Kohler 7ER Installation Manual

Installation

Commercial Mobile Generator Sets

Model:

7ER

TP-6034 10/02a

Table of Contents

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

Section 1. Introduction 1......................................................................

1.1 Installation Standards 1..................................................

1.2 Generator Set Specifications 1............................................

1.3 Generator Set Operation 1...............................................

Section 2. Location and Mounting 3..........................................................

2.1 General Considerations 3................................................

2.2 Location 3.............................................................

2.3 Vehicle-Floor Mounting 3.................................................

2.4 Extended-Shaft Mounting 4...............................................

Section 3. Cooling System 5.................................................................

3.1 Air Requirements 5......................................................

3.2 High Water Temperature Switch 5.........................................

Section 4. Exhaust System 7.................................................................

4.1 Planning 8.............................................................

4.2 Clearance Requirements 8...............................................

4.3 Exhaust Piping, If Used 8................................................

Section 5. Fuel System 9....................................................................

5.1 Fuel Tank 9............................................................

5.2 Fuel Lines 10............................................................

5.3 Fuel Pump Lift and Fuel Consumption 10....................................

5.4 Fuel Filters or Strainers 10.................................................

Section 6. Electrical System 11................................................................

6.1 Electrical Connections 11.................................................

6.2 AC Load Lead Connections 11.............................................

6.3 Circuit Protection 13......................................................

6.3.1 Circuit Breaker Considerations 13..................................

6.3.2 Circuit Breaker Installation 14......................................

6.4 Battery and Connections 15...............................................

6.5 Remote Switch Connection 16.............................................

Section 7. Installation Drawing 17.............................................................

Section 8. Reconnection/Adjustments 19......................................................

8.1 Four-Lead Reconnection 19...............................................

8.2 Voltage Regulation Adjustment 21..........................................

Appendix A. Generator Selection and Wattage Requirements A-1.................................

Appendix B. Glossary of Abbreviations A-2.....................................................

TP-6034 10/02 Table of Contents

Notes

TP-6034 10/02Table of Contents

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 several types of safety
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,orsubstantial
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
equipment connected to the set,
disable the generator set as follows:
(1) Place the generator set start/stop
switch in the STOP position.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.

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.

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 thecase
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.

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.

TP-6034 10/02

Safety Precautions and Instructions I

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

Combustible materials. A fire can
cause severe injury or death.

Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.

Exhaust System

WARNING

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.

WARNING

Fire.
Can cause severe injury or death.

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

Servicing the fuel system. A flash
fire can cause severe injury or death.

Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.

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

set with the air cleaner removed.

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 backinside
a potentially occupied building or
vehicle. Do not obstruct the exhaust
outlet when parking your vehicle. The
exhaust gases must discharge freely to
prevent carbon monoxide from
deflecting into the vehicle.

Installing the exhaust tail pipe.
Carbon monoxide can cause severe
nausea, fainting, or death. Install the

exhaust system tail pipe to prevent the
drawing of discharged exhaust gases
into the vehicle interior through
windows, doors, air conditioners, and
other openings. Do not use flexible tail
piping because it could crack and allow
lethal exhaust fumes to enter the
vehicle.

Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the

safety ofthevehicle’s occupants, install
a carbon monoxide detector. Consult
the coach builder or dealer for
approved detector location and
installation. Inspect the detector before
each generator set use. In addition to
routine exhaust system inspection, test
the carbon monoxide detector per the
manufacturer’s instructions and keep
the detector operational at all times.

II Safety Precautions and Instructions

TP-6034 10/02

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. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.

Explosive fuel vapors can cause
severe injury or death. Take

additional precautions when using the
following fuels:

Gasoline—Store gasoline only in
approved red containers clearly
marked GASOLINE.

Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an

explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.

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 severe injury, death, or
property damage.

Connect the generator set to the
building’s electrical system only
through an approved device and after
the building’s main switch is opened.

Moving rotor.

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 applicablecodes
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.

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.

Connect the generator set to the
building/campground electrical system
only through an approved device and
after the building/campground main
switch is opened. Backfeed
connections can cause severe injury or
death to utility personnel working on
power lines and/or personnel near the
work area. Some states and localities
prohibit unauthorized connection to the
utility electrical system. Install a
transfer switch to prevent
interconnection of the generator set
power and other sources of power.

TP-6034 10/02

Safety Precautions and Instructions III

Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have

trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and followtheinstructionsofthe
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.

(600 volts and under)

Hot Parts

WARNING

Hot coolant and steam.
Can cause severe injury or death.

Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

WARNING

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

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

Combustible materials. Fire can
cause severe injury or death. A hot

exhaust system can ignite adjacent
combustible materials. Do not locate
electrical wiring, fuel lines, or
combustible materials above the
exhaust muffler. Exercise caution
when parking your vehicle to prevent
the exhaust system and hot exhaust
gases from starting grass fires.

