the fuel line from the natural gas outlet port to the LP outlet port in the fuel block (or from the LP outlet to the natural gas outlet to convert from LP to natural gas). See Figure 6-6 for the fuel block and fuel inlet locations.

WARNING

Accidental starting. Can cause severe injury or death.

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

OUT IN

1. Fuel block

2. Fuel inlet, 1/2 in. NPT female

Figure 6-6 Multi-Fuel Generator Set Fuel Block

Location, Air Inlet Side

ADV-6600

WARNING

Explosive fuel vapors. Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

TP-6049 9/0230 Section 6 Installation

Page 41

Fuel Conversion Procedure for Multi-Fuel Systems

1. Place the generator set master switch in the OFF position.

2. Disconnect the power to the battery charger, if equipped.

3. Disconnect the generator set engine starting battery, negative (--) lead first.

4. Turn off the fuel supply.

10. Connect the new fuel supply.

11. Turn on the fuel supply and check for leaks using a gas leak detector.

12. Check that the generator set master switch is in the OFF position.

13. Reconnect the generator set engine starting battery leads, negative (--) lead last.

14. Reconnect power to the battery charger, if equipped.

5. Remove the hose clamp and fuel hose from the hose fitting in the fuel block. See Figure 6-7.

6. Remove the hose fitting from the natural gas (or LP) outlet port in the fuel block.

7. Remove the plug from the LP (or natural gas) port in the fuel block. Clean the plug with a dry cloth or brush, apply fresh pipe sealant, and install the plug into the natural gas (or LP) outlet port.

8. Clean the hose fitting with a dry cloth or brush, apply fresh pipe sealant to the threads, and install the fitting into the LP (or natural gas) port.

Note: Do not adjust the fuel metering valves.

9. Slide the hose onto the hose fitting and secure it with the clamp.

6.8 Electrical Connections

6.8.1 Accessory Electrical Connections

Some accessories, including a run relay and a common fault relay, can be connected to the generator set. Contact an authorized service distributor/dealer for a list of accessories.

Have the accessories installed by an authorized distributor/dealer or a licensed electrician. Follow the installation instructions provided with each kit. Most accessories operate on 12 volts DC; some may require AC line voltage. Use separate conduit for AC and DC leads to reduce the possibility of electrical interference. Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas. Verify that the electrical installation complies with the National Electrical Code (NEC) and all applicable local and state codes. See Section 5, Wiring Diagrams, for more information regarding generator set electrical connections.

OUT IN

1. Fuel block

2. Fuel metering valves—factory-sealed, do not adjust

3. Clamp

4. Fuel line hose

5. Plug

6. Fuel inlet, 1/2 in. NPT

Figure 6-7 Fuel Block Connections, Natural Gas

System Shown

TP-6049 9/02 31Section 6 Installation

ADV-6600

Page 42

6.8.2 AC Load Lead Connections

Have an authorized distributor/dealer or a licensed electrician make the following load connections. Connect the AC output leads in the controller compartment to the AC circuit breaker. Route AC and DC leads through the bottom of the generator set or through flexible conduit directly to the AC circuit breaker box. See Figure 6-2. Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas.

See Figure 6-8 and Section 5, Wiring Diagrams, for the generator set electrical connections. Make the following AC connections:

1. Connect the output leads going to the transfer switch (L1/L2 black leads) to the AC circuit breaker load side (top).

2. Connect the L0 white leads from the ATS and the main panel to the neutral stud.

3. Connect the green lead to the equipment ground stud (labeled GRD).

Verify that the electrical installation complies with the National Electrical Code (NEC) and all applicable local and state codes.

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.

6.8.3 Battery

6868

6767

7N7N

7070

FPFP

FNFN

GRD

3232

WARNING

Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolatethe battery charger from explosive fumes.

GM10615A-A

1. AC load leads

2. Ground terminal (GRD)

3. Neutral terminal (L0)

4. Circuit breaker

5. ATS engine start leads

Figure 6-8 Typical Controller, Top View with

Field-Installed Wiring

TP-6049 9/0232 Section 6 Installation

Page 43

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke

Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or

1. Battery cables and carburetor heater power cord, if equipped

2. Engine starting battery

OUT IN

Figure 6-10 Battery Location, Engine End

Battery Installation Procedure

A-358000A-C

Use a 12-volt battery with a minimum rating of 675 cold cranking amps at 0_F. The generator set uses a negative ground with a 12-volt engine electrical system. See Figure 6-9 for battery connections. Make sure that the battery is correctly connected and the terminals are tight.

