Kohler 12RESV, 8RESV, 10RESV, 12RESVL, RDC2 Installation Manual

Installation

Residential/Commercial Generator Sets

Models:

8/10/12RESV

8/10/12RESVL

Controllers:

RDC2

DC2

TP-6984 5/17a

California Proposition 65

California Proposition 65

WARNING

This product contains and/or emits
chemicals known to the State of California to
cause cancer, birth defects, or other
reproductive harm.

Kohler strongly recommends

that only factory-authorized

distributors or dealers install

and service the generator.

Product Identification Information

Generator Set Identification Numbers

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

Model Designation

Specification Number

Serial Number

WARNING

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

Engine Identification

Record the product identification information from the
engine nameplate.

Manufacturer

Model Designation

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

Table of Contents

Safety Precautions and Instructions 5.........................................................

Introduction 9...............................................................................

Startup and Registration 9.....................................................

Service Assistance 10.........................................................................

Section 1 Installation 11......................................................................

1.1 Introduction 11...........................................................

1.2 Lifting 12................................................................

1.3 Generator Set Inspection 12...............................................

1.4 Location and Mounting 12.................................................

1.4.1 Mounting Area 13................................................

1.4.2 Exhaust Requirements 13.........................................

1.5 Dimension Drawings 14...................................................

1.6 Access the Air Intake Area 14..............................................

1.7 Fuel Requirements 14.....................................................

1.7.1 Fuel Supply 14...................................................

1.7.2 Fuel Pipe Size 15.................................................

1.7.3 Connecting the Fuel Supply 16.....................................

1.8 Fuel Conversion 17.......................................................

1.9 Electrical Connections 19..................................................

1.9.1 Grounding 20....................................................

1.9.2 Electrical Lead Entry 20...........................................

1.9.3 Field-Connection Terminal Block 20.................................

1.9.4 AC Power Supply 21..............................................

1.10 ATS and Accessory Connections 22........................................

1.10.1 Transfer Switch Connection 22.....................................

1.10.2 Communication Cable Specifications 24.............................

1.10.3 System Connections with Accessory Modules 25.....................

1.11 Battery 28...............................................................

1.12 Prestart Installation Check 29..............................................

1.13 Set the Exerciser 30......................................................

1.13.1 RDC2 Controller 30...............................................

1.13.2 DC2 Controller 30................................................

1.13.3 Loaded Exercise 30...............................................

1.14 Operation Test 30........................................................

1.15 OnCue Plus Generator Management System 31..............................

Section 2 Accessories 33.....................................................................

2.1 Introduction 33...........................................................

2.2 Connect Optional Programmable Interface Module (PIM) 33...................

2.3 Load Management 34.....................................................

2.4 Carburetor Heater 35.....................................................

Section 3 Drawings and Diagrams 37..........................................................

Appendix A Abbreviations 43................................................................

TP-6984 5/17a Table of Contents 3

Notes

TP-6984 5/17a4

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 i njury, 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
equipment connected to the set,
disable the generator set as follows:
(1) Press the generator set off/reset
button to shut down the generator set.
(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.

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. Isolate the 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. 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. 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
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.

TP-6984 5/17a 5Safety Precautions and Instructions

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

Risk of fire.
Can cause severe injury or death.

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

set with the air cleaner removed.

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.

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.
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. Never operate the generator
set where exhaust gas could seep
inside or be drawn into a potentially
occupied building through windows, air
intake vents, or other openings.

Carbon monoxide detectors.
Carbon monoxide can cause severe
nausea, fainting, or death. Install

carbon monoxide detectors on each
level of any building adjacent to the
generator set. Locate the detectors to
adequately warn the building’s
occupants of the presence of carbon
monoxide. Keep the detectors
operational at all times. Periodically
test and replace the carbon monoxide
detectors according to the
manufacturer’s instructions.

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

monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. 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.

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

TP-6984 5/17a6 Safety Precautions and Instructions

Fuel System

Hazardous Noise

WARNING

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.

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

explosion. Check the LPG vapor 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.

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/
Moving Parts

DANGER

Hazardous voltage.
Will cause severe injury or death.

This equipment must be installed and
serviced by qualified electrical
personnel.

WARNING

Hazardous voltage.
Can cause severe injury or death.

Moving parts.

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.

CAUTION

Welding the generator set.
Can cause severe electrical
equipment damage.

Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).