Combustible materials. Fire can
cause severe injury or death. A hot

generator set can ignite debris in the
compartment. Keep the compartment
and generator set clean and free of
debris and combustible materials to
minimize the possibility of fire. Do not
block the fuel/oil drain opening in the
generator set mounting tray. Cut a
corresponding hole in the subfloor, if
used, for the drain opening.

Moving Parts

WARNING

Hazardous voltage.
Can cause severe injury or death.

Moving rotor.

WARNING

Airborne particles.
Can cause severe injury or
blindness.

Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.

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

the hardware or pulley to release from
the generator setengineandcancause
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.

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

Do not work on the generator set until
it cools.

Checking the coolant level. Hot
coolant can cause severe injury or
death. Allow the engine to cool.

Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure cap with a thick cloth and then
slowly turn the cap counterclockwise to
the first stop. Remove the cap after
pressure has been completely
released and the engine has cooled.
Check the coolant level at the tank if the
generator set has a coolant recovery
tank.

IV Safety Precautions and Instructions

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

WARNING

Rotating parts.
Can cause severe injury or death.

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

TP-6034 10/02

Notice

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.

NOTICE

This generator set does not comply
with United States Coast Guard
(USCG) requirements and must not
be used for marine applications. For

marine installations use only generator
sets specified for marine use. USCG
Regulation 33CFR183 requires that a
generator set must be ignition
protected when used in a
gasoline-fueled environment.

TP-6034 10/02

Safety Precautions and Instructions V

Notes

VI Safety Precautions and Instructions

TP-6034 10/02

Section 1 Introduction

All information in this publication represents data
available at the time of print. Kohler Co. reserves the right
to change this literature and the products represented
without incurring obligation.

The safe and successful operation of a mobile power
system depends primarily on the installation. Use this
manual as a guide for installing the mobile generator set.
Refer to the operation manual for operating instructions.

1.1 Installation Standards

Mobile generator set installations must comply with the
Kohler detailed installation instructions following and
state and local requirements.

The installer is responsible for improper installations
resulting in penalties from noncompliance with CARB or
EPA emission standards.

1.2 Generator Set Specifications

Refer to the model’s specification sheet for details. Use
the spec sheet as a guide for planning the installation.
Use the current dimension drawing and wiring diagrams.

1.3 Generator Set Operation

After the installer attaches the generator set to the
vehicle’s frame and connects the hoses, do the following
to make the generator set operational:

D Attach the exhaust system

D Add radiator coolant

D Add oil to the engine crankcase until the dipstick

indicates full

D Connect the fuel line

D Connect the remote switch, if equipped

D Connect the load leads

D Connect the battery terminals

IntroductionTP-6034 10/02

1

Notes

2

Introduction TP-6034 10/02

Section 2 Location and Mounting

2.1 General Considerations

Consider the following items concerning the generator
set and Section 2.2 for the proposed location.

1. Select a generator set having adequate capacity to
handle the electrical load.

2. Design the fuel system to prevent fuel starvation of
the main or generator set engine.

3. Ensure that the exhaust system meets all safety
requirements after installation.

4. Ensure compatibility of all electrical systems
(battery, load, and remote switch) with the vehicle’s
electrical systems.

2.2 Location

Note: This generator set is not designed for installation

in a compartment or enclosure.

Before making final plans for locating the generator set,
ensure the following:

1. The location has sufficient room to maintain
required minimum clearances.

2.3 Vehicle-Floor Mounting

Install the Kohler 7ER mobile generator set on an open
vehicle’s floor or truck bed. Follow the guidelines below.
Contact an authorized Kohler service distributor/dealer
with your specific application questions.

Minimum clearance. Allow clearance for vibration and
cooling during operation. Minimum clearance for
vibration (top, front, rear, and sides) is 38 mm (1 1/2 in.).
Keep the radiator end unobstructed for proper air flow.

Additional clearance. Generator set service requires
more clearance than 38 mm (1 1/2 in.). Design the
mounting location to allow for sufficient room to easily
remove the generator set to perform major service.

Mounting tray. Ensure that the structural members for
mounting can support the generator set’s weight and
withstand vibration. The generator set includes
vibration mounts and a mounting tray; if desired, install
additional vibration isolating pads underneath the
generator set’s base. Use the four mounting holes in the
mounting tray to mount the generator set securely to the
vehicle to avoid unwanted movement from vibration and
road shock.

2. The location provides enough air flow to allow
required cooling and combustion.

3. The location can support the generator set weight.

4. The location provides ample room for routine
service of the generator set’s engine, controller,
cooling system, and fuel system components.

See the current generator set specification sheet or
Section 7 of this manual for generator set dimensions
and weights.

For angular operating limits, consult the operation
manual.

TP-6034 10/02 Location and Mounting 3

2.4 Extended-Shaft Mounting

If the mobile generator set includes an extended shaft,
allow adequate space at the generator end of the set for
an adapter, flexible coupling, and the operating
equipment. The mounting flange conforms to
SAE J609a, Flange B. See Figure 2-1 for dimensions.