Note: The generator set will not start and circuit board

damage may occur if the battery is connected in reverse.

Figure 6-10 shows the location of the engine starting battery. Standard battery cables provide easy connection to the battery. Use the following procedure to install and connect the battery.

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

EZ-273000-J

Figure 6-9 12-Volt Engine Electrical System Single

Starter Motor Typical Battery Connection

1. Ensure that the starting battery is fully charged before placing the battery in service.

2. Clean the battery posts and/or adapters if necessary.

3. Install the battery post adapters, if needed.

4. Place the battery in the housing.

5. Verify that the controller master switch is in the OFF position.

6. Connect the positive (+) lead to the engine starting battery.

7. Connect the negative (--) lead to the engine starting battery.

Refer to Section 3.8 for battery maintenance instructions.

6.8.4 Battery Charger

Generator sets that are not exercised regularly require an external battery charger to keep the starting battery fully charged. Obtain a battery charger from your generator set supplier. Observe the battery polarity when connecting the battery charger. Plug the battery

TP-6049 9/02 33Section 6 Installation

Page 44

charger into a 110 or 120-volt outlet connected to the utility power.

Figure 6-11 shows the blower housing covers installed. The covers are not used on all units.

6.8.5 Carburetor Heater

The generator set may be equipped with a carburetor heater. The carburetor heater prevents condensation and carburetor icing. The heater turns on when the temperature at the thermostat falls below approximately 4_C(40_F) and turns off when the temperature rises above approximately 16_C(60_F). The thermostat continously senses temperature and controls the carburetor heater.

The heater requires a continuous source of 120 V power. The heater power cord and thermostat are located in the generator set housing air intake area/battery compartment. See Figure 6-10. Plug the carburetor heater into an outlet that has continuous 120 volt power.

Figure 6-11 shows the heater power cord running from inside the engine compartment to the air intake area/battery compartment. The heater thermostat is installed in the cord. Figure 6-12 shows the location of the thermostat on the power cord.

A DC version of the carburetor heater is available. Refer to the installation instructions provided with the DC carburetor heater kit.

1. Carburetor heater (air cleaner removed to show heater)

2. Blower housing covers (not used on all units)

3. Carburetor heater power cord

005tp1

Figure 6-11 Carburetor Heater Power Cord

Note: Do not place the heater thermostat inside the

generator set engine compartment. The thermostat must be exposed to the ambient air. The thermostat will shut off power to the heater when the ambient temperature reaches approximately 60_F(16_C).

1. Thermostat

2. Connector

3. Heater

2 3

Figure 6-12 Carburetor Heater with Thermostat

GM19463

TP-6049 9/0234 Section 6 Installation

Page 45

6.9 Generator Reconnection

The generator set can produce a variety of voltages at either 50 or 60 Hz. See Figure 6-13. This section gives voltage reconnection instructions. For frequency adjustments, refer to the generator set service manual, TP-5867.

Verify that the installation complies with the National Electrical Code (NEC) and all applicable local and state codes.

Wires 60 Hz 50 Hz

3* 120/240 110/220

* Factory connection [ Field reconnection

Figure 6-13 Generator Connection Options

6.9.1 Voltage Reconnection

240 220

120 110

Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

Moving rotor.

The following information illustrates the reconnection of 4-lead generator sets. Refer to the following connection schematics. Follow all the safety precautions and instructions at the beginning of this manual and in this section while performing the reconnection procedure.

Note: Order voltage reconnection decal 246242 from

an authorized service distributor/dealer and affix the decal to the generator set after reconnecting to a voltage different from the nameplate.

WARNING

Accidental starting. Can cause severe injury or death.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible

whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury

and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

TP-6049 9/02 35Section 6 Installation

Page 46

6.9.2 Factory Connections, 110/220 Volt 50 Hz or 120/240 Volt 60 Hz

Generator sets are available from the factory connected for 110/220 Volt 50 Hz or 120/240 Volt 60 Hz. See Figure 6-14 for the factory connections.

6.9.3 Reconnection Options

The following reconnections can be made using the factory two-pole circuit breaker provided. It is the responsibility of the individual performing the reconnection to meet all the electrical codes.

Leads L1 and L2 are of different phases. Never connect leads L1 and L2 together. After connection adjust the voltage regulator to obtain the desired voltage.

