Kohler kW User Manual
Installation
Industrial/Commercial/Residential
Generator Sets
Models:
20--2800 kW
TP-5700 7/93d
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California tocause cancer, birth
defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in thespaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
Table of Contents
Product Identification Information Inside front cover............................................
Safety Precautions and Instructions I........................................................
Introduction i...............................................................................
Service Assistance i........................................................................
Section 1 General 1.........................................................................
Section 2 Load and Transport 3..............................................................
2.1 Lifting the Generator Set 3...............................................
2.1.1 Weather Housing 5..............................................
2.1.2 Sound Shield 5.................................................
2.1.3 Subbase Fuel Tank 5............................................
2.2 Transporting the Generator Set 5.........................................
Section 3 Location 7........................................................................
3.1 Location Factors 7......................................................
3.2 Weight 7...............................................................
3.3 Mounting 8.............................................................
3.4 Vibration Isolation 9.....................................................
Section 4 Air Requirements 11................................................................
4.1 General 11..............................................................
4.2 Air-Cooled Generators 12.................................................
4.3 Forced Air 13............................................................
4.4 Air-Vac Cooling System 14................................................
4.5 Air Vent 15..............................................................
4.6 Liquid-Cooled Models 16..................................................
4.7 Unit-Mounted Radiator Cooling 16..........................................
4.8 Remote Radiator Cooling 17...............................................
4.9 City Water Cooling 18....................................................
4.10 Cooling Tower 18........................................................
4.11 Block Heaters 20........................................................
4.12 Recommended Coolant 20................................................
Section 5 Exhaust System 21.................................................................
5.1 Flexible Section 22.......................................................
5.2 Condensation Trap 22....................................................
5.3 Piping 22...............................................................
5.4 Double-Sleeve Thimbles 23...............................................
Section 6 Fuel Systems 25...................................................................
6.1 Diesel Fuel Systems 25...................................................
6.2 Main Fuel Tank 26.......................................................
6.3 Fuel Lines 27............................................................
6.4 Transfer Tanks 27........................................................
6.5 Auxiliary Fuel Pumps 28..................................................
6.6 Gasoline Fuel Systems 29................................................
6.7 Natural or LP Gas Fuel Systems 30........................................
6.8 Flexible Connector 32....................................................
6.9 Gas Piping 32...........................................................
6.10 Fuel Regulators 32.......................................................
6.11 LP Gas Fuel Characteristics 33............................................
6.12 Vapor Withdrawal Systems 33.............................................
6.13 Liquid Withdrawal Systems 33.............................................
6.14 Dual Systems (Natural and LP Gas) 33.....................................
6.15 Natural Gas 34..........................................................
6.16 Combination Gas-Gasoline 34.............................................
TP-5700 7/93 Table of Contents
Table of Contents, continued
Section 7 Electrical Requirements 35..........................................................
7.1 Batteries 35.............................................................
7.2 Electrical Connections 36.................................................
7.3 Load Lead Connections 36................................................
7.4 Terminal Connector Torque 37.............................................
7.5 Automatic Transfer Switches 38............................................
7.6 Control Connections 38...................................................
7.7 Remote Annunciator 38...................................................
7.8 Audiovisual Alarm 38.....................................................
7.9 Remote Emergency Stop Switch 39........................................
7.10 Dry Contact Kit 39.......................................................
7.11 Wiring 39...............................................................
Appendix A Abbreviations A-1................................................................
TP-5700 7/93Table of Contents
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, transfer
switches, switchgear,andaccessories,
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.
NOTE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
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 wristwatch, rings, and other
jewelry before servicing theequipment.
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 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.
TP-5700 7/93 ISafety Precautions and Instructions
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 wristwatch,
rings, and other 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.
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.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Servicing the 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.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
Copper tubing exhaust systems.
Carbon monoxide can cause severe
nausea, fainting, or death. Do not
use copper tubing in diesel exhaust
systems. Sulfur in diesel exhaust
causes rapid deterioration of copper
tubing exhaust systems, resulting in
exhaust leakage.
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.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide
poisoning symptoms include but are
not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
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.
LP liquid withdrawal fuel leaks.
Explosive fuel vapors can cause
severe injury or death. Fuel leakage
can cause an explosion. Check the LP
liquid withdrawal gas fuel system for
leakage by using a soap and water
solution with the fuel system test
pressurized to at least 90 psi
(621 kPa). 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.
TP-5700 7/93II Safety Precautions and Instructions
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.