Note: Customers must provide the adapter and flexible

coupling for the extended-shaft option.

1-921

Figure 2-2 Hydraulic Pump

Note: Adding a hydraulic-pump drive lowers the engine

horsepower available to drive the generator.
Therefore, the engine can be overloaded. Be
aware of reduced generator output when
powering external equipment.

Figure 2-1 Extended Shaft Dimensions

Figure 2-2 shows a Kohler mobile generator set
mounted to a hydraulic pump. The generator set
equipped with the extended-shaft option can power
external equipment to the limit of the engine’s capacity.

Note: The output shaft can pull max. horsepower. The

extended shaft is designed for powering a
direct-driven hydraulic pump.

4 Location and Mounting TP-6034 10/02

ADV-6450-E

Section 3 Cooling System

3.1 Air Requirements

Air flow around the generator set is necessary for
adequate cooling. See the current generator set
specification sheet for air requirements. The air intake
silencer/cleaner provides combustion air to the engine.
See Figure 3-1 for allowable intake restriction. The
engine/generator performance will be adversely
affected if these guidelines are neglected. Follow these
guidelines to optimize generator set performance.

Model Normal Intake Restriction

7ER 0.03 psi (0.79 in. H2O)

Figure 3-1 Intake Restriction

3.2 High Water Temperature
Switch

Each generator set includes a high water temperature
shutdown switch that automatically shuts down the set if
operating temperatures climb too high. Follow the
guidelines described in Section 3.1 to prevent
shutdowns.

TP-6034 10/02 Cooling System 5

Notes

6 Cooling System TP-6034 10/02

Section 4 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 or vehicle. Do not obstruct the
exhaust outlet when parking your vehicle. The exhaust gases
must discharge freely to prevent carbon monoxide from
deflecting into the vehicle.

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

is a poisonous gas 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.

Installing the exhaust tail pipe. Carbon monoxide can
cause severe nausea, fainting, or death. Install the exhaust

system tail pipe to prevent the drawing of discharged exhaust
gases into the vehicle interior through windows, doors, air
conditioners, and other openings. Do not use flexible tail
piping because it could crackand allowlethal exhaust fumesto
enter the vehicle.

Inspecting the exhaust system. Carbon monoxide can
cause severe nausea, fainting, or death. For the safety of

the vehicle’s occupants, install a carbon monoxide detector.
Consult the coach builder or dealer for approved detector
location and installation. Inspect the detector before each
generator set use. In addition to routine exhaust system
inspection, test the carbon monoxide detector per the
manufacturer’s instructions and keep the detector operational
at all times.

WARNING

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

Do not work on the generator set until
it cools.

Combustible materials. Fire can cause severe injury or
death. A hot exhaust system can ignite adjacent combustible

materials. Do not locate electrical wiring, fuel lines, or
combustible materials above the exhaust muffler. Exercise
caution when parking your vehicle to prevent the exhaust
system and hot exhaust gases from starting grass fires.

TP-6034 10/02 Exhaust System 7

7

4.1 Planning

4.3 Exhaust Piping, If Used

Carefully plan the generator exhaust system to ensure a
safe, quiet installation. Verify that the installation
complies with all state and local requirements and
applicable articles of the codes listed at the beginning of
this manual.

4.2 Clearance Requirements

Kohler Co. recommends a clearance of 38 mm
(1 1/2 in.) between the exhaust system parts and the
fuel system, the electrical system, and all combustible
components to protect the generator set components
and to avoid igniting adjacent combustible materials.

Route the exhaust piping to maintain minimum
clearances and to minimize exhaust piping bends. Use
a tail pipe as short as possible with as few bends as
possible to reduce back pressure. Design the exhaust
piping to prevent excessive back pressure of the
unit-mounted muffler. See Figure 4-1 for the allowable
exhaust back pressure. Do not apply weight or pressure
to the unit-mounted muffler, otherwise premature
exhaust-system damage will occur. Adding
exhaust-pipe extensions to the unit-mounted muffler
may cause excessive vibration and noise transmitted to
the vehicle.

Allowable Exhaust

Model

7ER < 1.42 psi (1000 mm H2O)

Figure 4-1 Allowable Exhaust Back Pressure

Back Pressure

TP-6034 10/028 Exhaust System

Section 5 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 in a
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit
flames or sparks to occur near sources of spilled fuel or fuel
vapors. Keep the fuel lines and connections tight and in good
condition. Do not replace flexible fuel lines with rigid lines. Use
flexible sections to avoid fuel line breakage caused by
vibration. Do not operate the generator set in the presence of
fuel leaks, fuel accumulation, or sparks. Repair fuel systems
before resuming generator set operation.

Draining the fuel system. Explosive fuel vapors can
cause severe injury or death. Spilled fuel can cause an

explosion. Use a container to catch fuel when draining the fuel
system. Wipe up spilled fuel after draining the system.