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

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

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

TP-6984 5/17a 7Safety Precautions and Instructions

Welding on the generator set. Can
cause severe electrical equipment
damage. Before welding on the

generator set perform the following
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery­charging alternator connections.
(5) Attach the weld ground connection
close to the weld location.

Hot Parts

WARNING

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

Do not work on the generator set until
it cools.

Notice

NOTICE

Canadian installations only.For

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

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.

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.

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.

Servicing the engine heater. Hot
parts can cause minor personal
injury or property damage. Install the

heater before connecting it to power.
Operating the heater before installation
can cause burns and component
damage. Disconnect power to the
heater and allow it to cool before
servicing the heater or nearby parts.

Heavy Equipment

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.

TP-6984 5/17a8 Safety Precautions and Instructions

Introduction

This manual provides installation instructions for Model
8/10/12RESV or 8/10/12RESVL generator sets. See
Figure 1. Refer to TP-6880, Operation Manual, for
generator set operation and maintenance instructions.

The generator set is approved for use in stationary
applications in locations served by a reliable utility
power source.

Have a Kohlerr authorized distributor/dealer install the
generator set outdoors according to the instructions in
this manual. The generator set installation must comply
with the National Electrical Code (NEC) and local code
requirements. Do not install this generator set indoors.

Information in this publication represents data available
at the time of print. 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.

List of Related Literature

Figure 2 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.

Literature Type Part Number

Spec Sheet, 8RESV G4--252

Spec Sheet, 8RESVL G4--253

Spec Sheet, 10/12RESV G4--254

Spec Sheet, 10/12RESVL G4--255

Operation Manual, Generator Set TP-6880

Operation/Installation Manual, Model
RXT Automatic Transfer Switch

Operation Manual, OnCuer Plus
Software

Operation Manual, SiteTecht
Software

Operation/Installation Manual,
Model RDT Transfer Switch

Installation Instructions,
Programmable Interface Module (PIM)

Installation Instructions, Load Shed Kit TT-1609

Installation Instructions, USB Utility TT-1636

Figure 2 Related Literature

TP-6807

TP-6928

TP-6701

TP-6345

TT-1584

Figure 1 Model RESV Generator Set

Startup and Registration

When the generator set is installed, complete the
startup and installation checklists supplied with the
startup notification form. Complete the startup
notification form and register the unit using the Kohler
online Warranty Processing System.

TP-6984 5/17a 9

Service Assistance

For professional advice on generator set 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

KOHLERPower.com.

D Look at the labels and decals 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.

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler Power Systems Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

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

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

TP-6984 5/17a10

Section 1 Installation

1.1 Introduction

DANGER

Hazardous voltage.
Will cause severe injury or death.

This equipment must be installed and
serviced by qualified electrical per­sonnel.

WARNING

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

The exhaust system must be
leakproof and routinely inspected.

Note: DO NOT install these generator sets inside a

building.

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

each level of any building adjacent to a generator
set. Locate the detectors to adequately warn the
building’s occupants of the presence of carbon
monoxide.

Obtain a building permit and contact your local utility
companies to mark the locations of underground pipes
and cables.

Read and follow the safety precautions in this manual
and observe the decals on the equipment. Refer to the
diagrams and drawings in this manual for dimensions
and electrical connections during the installation
procedure. Read the entire installation procedure and
obtain the accessories and tools needed before
beginning installation. Perform the steps in the order
shown.

To install optional accessories, follow the instructions
provided with each kit.

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. Never operate the
generator set where exhaust gas could seep inside or be
drawn into a potentially occupied building through windows, air
intake vents, or other openings.

Carbon monoxide detectors. Carbon monoxide can
cause severe nausea, fainting, or death. Install carbon

monoxide detectors on each level of any building adjacent to
the generator set. Locate the detectors to adequately warn the
building’s occupants of the presence of carbon monoxide.
Keep the detectors operational at all times. Periodically test
and replace the carbon monoxide detectors according to the
manufacturer’s instructions.

Have the generator set installed b y an authorized Kohler
distributor/dealer or authorized representative. Install
the equipment in compliance with the National Electrical
Code (NEC) and local codes. For Canadian
installations, refer to the Canadian Electrical Code
(CEC).

The generator set must be installed outdoors. The
exhaust systems on enclosed units are designed for
outdoor installation only.

TP-6984 5/17a 11Section 1 Installation

1.2 Lifting

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.