Propane (LP)—Adequate ventilation
is mandatory. Because propane is
heavier than air, install propane gas
detectors low in a room. Inspect the
detectors per the manufacturer’s
instructions.
Natural Gas—Adequate ventilation is
mandatory. Because natural gas rises,
install natural gas detectors high in a
room. Inspect the detectors per the
manufacturer’s instructions.
Fuel tanks. Explosive fuel vapors
can cause severe injury or death.
Gasoline and other volatile fuels stored
in day tanks or subbase fuel tanks can
cause an explosion. Store only diesel
fuel in tanks.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. A successful
test depends on the ability of the
solution to bubble.
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Hazardous Voltage/
Electrical Shock
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
(over 600 volts)
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
servicing. Install the barrier after
adjustments, maintenance, or
servicing.
(over 600 volts)
WARNING
Hazardous voltage.
Can cause severe injury or death.
Disconnect all power sources before
servicing. Install the barrier after
adjustments, maintenance, or
servicing.
(600 volts and under)
WARNING
Hazardous voltage.
Can cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
(600 volts and under)
WARNING
Hazardous voltage.
Can cause severe injury or death.
Moving rotor.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
TP-5700 7/93 IIISafety Precautions and Instructions
WARNING
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Open the main circuit
breakers of all power sources before
servicing the equipment. Configure the
installation to electrically ground the
generator set, transfer switch, and
related equipment and electrical
circuits to comply with 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.
Installing the battery charger.
Hazardous voltage can cause
severe injury or death. An
ungrounded battery charger may
cause electrical shock. Connect the
battery charger enclosuretotheground
of a permanent wiring system. As an
alternative, install an equipment
grounding conductor with circuit
conductors and connect it to the
equipment grounding terminal or the
lead on the battery charger. Install the
battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Servicing the day tank. Hazardous
voltage can cause severe injury or
death. Service the day tank electrical
control module (ECM) as prescribed in
the equipment manual. Disconnect the
power to the day tank before servicing.
Press the day tank ECM OFF
pushbutton to disconnect the power.
Notice that line voltage is still present
within the ECM when the POWER ON
light is lit. Ensure that the generator set
and day tank are electrically grounded.
Do not operate the day tank 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 wristwatch, rings, and jewelry
before servicing the equipment.
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
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 serious
injury or death to utility personnel
working on power lines.
Installing accessories to the
transformer assembly. Hazardous
voltage can cause severe injury or
death. To prevent electrical shock
disconnect the harness plug before
installing accessories that will be
connected to transformer assembly
primary terminals 76, 77, 78, and 79.
Terminals are at line voltage. (Models
with E33+, S340, S340+, 340, R340,
and R33 controls only)
Installing accessories to the
transformer assembly. Hazardous
voltage can cause severe injury or
death. To prevent electrical shock
disconnect the harness plug before
installing accessories that will be
connected to the transformer assembly
primary terminals on microprocessor
logic models. Terminals are at line
voltage.
Making line or auxiliary
connections. Hazardous voltage
can cause severe injury or death. To
prevent electrical shockdeenergizethe
normal power source before making
any line or auxiliary connections.
Servicing the transfer switch.
Hazardous voltage can cause
severe injury or death. Deenergize all
power sources before servicing. Open
the main circuit breakers of all transfer
switch power sources and disable all
generator sets as follows: (1) Move all
generator set master controller
switches to the OFF position. (2)
Disconnect power to all battery
chargers. (3) Disconnect all battery
cables, negative (--) leads first.
Reconnect negative (--) leads last when
reconnecting the battery cables after
servicing. Follow these precautions to
prevent the starting of generator sets
by an automatic transfer switch, remote
start/stop switch, or engine start
command from a remote computer.
Before servicing any components
inside the enclosure: (1) Remove
rings, wristwatch, and jewelry. (2)
Stand on a dry, approved electrically
insulated mat. (3) Test circuits with a
voltmeter to verify that they are
deenergized.
TP-5700 7/93IV Safety Precautions and Instructions
Servicing the transfer switch
controls and accessories within the
enclosure. Hazardous voltage can
cause severe injury or death.
Disconnect the transfer switch controls
at the inline connector to deenergize
the circuit boards and logic circuitry but
allow the transfer switch to continue to
supply power to the load. Disconnect
all power sources to accessories that
are mounted within the enclosure but
are not wired through the controls and
deenergized by inline connector
separation. Test circuits with a
voltmeter to verify that they are
deenergized before servicing.
Heavy Equipment
WARNING
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
Moving Parts
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Moving rotor.
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.
WARNING
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Use adequate lifting capacity.