5.1 Fuel Tank

Fuel system design. Design the generator set
gasoline fuel system to operate independently of the
vehicle engine fuel system if the operator may operate
both engines simultaneously. Kohler Co. recommends
using separate fuel tanks, if possible; using separate
fuel tanks is usually impractical because of space
restrictions. In most installations, both engines operate
off a common tank with a separate dip-tube
arrangement as shown in Figure 5-1. The dip-tube
arrangement prevents the larger engine from starving
the smaller engine of fuel. The generator set dip tube is
generally shorter than the vehicle dip tube to stop the
generator set before the vehicle engine runs out of fuel.
With the dip-tube arrangement, the generator may not
get fuel during a low fuel-supply situation.

Tee arrangement. Do not use the tee arrangement. Do
not tee into the fuel-supply or -return line of fuel-injected
systems.

1

2

1. Fuel line to the generator set

2. Fuel line to the vehicle engine

5605613

Figure 5-1 Two Dip Tubes in Fuel Tank

Note: Supply the fuel using a two dip-tube arrangement

if the generator shares the vehicle engine fuel
tank. Consult an authorized Kohler service
distributor/dealer for further fuel system
installation information.

TP-6034 10/02 Fuel System 9

5.2 Fuel Lines

Note: Keep fuel lines away from the exhaust system.

Routing fuel lines. Take care when routing the fuel line

from the fuel tank to the generator set. Keep the fuel
lines as short as possible but maintain adequate
clearance from the exhaust system. Route the fuel lines
along the frame or undercarriage—never route the fuel
lines inside the habitable area of the vehicle. Locate the
fuel lines with the entry point near the fuel pump. See
Section 5.3 for the fuel pump lift.

5.3 Fuel Pump Lift and Fuel
Consumption

See Figure 5-2 for the fuel pump lift capability. Consult
the current generator set specification sheet for the
generator set fuel consumption rates. Do not exceed
3 1/2 psi fuel pump pressure to the carburetor.

Note: Fuel system alterations may adversely affect

emissions levels. Fines resulting from
higher-than-allowable emissions levels are the
responsibility of the user.

Sizing fuel lines. Size the fuel line to handle the flow of
fuel and to withstand road shock and year-round climate
conditions. Use steel tubing as the codes require. Use a
6 mm (1/4 in.) ID tubing with an 230 mm (8 in.)
(minimum) flexible section to allow free movement of the
generator set.

Fuel line size:

Fuel inlet 6 mm (1/4 in.) ID

Flexible hose sections. If a metal fuel line draws fuel
from the fuel tank, install a flexible hose section to
connect the metal line to the fuel pump. The flexible
section allows generator set vibrational motion during
operation. See Section 7 for the fuel inlet-line
connection point.

Note: Gasoline-fueled engines require a type A1 hose.

Model

7ER 0.9 (3)

Figure 5-2 Fuel Pump Lift Capability (Max.)

Fuel Pump Lift

m (ft.)

5.4 Fuel Filters or Strainers

These generator sets are shipped with a fuel filter. No
additional fuel filter or strainer is required.

1. Fuel filter

Figure 5-3 Fuel Filter Location

1

ADV-6450-E

TP-6034 10/0210 Fuel System

Section 6 Electrical System

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

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

generator set to the building/campground electrical system
only through an approved device and after the
building/campground main switch is opened. Backfeed
connections can cause severe injury or death to utility
personnel working on power lines and/or personnel near the
work area. Some states and localities prohibit unauthorized
connection to the utility electrical system. Install a transfer
switch to prevent interconnection of the generator set power
and other sources of power.

Moving rotor.

6.1 Electrical Connections

Have qualified electricians make connections.
Connections to the load leads, battery, and remote
switch panel complete the installation. To prevent
unintentional starting, make final connections to the
battery only after making all other connections.

6.2 AC Load Lead Connections

Routing. Each generator set has four color-coded load
leads. The black leads (L1 and L2) are hot, the white
lead (L0) is neutral, and the green lead is the hazard
ground. See Section 8 for the AC load lead connections.
Route the load leads directly from the junction box to the
vehicle AC circuit or transfer switch connection. Route
the load leads of all installations through flexible conduit
from the generator end bracket to the junction box.
Keep the load lead junction box accessible for service
and inspection.

Note: Keep the load lead circuit away from the

generator fuel and exhaust system components.

Note: Use field-supplied wiring capable of withstanding

temperatures of 75_C (167_F).

Connect the neutral of the AC circuit in the vehicle to the
lead L0 (white or gray). If the vehicle uses equipment
ground-type plugs and receptacles (3-pronged),
connect the green wire to the U-shaped pin. On vehicles
that also have provisions for using an outside AC power
source, completely isolate the neutral as well as the hot
(black) leads from the generator set when switching
power to the outside source. See Figure 6-1.

The following paragraphs provide details on each
connection. Refer also to the wiring diagram in the
operation manual.

Securely support or harness all wiring to the generator
set to prevent abrasion. Provide additional support for
the wiring to prevent exposure to the exhaust system
and drippage of fuel, oil, or grease. Allow at least a
51 mm (2 in.) clearance between the electrical wiring
and hot exhaust parts. Do not locate the wiring directly
below or near the fuel system parts or the oil-fill tube.