Approximate generator set weights are shown in
Figure 1-1. Use lifting bars inserted through the holes in
the skid to lift the unit. See the dimension drawings in
Section 3 for lifting hole locations.

Model Weight, kg (lb.)

8RESV/RESVL 170 (375)
10RESV/RESVL 194 (428)
12RESV/RESVL 196 (433)

Figure 1-1 Approximate Shipping Weights

1.3 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 viscosity and grade of oil. Use
synthetic oil, API (American Petroleum Institute)
Service Class SG or higher. See TP-6880,
Operation Manual, for additional information.

1.4 Location and Mounting

Install the generator set outdoors near the incoming gas
service. The generator set location must allow easy
access for maintenance and service. The required
distance from a structure is dependent on state and local
codes. See the dimension drawing in Section 3 for the
minimum clearance from structures and
non-combustible materials.

Locate the generator set so that the hot exhaust does
not blow on plants or other combustible materials. No
plants, shrubs, or other combustible materials are
allowed within 1.2 m (4 ft.) of the exhaust end of the
generator set.

Do not install the generator set where exhaust gas could
accumulate and seep inside or be drawn into a
potentially occupied building. Furnace and other similar
intakes must be at least 3 m (10 ft.) from the exhaust
end of the generator set.

Notice

DO NOT locate the generator set near patios,

decks, play areas, or animal shelters. Keep items
such as lawn furniture, toys, sports equipment,
and all combustible materials away from the
generator set exhaust outlet.

Remind family members, children, and visitors to
use caution near the generator set. Generator sets
connected to automatic transfer switches start
automatically during exercise periods and power
outages. Some generator set components
become hot when the generator set is running and
remain hot for a time after the generator set shuts
down.

Note: The reduced minimum clearance from a structure

contained in ADV--8774 only applies to
generators that are compliant with clause (2) of
section 4.1.4 of NFPA 37. To verify that the
generator is compliant, check the Specification
Number located on the generator name plate.
See Figure 1-2. If the name plate displays one of
the following specification numbers, then the
generator is compliant with clause (2) of section

4.1.4 of NFPA 37 and the reduced clearance in
ADV--8774 (Figure 3-5) will apply.

D 8RESV: GM88347--GA7 or higher

D 8RESVL: GM88347--GA10 or higher

D 10RESV: GM88347--GA8 or higher

D 10RESVL: GM88347--GA11 or higher

D 12RESV: GM88347--GA9 or higher

D 12RESVL: GM88347--GA12 or higher

Note: If the generator set name plate does not

display one of the specification numbers set
forth above, refer to ADV-8539in installation
manual TP--6879 for the minimum
clearance from a structure.

TP-6984 5/17a12 Section 1 Installation

1.4.2 Exhaust Requirements

8RESV-SA1

GM88347-GA7

XXXXXXXX

XXXXXXXX

29

Amps

Phase

RPM

3600

Battery

12V

NAT GAS

Fuel

kW

7.00

7.00

1

kVA

PF

1.0

Hz

60

1. Specification
Number

Genset Model

Spec Number

Serial Number

Material Number

Service Duty

STANDBY

Voltage

240

Alt Model

2F3

Insulation

07/31/2015

MFG Date

H

Figure 1-2 Name Plate

1.4.1 Mounting Area

The generator set is shipped on a wooden pallet.
Remove the wooden pallet before positioning the
generator set. Prepare a flat, level mounting area
covered with a weed barrier and gravel or a concrete
mounting pad. Set the generator set directly on the
gravel or concrete.

Note: When installing a concrete mounting pad, the

generator set must be secured to the mounting
pad to prevent shifting or movement caused by
engine vibration. For mounting pads
GM92228-KP1-QS and GM92228-KP2-QS, use
the screw inserts in the mounting pad to secure
the generator set. See TT--1619 for concrete
mounting pad installation instructions.

Do not install the generator set directly on grass, wood,
or other combustible materials. Clear all combustible
materials, including plants and shrubs, building
materials, and lawn furniture, from an area at least 1.2 m
(4 ft.) beyond the exhaust end of the generator set. See
the dimension drawing in Section 3.

1

WARNING

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

Do not work on the generator set until
it cools.

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.

Figure 1-3 gives the exhaust temperature at rated load.
Mount the generator set so that the hot exhaust does not
blow on plants or other combustible materials. Maintain
the clearances shown in the dimension drawing in
Section 3.