Note: Use a circuit breaker manufacturer’s two-pole

circuit breaker. Two single-pole circuit breakers do not conform to NEC requirements when supplying a 220 or 240 volt load. This is true even if they are mechanically attached together.

LO (Neutral)

Ground

Load Side

Line Side

4321

Stator Leads

L0-L1 L0-L2 L1-L2

120 volt 120 volt 240 volt

60 Hz

LO GRD

L2 L1

Factory two-pole circuit breaker

50 Hz

110 volt 110 volt 220 volt

TP-5867

Figure 6-14 110/220 and 120/240 Volt, 3-Wire

Configurations

See Figure 6-15 for four-lead reconnectable (singlephase) generator set voltage options.

60 Hz 50 Hz

120 Volt 110 Volt

120/240 Volt 110/220 Volt

240 Volt 220 Volt

Figure 6-15 Four-Lead, Single-Phase Generator Set

Voltage Connection Options

110 and 120 Volt Configurations

When connecting stator phase leads, size output lead (L1) accordingly. Use a jumper lead with the same ampere rating as the output lead L1 on the side of the circuit breaker shown. After connection adjust the voltage regulator to obtain the desired voltage.

Note: Electrical Codes: The 110 and 120 Volt

reconnection configurations require a jumper lead on one end of the circuit breaker. This configuration is acceptable per the National Electrical Code, NFP A #70. Never jumper both the line and load

ends of the circuit breaker. A jumper on both the line and load ends violates the National Electrical Code by paralleling the breaker poles. On occasion local electrical inspectors have

objected to a jumper on the load side of the circuit breaker. It is the responsibility of the individual who is reconnecting the output to make certain the reconnection satisfies the local inspector. The purchase and installation of a single pole breaker to replace the two-pole breaker may be necessary .

Note: Jumper Sizing: Use a jumper lead with the same

ampere rating as the output lead L1 on the side of the circuit breaker shown.

TP-6049 9/0236 Section 6 Installation

Page 47

Ground

Load Side

Line Side

43 21

Stator Leads

LO (Neutral)

LO GRD

L1 L2

Factory two-pole circuit breaker

Field installed jumper lead

220 and 240 Volt Configuration

A jumper lead is not used. After connection adjust the voltage regulator to obtain the desired voltage.

Load Side

Line Side

LO (Neutral)

Ground

Factory two-pole circuit breaker

GRD

L0-L1 L0-L2

60 Hz

120 volt 120 volt

50 Hz

110 volt 110 volt

TP-5867

Figure 6-16 110 and 120 Volt, 3-Wire Configurations

Ground

Load Side

4321

Stator Leads

L0-L1

100--120 volt

LO (Neutral)

Line Side

60 Hz

LO GRD L1

Field installed jumper lead

Two-pole circuit breaker

50 Hz

110--120 volt

Note: The existing ammeter lower scale indicates

half of the actual L1 current. DO NOT PUT THE CT ON L1. Either label the ammeter with a note indicating lower scale times two, or purchase a new ammeter scaled twice the existing ammeter and install the new ammeter.

TP-5867

4321

Stator Leads

L0-L1

Tape to insulate from ground

60 Hz

240 volt

50 Hz

220 volt

TP-5867

Figure 6-18 220 and 240 Volt, 2-Wire Configurations

6.10 Prestart Installation Check

Review the entire installation section. Inspect all wiring and connections to verify that the generator set is ready for operation. Check that there are no obstructions to the air inlet and outlet.

Complete the startup procedure and installation checklists supplied with the startup notification form. Return the form to the distributor/dealer or mail it directly to:

Kohler Power Systems Generator Warranty Administrator M.S. 072 Kohler, Wisconsin 53044

Figure 6-17 110 and 120 Volt, 2-Wire Configurations

TP-6049 9/02 37Section 6 Installation

Page 48

Notes

TP-6049 9/0238 Section 6 Installation

Page 49

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional

AHWT anticipatory high water

AISI American Iron and Steel

ALOP anticipatory low oil pressure alt. alternator Al aluminum ANSI American National Standards

AO anticipatory only API American Petroleum Institute approx. approximate, approximately AR as required, as requested AS as supplied, as stated, as

ASE American Society of Engineers ASME American Society of

assy. assembly ASTM American Society for Testing

ATDC after top dead center ATS automatic transfer switch auto. automatic aux. auxiliary A/V audiovisual avg. average AVR automatic voltage regulator AWG American Wire Gauge AWM appliance wiring material bat. battery BBDC before bottom dead center BC battery charger, battery