The following paragraphs cover some other points to
consider when making AC load connections.

Note: At the time of installation, make the wiring

connections accessible for inspection and
service.

TP-6034 10/02 Electrical System 11

Note: Transfer switch. Use a triple-pole, double-throw

transfer switch rated for the calculated load of the
vehicle to transfer the load from one source to the
other. Install a ground-fault circuit interrupter in
the wiring system to protect all branch circuits.

Note: AC load circuit protection. Protect the AC load

circuit of the generator set against overloading or
short circuiting with a circuit breaker(s).

Note: For standby service connect output of the

generator to a suitably rated transfer switch in
accordance with the Canadian Electrical Code,
Part 1.

AC Vehicle Circuit

Ground Fault
Circuit Protection

L0

NNN

120-V
Outside
Power

L1

L2

Gen.
Set

120 Volt

Figure 6-1 Transfer Switch Connections, 3-Wire AC Circuit

NNN

240-V
Outside
Power

120/240 Volt

AC Vehicle Circuit

Ground Fault
Circuit Protection

L0

L1

Gen.
Set

L2

12 Electrical System TP-6034 10/02

6.3 Circuit Protection

The AC circuit breakers protect the generator set from
extreme overload. AC circuit breakers trip when they
detect a fault in the output circuit.

For application and selection information contact an
authorized distributor/dealer.

After correcting the fault, reset the AC circuit breaker(s)
by placing them in the ON position. Restart the unit. See
an authorized service distributor/dealer for AC circuit
breaker ratings. The unit’s voltage configuration
determines the circuit breaker selection.

Note: Circuit breaker ampere rating and availability are

subject to change.

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

generator set or equipment connected to the set, disable the
generator set asfollows: (1) Place the generator set start/stop
switch in the STOP position. (2) Disconnect the power to the
battery charger, if equipped. (3) Remove the battery cables,
negative (--) lead first. Reconnect the negative (--) lead last
when reconnecting the battery. Follow these precautions to
prevent the starting of the generator set by the remote
start/stop switch.

WARNING

Hazardous voltage.
Can cause severe injury or death.

Moving rotor.

6.3.1 Circuit Breaker Considerations

Mounting location. Mount the circuit breakers in the
generator set controller.

Sizing. Use the generator set voltage/frequency
configuration to determine the circuit breaker
amperage. If the circuit breaker was sized for one
voltage configuration and later the generator set is
reconnected to a different voltage, change the circuit
breaker accordingly to provide optimum protection.

Have a qualified electrician or technician install circuit
breakers and reconnect the generator set. Comply with
all governing standards and codes.

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.

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

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.

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

generator set to the building/campground electrical system
only through an approved device and after the
building/campground main switch is opened. Backfeed
connections can cause severe injury or death to utility
personnel working on power lines and/or personnel near the
work area. Some states and localities prohibit unauthorized
connection to the utility electrical system. Install a transfer
switch to prevent interconnection of the generator set power
and other sources of power.

TP-6034 10/02 Electrical System 13

6.3.2 Circuit Breaker Installation
(Only Required for Changing
from Factory-Installed and -Wired,
120 Volt, 2 Wire)

Note: Wire material. Use stranded copper for all

wiring. Use wire gauges and insulation,
conductor temperature ratings, sheath stripping,
conductor support and protection, conductor
terminals and splices, and overcurrent protection
(circuit breakers, fuses) that conform to
standards and codes.

Note: Wire protection. Use rubber grommets and

cable ties as necessary to protect and secure the
wiring from sharp objects, the exhaust system,
and any moving parts.

1. Turn the generator set off and disconnect the
generator set engine starting battery, the
negative (--) lead first.

2. Remove the controller cover screws and remove
the controller access cover.

3. Remove the screws and nuts to remove the circuit
breaker cover plate. Save the mounting hardware.

7. Make the recommended connections for the
following three reconnection systems using circuit
breakers.

Two-pole circuit breaker with a single-voltage
system (example: 120 volt, 3 wire).

Attach stator leads marked 2 and 4 to the side of the
circuit breaker marked LINE. Install the jumper
lead across the LINE side of the circuit breaker
terminals (see Section 8). Attach stator leads
1and3toL0.

Two-pole circuit breaker with a dual-voltage
system (example: 120/240 volt, 3 wire).

Attach stator leads marked 1 and 4 to the side of the
circuit breaker marked LINE. Do not use a jumper
lead (see Section 8). Attach stator leads 2 and 3 to
L0.

Single-pole circuit breaker with a
single-voltage system (example: 240 volt,
2 wire).

Attach the stator lead marked 2 to the side of the
circuit breaker marked LINE (see Section 8). Bolt
together leads 1 and 4 and tape the leads to
insulate them from ground. Attach the stator lead
marked3toL0.