Never leave the transfer switch
standing upright unless it is securely
bolted in place or stabilized.
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.
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.
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
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.
TP-5700 7/93 VSafety Precautions and Instructions
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
Hardware damage. The transfer
switch may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads and nuts.
NOTICE
When replacing hardware, do not
substitute with inferior grade
hardware. Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.
NOTICE
Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
TP-5700 7/93VI Safety Precautions and Instructions
Introduction
This manual provides installation instructions for
20--2800 kW generator sets. Operation manuals and
wiring diagram manuals are available separately.
x:in:001:001
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.
For professional advice on generator power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading
Generators—Electric
D Visit the Kohler Power Systems website at
KohlerPowerSystems.com
D Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product
D Call toll free in the US and Canada 1-800-544-2444
D Outside the US and Canada, call the nearest regional
office
Africa, Europe, Middle East
London Regional Office
Langley, Slough, England
Phone: (44) 1753-580-771
Fax: (44) 1753-580-036
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
x:in:001:002:a
Service Assistance
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
X:in:008:001a
TP-5700 7/93 iIntroduction
Section 1 General
Industrial power systems give years of dependable
service if installed using the guidelines provided in this
manual and in applicable codes. Incorrect installation
can cause continuing problems. Figure 1-1 illustrates a
typical installation.
Your authorized generator set distributor/dealer may
also provide advice about or assistance with your
installation.
This manual references several organizations and their
codes that provide installation requirements and
guidelines such as the National Fire Protection
Association (NFPA) and Underwriter’s Laboratories Inc.
(UL).
D NFPA 54 National Fuel Gas Code
D NFPA 70 National Electrical Coder; the National
Electrical Code is a registered trademark of the NFPA
D NFPA 99 Standard for Health Care Facilities
D NFPA 101 Life Safety Code
D NFPA 110 Emergency and Standby Power Systems
D UL-486A The Standard for Wire Connectors and
Soldering Lugs for Use with Copper Conductors
D UL-486B The Standard for Wire Connectors for Use
with Aluminum Conductors
D UL-486E Equipment Wiring Terminals for Use with
Aluminum and/or Copper Conductors
D UL-2200 Stationary Engine Generator Assemblies
These organizations provide information specifically for
US installations. Installers must comply with their
respective national and local codes.
TP-5700 7/93 1Section 1 General
2
3
1
10
9
5
4
8
7
6
1. Exhaust thimble (for wall or ceiling)
2. Silencer
3. Supports
4. Flexible sections
5. Duct work for cooling air outlet
10. Fresh air intake
Figure 1-1 Typical Stationary-Duty Generator Set Installation
TP-5700-1
6. Mounting base
7. Controller
8. Electrical conduit
9. Watertrapwithdrain
TP-5700 7/932 Section 1 General
Section 2 Load and Transport
To ensure personal safety while preventing damage to
the product, we strongly recommend the following
guidelines be observed when loading and transporting
standby generator sets. Due to the different designs,
dimensions and weights of the generators involved,
specific instructions for each model are not provided.
However, these guidelines are applicable to the full
standby line (although minor procedural changes may
be necessary between sets). It is the responsibility of the
dealer/distributor to see that generator loading and
transport be performed within the framework of these
guidelines. Obviously, prepackaged (crated) sets may
be exempt from certain aspects of this section.
(Prepackaged generators generally are loaded in their
containers with the aid of lift trucks.)
2.1 Lifting the Generator Set
D Do not lift the generator set by the lifting eyes
attached to the engine and/or alternator. These
lifting eyes are only used during generator assembly
and are not capable of supporting the entire weight of
the generator. The mounting skid of each standby
generator set includes four holes for attaching the
lifting device. These holes are strategically placed to
avoid damage to generator components by lifting
cables and to maintain balance during lifting. In some
cases, it may be necessary to remove protruding
generator components (air cleaner, shrouding) to
avoid damage by lifting cables.
TP-5700 7/93 3Section 2 Load and Transport
D A four-point lifting method is necessary to lift the
generator set. To maintain generator balance during
lifting, the lifting apparatus must utilize the four skid
lifting holes mentioned in the previous paragraph.
One method of lifting standby generators uses an
apparatus of hooks and cables joined at a single
rigging point. See Figure 2-2. The use of spreader
bars is necessary with this method to avoid damage
to the set during the lifting procedure. The spreader
bars should be slightly wider than the generator skid
so the set is not damaged by lifting cables and only
vertical force is applied to the skid while lifting. The
generators may also be lifted by placing bars through
the skid lifting holes and attaching hooks to the ends
of the bars. See Figure 2-1. Be sure the bars are
properly sized for the weight of the generator set.