BCA battery charging alternator BCI Battery Council International BDC before dead center BHP brake horsepower blk. black (paint color), block

blk. htr. block heater BMEP brake mean effective pressure bps bits per second br. brass BTDC before top dead center Btu British thermal unit Btu/min. British thermal units per minute C Celsius, centigrade cal. calorie CARB California Air Resources Board CB circuit breaker cc cubic centimeter CCA cold cranking amps ccw. counterclockwise CEC Canadian Electrical Code cert. certificate, certification, certified

drawing

temperature

Institute

Institute (formerly American Standards Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

cfh cubic feet per hour cfm cubic feet per minute CG center of gravity CID cubic inch displacement CL centerline cm centimeter CMOS complementary metal oxide

cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards

CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., ° degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung

DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems

EIA Electronic Industries

EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection

EPS emergency power system ER emergency relay ES engineering special,

ESD electrostatic discharge est. estimated

substrate (semiconductor)

Association

e. V. (also Deutsche Industrie Normenausschuss)

Association

Agency

engineered special

E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. external F Fahrenheit, female fglass. fiberglass FHM flat head machine (screw) fl. oz. fluid ounce flex. flexible freq. frequency FS full scale ft. foot, feet ft. lbs. foot pounds (torque) ft./min. feet per minute ggram ga. gauge (meters, wire size) gal. gallon gen. generator genset generator set GFI ground fault interrupter

GND, gov. governor gph gallons per hour gpm gallons per minute gr. grade, gross GRD equipment ground gr. wt. gross weight H x W x D height by width by depth HC hex cap HCHT high cylinder head temperature HD heavy duty HET high exhaust temperature,

hex hexagon Hg mercury (element) HH hex head HHC hex head cap HP horsepower hr. hour HS heat shrink hsg. housing HVAC heating, ventilation, and air

HWT high water temperature Hz hertz (cycles per second) IC integrated circuit ID inside diameter, identification IEC International Electrotechnical

IEEE Institute of Electrical and

IMS improved motor starting in. inch in. H in. Hg inches of mercury in. lbs. inch pounds Inc. incorporated ind. industrial int. internal int./ext. internal/external I/O input/output IP iron pipe

ground

high engine temperature

conditioning

Commission

Electronics Engineers

O inches of water

TP-6049 9/02 Appendix A-1

Page 50

ISO International Organization for

Standardization J joule JIS Japanese Industry Standard k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 kg kilogram

kg/cm

kgm kilogram-meter kg/m

kilograms per square

centimeter

kilograms per cubic meter

bytes)

kHz kilohertz kJ kilojoule km kilometer kOhm, kW kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds

lbm/ft

pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side L

sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (10

units), male

cubic meter

/min. cubic meters per minute

when used with SI

mA milliampere man. manual max. maximum MB megabyte (2

bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, mW

milliohm

MOhm, MW

megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour

MS military standard m/sec. meters per second MTBF mean time between failure MTBO mean time between overhauls mtg. mounting MW megawatt mW milliwatt mF microfarad N, norm. normal (power source) NA not available, not applicable nat. gas natural gas NBS National Bureau of Standards NC normally closed NEC National Electrical Code NEMA National Electrical

Manufacturers Association

NFPA National Fire Protection

Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe

thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment

manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health

Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., Æ phase PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only

memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency)

power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference

RH round head RHM round head machine (screw) rly. relay rms root mean square rnd. round ROM read only memory rot. rotate, rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive

Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s, sec. second SI Systeme international d’unites,

International System of Units SI/EO side in/end out sil. silencer SN serial number SPDT single--pole, double--throw SPST single--pole, single-- throw spec, specs

specification(s) sq. square sq. cm square centimeter sq. in. square inch SS stainless steel std. standard stl. steel tach. tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to

normal TDES time delay engine start TDNE time delay normal to

emergency TDOE time delay off to emergency TDON time delay off to normal temp. temperature term. terminal TIF telephone influence factor TIR total indicator reading tol. tolerance turbo. turbocharger typ. typical (same in multiple

locations) UF underfrequency UHF ultrahigh frequency UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ. universal US undersize, underspeed UV ultraviolet, undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency W watt WCR withstand and closing rating w/ with w/o without wt. weight xfmr transformer

TP-6049 9/02A-2 Appendix

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TP-6049 9/02f

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 KohlerPowerSystems.com

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455