4. Install the circuit breaker from the inside of the
cutout panel and mount it using the existing
screws. Position the circuit breaker with ON in the
normal upright position or to the left side. Cover the
cutout opening, if applicable, with the circuit
breaker coverplate. Use the existing screws and
nuts.

5. See Section 8 for voltage reconnection.

6. Install insulation boots over the stator lead
terminals if the kit includes insulation boots.

Note: See Section 8 for wiring instructions.

Connect the stator lead(s) used for neutral
connection to the L0 stud. See illustrations in
Section 8.

8. Connect the side of the circuit breaker marked
LOAD to the transfer switch or vehicle. Attach
insulation boots to the black leads if the kit includes
insulation boots. With a single-pole circuit breaker
use one black lead L1. With a two-pole circuit
breaker use two black leads L1 and L2. Connect
the neutral white lead to the L0 stud. Connect the
equipment ground green lead to the GRD. stud.

9. Replace the controller cover or circuit breaker box
access panel.

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

11. For voltage or frequency adjustments, refer to the
procedure in Section 8.2.

14 Electrical System TP-6034 10/02

6.4 Battery and Connections

Distancebetween

Lengths and sizes. See Figure 6-3 for the lengths and
recommended sizes of the battery cables.

WARNING

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

Use protective goggles and clothes.
Battery acid can cause permanent
damage to eyes, burn skin, and eat
holes in clothing.

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

or permit flames or sparks to occur near a battery at any time,
particularly when 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.

Starting battery. A 12-volt separate battery is
recommended for the generator set. With a separate
battery, the battery can be installed closer to the
generator set and the cable length can be minimized to
eliminate voltage drop. See Figure 6-2 for the minimum
cold cranking amps (CCA) battery recommendation.

Cable Size (AWG)

Generator Set

and Battery, m (ft. )

12.2 (40) 00 0 1

9.1 (30) 0 1 2

7.6 (25) 1 2 4

6.1 (20) 2 2 6

4.6 (15) 2 4 6

3.0 (10) 4 6 8

1.5 (5) 6 6 8

0.8 (2.5) 8 8 8

At -18°C

(0°F)

At 0°C

(32°F)

At 24°C

(75°F)

Figure 6-3 Battery Cable Size

Cable connections. See Section 7 for the battery

positive and negative connection points. Refer to
Figure 6-4 (View A) for cable connections. (Note that
installers must connect a ground strap between the
ground lug on the generator set and the frame of the
vehicle with this arrangement.)

For installations where the starting battery for the
vehicle engine must also be used for starting the
generator engine, ground the negative battery terminal
to the vehicle frame and connect a heavy gauge (#4)
ground strap to the ground lug on the generator set to
the vehicle frame as illustrated in Figure 6-4 (View B).

Note: Ensure a ground connection between the

generator and the vehicle frame even if the
battery used to start the generator is not the same
as the vehicle.

Model CCA

7ER 260

Figure 6-2 Battery Recommendation

TP-6034 10/02 Electrical System 15

Using a Separate Battery

for the Generator Set

View A

6.5 Remote Switch Connection

Controllers include an accessory plug (P3) for easy
connection of the remote switch to the following:

D Oil pressure gauge, if equipped

D Water temperature gauge, if equipped

Battery

Positive

Using the Same Battery

as the Vehicle Engine

Vehicle Frame

-- +

N

D Battery voltage

D Hourmeter

D Start/Stop switch including run light

Available panels:

12-Volt
Battery

View B

Ground Strap

Vehicle Frame

12-Volt
Battery

D Start/Stop switch with hourmeter

D Start/Stop switch with hourmeter and battery

voltage

D Start/Stop switch with hourmeter, battery voltage,

water temperature, and oil pressure

One end of the 38.1 cm (15 in.) P3 wiring harness plugs
directly into the controller. The pigtail leads on the
remaining end of the harness connect to the remote
panel terminals via customer-supplied wiring. Connect

N

-- +

the remote operating controls to the P3 wire harness
lead. See the wiring diagram in the operation manual to
identify the P3 harness connections.

Battery

Positive

Vehicle

Frame

Battery Negative
to Vehicle Frame

Figure 6-4 Battery Connection Details

16 Electrical System TP-6034 10/02

Section 7 Installation Drawing

Figure 7-1 Dimension Drawing

ADV-6450-E

Installation Drawing 17TP-6034 10/02

Notes

TP-6034 10/0218 Installation Drawing

Section 8 Reconnection/Adjustments

8.1 Four-Lead Reconnection

The following drawings illustrate the reconnection of
four-lead generator sets. In all cases, conform to the
National Electrical Code (NEC).

NOTICE

Voltage reconnection. Affix a 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.

100--120-Volt Configurations

Load
Side

Line
Side

L0 (Neutral)

Ground

L0

GRD.

L1
L2

Two-Pole
Circuit
Breaker

If the installation requires a factory two-pole circuit
breaker, do not connect the load-side terminals of the
circuit breaker. See Figure 8-1. If the installation
requires a 100--120-volt, 2-wire system, use a
single-pole circuit breaker. See Figure 8-2. When
connecting stator phase leads together, size the output
lead (L1) to handle the amperage. Use a jumper lead on
the line side of the circuit breaker to balance the load of
the generator set.