Precautions must be taken to prevent the lifting hooks
from sliding off the ends of the bars. Spreader bars
may be necessary with this arrangement if lifting
cables are in contact with the set. A specially
designed lifting fixture is often used to lift the larger
standby generators. The fixture usually includes
adjustable cables to adapt to different size generators
and to compensate for unit imbalance. See
Figure 2-3. In all cases, be sure the components of
the lifting device (cables, chains, bars) are properly
sized for the weight of the generator set.
1
TP-5700-2
1. Spreader bars may be necessary to protect generator set
Figure 2-2 Generator Set with Lifting Hooks in Skid
1
1
2
TP-5700-2
1. Spreader bars may be necessary to protect generator set
2. Lifting bars
Figure 2-1 Generator Set with Lifting Bars in Skid
1
TP-5700-2
1. Lifting fixture
Figure 2-3 Generator Set with Lifting Fixture
TP-5700 7/934 Section 2 Load and Transport
D Do not attach lifting hooks to outside reinforcing
plate on skid. Attach lifting hooks to skid exactly as
shown in Figure 2-4. This method utilizes the
strongest portion of the mounting skid and also
prevents the lifting hooks from slipping. Generators
without skid reinforcing plates can be raised with lift
hooks on the inside or outside of the skid.
The following information pertains to lifting a generator
set with subbase fuel tank, weather housing, and/or
sound shield.
1
TP-5700-2
1. Reinforcing plate
Figure 2-4 Lifting Hook Placement (above 1000 kW)
2.1.1 Weather Housing
Lift the weather housing and generator set together as
one unit using the generator set guidelines.
2.1.2 Sound Shield
If the generator set has an installed sound shield and
subbase fuel tank the assembly can be lifted as one unit
provided the subbase fuel tank has lifting eyes installed
and meets the criteria of subbase fuel tank paragraph 2.
In all other cases, remove the sound shield per the
following paragraphs.
Remove the sound shield, if installed, from the
generator set before lifting the generator set. The sound
shield attaching bolts may be hidden by the sound shield
insulation. To locate the hardware carefully lift the sound
insulation near the skid.
Remove the wood skid before lifting the sound shield
using the eye bolts. Use the sound shield eye bolts, if
equipped, to lift only the sound shield.
Reinstall the sound shield after lifting and mounting the
generator set.
2.1.3 Subbase Fuel Tank
The lifting contractor determines the type and suitability
of the subbase fuel tank lifting device. Lift the subbase
fuel tank as one unit if shipped separately from the
generator set. Use lifting eyes if equipped on subbase
fuel tank; otherwise, use chains or cables to lift the
subbase fuel tank. If using lifting straps, protect the
strap from sharp fuel tank edges.
Lift the generator set (up to 400 kW) and subbase fuel
tank together provided the fuel tank is empty and the
subbase fuel tank does not extend beyond the perimeter
of the generator set skid.
In all other cases, remove the mounting hardware and
wiring between the the generator set and subbase fuel
tank. Lift the generator set and subbase fuel tank
separately. It is not necessary to drain fuel tank when
lifting just the fuel tank.
2.2 Transporting the Generator Set
D The transporting vehicle/trailer must be sized for
the dimension and weight of the generator set.
Consult the set dimensional drawing or contact the
factory for information (weight, dimensions) pertinent to
planning transport. The overall height of a generator set
in transit (including vehicle/trailer) must not exceed
13.5 ft. (4.1 m) unless special hauling permits are
obtained (check Federal, State, and local laws prior to
transporting). Larger units (above 1000 kW) should be
transported on low-boy-type trailers with a deck height
of 25 in. (635 mm) or less to meet clearance
requirements. Large (unboxed) generators with
radiators should be loaded with the radiator facing the
rear to reduce wind resistance while in transit. Radiators
with free-wheeling fans must have the fan secured to
prevent rotation that might introduce flying objects to the
radiator core or fan blades.
D Be sure the generator set is securely fastened to
the vehicle/trailer and covered with a tarpaulin.
Even the heaviest of units is capable of movement
during shipment unless properly secured. Fasten the
set to the vehicle/trailer bed with properly sized chain
routed through the mounting holes of the skid. Use
chain tighteners to remove slack from the mounting
chain. Cover the entire unit with a heavy-duty
tarpaulin and secure tarpaulin to the generator or
trailer.
TP-5700 7/93 5Section 2 Load and Transport
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