Temperature,

Exhaust Model

Exhaust gas exiting the

8RESV(L) 190 (374)

enclosure at rated kW,
_C(_F)

10/12RESV(L) 106 (224)

Figure 1-3 Exhaust Flow and Temperature

The generator set requires correct air flow for cooling
and combustion. The inlet and outlet openings in the
sound enclosure provide the cooling and combustion
air. Figure 1-4 shows the locations of the cooling air
intake and exhaust vents. Inspect the air inlet and outlet
openings inside and outside the housing to ensure that
the air flow is not blocked.

1

_C(_F)

2

1. Air intake

2. Exhaust outlet

FRONT VIEW

Figure 1-4 Cooling Air Intake and Exhaust

TP-6984 5/17a 13Section 1 Installation

tp6879

1.5 Dimension Drawings

See the dimension drawings in Section 3 for the
generator set dimensions, fuel and electric inlet
locations, and recommended clearance.

1.6 Access the Air Intake Area

1.7 Fuel Requirements

WARNING

The battery, fuel system, and electrical connections are
located in the air intake area. Raise the roof and remove
the enclosure panel to access the air intake area during
installation as described below.

Note: Ensure that the battery is positioned toward the

front of the generator so it does not block the
alternator air intake vent. See Figure 1-5.

1. Remove panel screws and remove the panel. Pull
the panel up and off. See Figure 1-5.

2. To make the electrical connections, you will also
need to remove the cover panel over the terminal
block.

3. Reinstall the panels after all electrical connections
are complete and the battery is installed and
connected.

1

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.

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

the LPG vapor 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.

1

3

4

1. Panel screws

2. Left side panel

3. Electrical cover panel

4. Alternator air intake vent

2

Figure 1-5 Remove Left Panel

GM80110

Explosive fuel vapors can cause severe injury or death.

Take additional precautions when using the following fuels:

Propane (LPG)—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.

The generator set operates using natural gas or LPG
fuel. The generator set is EPA-certified for both natural
gas and LPG fuels.

The fuel system installation must comply with applicable
national, state, and local codes.

TP-6984 5/17a14 Section 1 Installation

1.7.1 Fuel Supply

Verify that the output pressure from the primary gas
utility pressure regulator is as shown in Figure 1-6 and

Because of variable climates and geographical
considerations, contact the local fuel supplier for fuel
system planning and installation. Figure 1-6 lists the
recommended fuel ratings and other fuel supply
information for natural gas and LPG fuels.

that the utility gas meter flow rate is sufficient to supply
the generator set at rated load plus all other
gas-consuming appliances. For LPG tanks, verify that
the output pressure is as shown in Figure 1-6. See
Figure 1-9 for fuel consumption. Contact the fuel
supplier for flow rate information or a gas meter

Natural

3

Gas

0.87--2.7
(3.5-11)

LPG

1.7--2.7
(7-11)

Fuel type

Fuel supply inlet 1/2 NPT

Fuel supply pressure,
kPa (in. H

Fuel flow rate, maximum, Btu/hr.:

8RESV/RESVL 99,200 160,800

10RESV/RESVL 179,000 222,500

12RESV/RESVL 216,000 257,500

Nominal Fuel Rating, Btu/ft.

Natural gas 1000

LPG 2500

O)

2

upgrade, if necessary.

1.7.2 Fuel Pipe Size

Ensure that the fuel pipe size and length meet the
specifications in Figure 1-7. 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 total pipe length with the chart in
Figure 1-7 to find the required pipe size.

Contact local LPG provider for LPG installation
information.

Figure 1-6 Fuel Supply

Minimum Gas Pipe Size Recommendation, in. NPT

8RESV/RESVL 10RESV/RESVL 12RESV/RESVL

Pipe Length,

m (ft.)

8 (25) 1/2 3/4 3/4 3/4 3/4 3/4

15 (50) 3/4 3/4 1 3/4 1 1

30 (100) 1 3/4 1 1 11/4 1

46 (150) 1 1 11/4 1 11/4 11/4

61 (200) 1 11/4 11/4 11/4 11/4 11/4

Natural Gas

(99,200 Btu/hr.)

LPG

(160,800 Btu/hr.)

Natural Gas

(179,000 Btu/hr.)

LPG

(222,500 Btu/hr.)

Natural Gas

(216,000 Btu/hr.)

(257,500 Btu/hr.)

Figure 1-7 Fuel Pipe Size Recommendations

LPG

TP-6984 5/17a 15Section 1 Installation