Jumper
Lead

4321

Figure 8-1 100--120-Volt, 3-Wire Configuration

L0 (Neutral)

Ground

Load
Side

Line
Side

4321

Stator Leads

L0

GRD.

L1

Single-Pole
Circuit
Breaker

TP-6034 10/02 Reconnection/Adjustments 19

60 Hz 50 Hz

L0--L1 100--120 Volt 100--120 Volt
L0--L2 100--120 Volt 100--120 Volt

Figure 8-2 100--120-Volt, 2-Wire Configuration

(Factory Installed and Wired)

100--120/200--240-Volt Configurations

200--240-Volt Configurations

The 100--120/200--240-volt configuration does not use
a jumper lead. If the unit was originally wired for straight
100--120 volt, 3 wire, remove the jumper lead (see
Figure 8-1 for location). Select a two-pole circuit
breaker. Application of two single-pole circuit breakers
does not conform to NEC requirements for supplying a
200--240 volt load—even if the breakers are
mechanically attached. Leads L1 and L2 are for
different phases—never connect them.

L0 (Neutral)

Ground

Load
Side

Line
Side

100--120/200--240 Volt,

4321

Stator Leads

L0--L1 100--120 Volt 100--120 Volt
L0--L2 100--120 Volt 100--120 Volt
L1--L2 200--240 Volt 200--240 Volt

3 Wire

60 Hz 50 Hz

L0

GRD.

L2

L1

Factory
Two-Pole
Circuit
Breaker

The 200--240-volt configuration does not use a jumper
lead. If the unit was originally wired for straight
100--120 volt, 3 wire, remove the jumper lead (see
Figure 8-1 for location).

L0 (Neutral)

Ground

Load
Side

Line
Side

4321

Stator Leads

60 Hz

L0--L1 not used 200--220--240 Volt

Single-Pole
Circuit
Breaker

Tape to insulate
from ground

200--220--240 Volt,
2 Wire

50 Hz

L0

GRD.

L1

Figure 8-4 200--220--240-Volt,

2-Wire Configuration

Figure 8-3 100--120/200--240-Volt,

3-Wire Configuration

20 Reconnection/Adjustments TP-6034 10/02

8.2 Voltage Regulator Adjustment

WARNING

Hazardous voltage.
Can cause severe injury or death.

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

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)

Moving rotor.

The controller typically contains the voltage regulator.
Voltage regulator adjustments are possible without
removing the voltage regulator. The voltage regulator
adjustment procedure applies to the PowerBoostä IIIE
(Figure 8-5) voltage regulator.

Note: The following adjustment procedure is for

readjustment of the voltage regulator and
governor for broadrange generator sets with
mechanical governors.

1

1. Voltage adjustment potentiometer

2. Stability adjustment potentiometer

3. Volts/Hz adjustment potentiometer

2

3

TT-875-11

Figure 8-5 PowerBoostä IIIE Voltage Regulator

Note: A customer-provided rheostat may be connected

across regulator leads/terminals 33 and 66 to
adjust the generator output voltage from a
location remote from the set. The rheostat (10k
Ohm, 1/2 watt minimum) provides a 5-volt
adjustment range.

Note: Special Tools: Frequency meter 50/60 Hz.

TP-6034 10/02 Reconnection/Adjustments 21

See Figure 8-5 to identify the potentiometers on the
PowerBoostt IIIE voltage regulator.

6. Rotate the stability pot clockwise to minimize
light flicker.

Stabilizer Potentiometer (Pot)—Fine-tunes the
regulator circuitry to reduce light flicker.

Voltage Adjustment Potentiometer (Pot)—Adjusts
the generator voltage output within a range of
approximately 100--130 volts.

Volts/Hz Potentiometer (Pot)—Determines the engine
speed (Hz) at which the generator output voltage begins
to drop.

Note: For optimum results, apply full load for voltage

regulator adjustment.

Voltage Regulator Adjustment Procedure

1. With the generator set off, turn the remote
rheostat, if equipped, to midpoint.

2. Turn voltage, volts/Hz, and stability pots fully
counterclockwise.

3. Connect the voltmeter and frequency meter to the
AC circuit or an electrical outlet.

4. Start the generator set.

7. Readjust the voltage adjustment pot, if
necessary.

8. Adjust the engine speed to the desired cut-in
frequency (factory setting 57.5--58 Hz for 60-Hz
models) as measured on the frequency meter.

9. Rotate the volts/Hz adjustment pot clockwise
until the voltage level (as measured on voltmeter)
begins to drop. When set to these specifications,
the generator attempts to maintain normal output
until the engine speed drops below the frequency
set in step 5 (as load is applied).

10. Readjust the engine speed to normal (63 Hz/
1890 RPM for 60 Hz).

11. Readjust the voltage adjustment pot, if
necessary.

12. Readjust the stability pot, if necessary.

13. Use the remote rheostat, if equipped, to make final
voltage adjustments.

14. Stop the generator set.

5. Rotate the voltage adjustment pot clockwise to
increase the voltage (counterclockwise to
decrease the voltage) to the desired output
voltage.

22 Reconnection/Adjustments TP-6034 10/02

Appendix A Generator Selection and Wattage Requirements

General Wattage Requirements

Consider the total wattage requirements (lights, motors,
appliances) when selecting a generator set, or when
sizing wattage usage in which available space and
construction limit the size of the generator set.

Motor Loads

When figuring generator set capacity requirements for
loads that include electric motors, consider the high
current demanded by the motors during startup. The
inrush or starting current is typically 2 to 3 times higher
than that required when the motor reaches normal
operating speed. Allow a reserve for inrush demands
plus other loads that could be on the line as the electric
motor starts. Use Figure 1 as a guide when selecting
generator set capacity requirements involving motor
loads.

Starting

Motor

HP

1/4 750 330
1/3 1000 400
1/2 1500 600
3/4 2000 750

1 3300 1100
2 4000 2000
3 5000 3000

Figure 1 Motor Requirements

(Inrush)

Watts

Running

Watts

Appliance Loads

Generator sets often furnish AC for appliances such as
TVs, stereos, and electric water heaters. Except for the
resistance-type loads such as the water heater, the
requirements for appliances are usually low. Do not
overlook such loads when figuring the total
requirements. Allow a reserve capacity for anticipated
appliance loads to avoid overloading a generator set.

Lighting Load

To calculate the lighting load, add the wattage of each
generator set-operated lamp. Note that not all of the
lights or lamps are on the generator set AC
circuit—some are DC powered by a 12-volt battery.
Ensure that the calculated total wattage includes only
lights actually on the generator set AC circuit.

Air Conditioners

The starting characteristics of air conditioners vary
greatly—for example, one 12,000 Btu unit has lower
starting requirements than a 10,000 Btu unit of another
variety. When using only one unit, there is usually no
starting problem provided that the lighting and appliance
load is not too high when starting the generator set.

Simultaneous starting of two air conditioning units,
however, can present problems if the generator set
capacity is marginal. Because of the variation in starting
characteristics among air conditioners, this publication
makes no statements regarding multiple-motor starting
capabilities of the generator set covered. Consider
delayed starting or the use of easy-starting devices on
air conditioner units whenever simultaneously starting
more than one motor.

Voltage 115 230 115 230 115 230 115 230 230
Full load amps 9.3 4.8 9.9 5.0 11.8 6.3 16.3 8.0 11.6
Rated load amps 7.7 4.0 7.0 3.5 8.9 4.8 13.0 6.2 10.2
Locked rotor amps 34.0 20.0 40.0 20.0 50.0 31.0 75.0 36.0 56.0
Starting (inrush) watts 3910 4600 4600 4600 5750 7130 8630 8280 12,900
Running watts 886 920 805 805 1020 1100 1500 1430 2350

Figure 2 Typical Air Conditioner Requirements (60 Hz)

TP-6034 10/02 Appendix A-1

See Figure 2 for typical air conditioner requirements.
The requirements vary among different manufacturers.

Air Conditioner Size (Btu)

7,000 9,000 12,000 16,000 24,000

Appendix B 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
cfh cubic feet per hour
cfm cubic feet per minute

drawing

temperature

Institute

Institute
(formerly American Standards
Association, ASA)

suggested

Mechanical Engineers

Materials

charging

(engine)

CG center of gravity
CID cubic inch displacement
CL centerline
cm centimeter
CMOS complementary metal oxide

cogen. cogeneration
Com communications (port)
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
E-Stop emergency stop
etc. et cetera (and so forth)
exh. exhaust
ext. external
F Fahrenheit, female

substrate (semiconductor)

Association

e. V.
(also Deutsche Industrie
Normenausschuss)

Association

Association

Agency

engineered special

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
ISO International Organization for

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

ground

conditioning

Commission

Electronics Engineers

O inches of water

2

Standardization

10

bytes)

TP-6034 10/02A-2 Appendix

kg kilogram

2

kg/cm

kgm kilogram-meter
kg/m

kilograms per square
centimeter

3

kilograms per cubic meter
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

3

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

wa

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

3

m

3

m

units), male

cubic meter

/min. cubic meters per minute

6

when used with SI

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

20

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
qty. quantity
R replacement (emergency)

power source
rad. radiator, radius
RAM random access memory
RDO relay driver output
ref. reference
rem. remote
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-6034 10/02 Appendix A-3

TP-6034 10/02a

E 1998, 2001, and 2002 by Kohler Co. All rights reserved.

KOHLER CO. Kohler, Wisconsin 53044
Phone [phone], Fax [phone]
For the nearest sales/service outlet in the
US and Canada, phone [phone]
KohlerPowerSystems.com

Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]