Residential/Commercial Generator Sets Install.pdf · Residential/Commercial Generator Sets Models:...

Residential/Commercial Generator Sets

Models:

8/10/12RESV8/10/12RESVL

Controllers:RDC2DC2

TP-6879 8/14

Installation

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

WARNINGCalifornia Proposition 65

Product Identification Information

Generator Set Identification NumbersRecord the product identification numbers from thegenerator set nameplate(s).

Model DesignationSpecification NumberSerial Number

Accessory Number Accessory Description

Engine IdentificationRecord the product identification information from theengine nameplate.

ManufacturerModel DesignationSerial Number

Controller IdentificationRecord the controller description from the generator setoperation manual, spec sheet, or sales invoice.

Controller Description

Table of Contents

TP-6879 8/14 Table of Contents 3

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 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.2 Exhaust Requirements 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Dimension Drawings 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 Access the Air Intake Area 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7 Fuel Requirements 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.1 Fuel Supply 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7.2 Fuel Pipe Size 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7.3 Connecting the Fuel Supply 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.8 Fuel Conversion 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9 Electrical Connections 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9.1 Grounding 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9.2 Electrical Lead Entry 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9.3 Field-Connection Terminal Block 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9.4 AC Power Supply 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.10 ATS and Accessory Connections 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10.1 Transfer Switch Connection 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10.2 Communication Cable Specifications 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10.3 System Connections with Accessory Modules 24. . . . . . . . . . . . . . . . . . . . .

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 Control Module (LCM) 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Load Shed Kit 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Special Equipment 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 Carburetor Heater 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

TP-6879 8/144

Notes

TP-6879 8/14 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, or substantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

Battery

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

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

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

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery electrolyte is a dilutedsulfuric acid. Batteryacid can causesevere injury or death. Battery acidcan cause blindness and burn skin.Always wear splashproof safetygoggles, rubber gloves, and bootswhen servicing the battery. Do notopen a sealed battery or mutilate thebattery case. If battery acid splashes inthe eyes or on the skin, immediatelyflush the affected area for 15 minuteswith large quantities of clean water.Seek immediatemedical aid in the caseof eye contact. Never add acid to abattery after placing the battery inservice, as this may result in hazardousspattering of battery acid.

Battery acid cleanup. Battery acidcan cause severe injury or death.Battery acid is electrically conductiveand corrosive. Add 500 g (1 lb.) ofbicarbonate of soda (baking soda) to acontainer with 4 L (1 gal.) of water andmix the neutralizing solution. Pour theneutralizing solution on the spilledbattery acid and continue to add theneutralizing solution to the spilledbattery acid until all evidence of achemical reaction (foaming) hasceased. Flush the resulting liquid withwater and dry the area.

TP-6879 8/146 Safety Precautions and Instructions

Battery gases. Explosion can causesevere injury or death. Battery gasescan cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of abattery in a fire. To prevent burns andsparks that could cause an explosion,avoid touching the battery terminalswith tools or other metal objects.Remove all jewelry before servicing theequipment. Discharge static electricityfrom your body before touchingbatteries by first touching a groundedmetal surface away from the battery. Toavoid sparks, do not disturb the batterycharger connections while the batteryis charging. Always turn the batterycharger off before disconnecting thebattery connections. Ventilate thecompartments containing batteries toprevent accumulation of explosivegases.

Battery short circuits. Explosioncan cause severe injury or death.Short circuits can cause bodily injuryand/or equipment damage.Disconnect the battery beforegenerator set installation ormaintenance. Remove all jewelrybefore servicing the equipment. Usetools with insulated handles. Removethe negative (--) lead first whendisconnecting the battery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnect the negative (--) battery cableto the positive (+) connection terminalof the starter solenoid. Do not test thebattery condition by shorting theterminals together.

Engine Backfire/FlashFire

Fire.Can cause severe injury or death.

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

WARNING

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner removed.

Servicing the fuel system. A flashfirecancausesevere injury or death.Do not smoke or permit flames orsparks near the carburetor, fuel line,fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors.Catch fuels in an approved containerwhen removing the fuel line orcarburetor.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.

Exhaust System

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

The exhaust system must beleakproof and routinely inspected.

WARNING

Generator set operation. Carbonmonoxide can cause severe nausea,fainting, or death. Carbon monoxideis an odorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Avoidbreathing exhaust fumeswhenworkingon or near the generator set. Neveroperate the generator set inside abuilding. Never operate the generatorset where exhaust gas could seepinside or be drawn into a potentiallyoccupied building through windows, airintake vents, or other openings.

Carbon monoxide detectors.Carbon monoxide can cause severenausea, fainting, or death. Installcarbon monoxide detectors on eachlevel of any building adjacent to thegenerator set. Locate the detectors toadequately warn the building’soccupants of the presence of carbonmonoxide. Keep the detectorsoperational at all times. Periodicallytest and replace the carbon monoxidedetectors according to themanufacturer’s instructions.

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness in

joints and musclesD Sleepiness, mental fatigue,

inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

TP-6879 8/14 7Safety Precautions and Instructions

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

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

WARNING

The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecausedby vibration. Donot operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.

Gas fuel leaks. Explosive fuelvapors can cause severe injury ordeath. Fuel leakage can cause anexplosion. Check the LP vapor gas ornatural gas fuel system for leakage byusing a soap and water solution withthe fuel system test pressurized to6--8 ounces per square inch(10--14 inches water column). Do notuse a soap solution containing eitherammonia or chlorine because bothprevent bubble formation. A successfultest depends on the ability of thesolution to bubble.

Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Engine noise. Hazardous noise cancause hearing loss. Generator setsnot equipped with sound enclosurescan produce noise levels greater than105 dBA. Prolonged exposure to noiselevels greater than 85 dBA can causepermanent hearing loss. Wear hearingprotection when near an operatinggenerator set.

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

This equipment must be installed andserviced by qualified electricalpersonnel.

DANGER

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Hazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.

If the generator set is used forstandby power, install an automatictransfer switch to prevent inadvertentinterconnection of standby andnormal sources of supply.

WARNING

Welding the generator set.Can cause severe electricalequipment damage.

Never weld components of thegenerator set without firstdisconnecting the battery, controllerwiring harness, and engine electroniccontrol module (ECM).

CAUTION

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

TP-6879 8/148 Safety Precautions and Instructions

Welding on the generator set. Cancause severe electrical equipmentdamage. Before welding on thegenerator set perform the followingsteps: (1) Remove the battery cables,negative (--) lead first. (2) Disconnectall engine electronic control module(ECM) connectors. (3) Disconnect allgenerator set controller and voltageregulator circuit board connectors.(4) Disconnect the engine battery-charging alternator connections.(5) Attach the weld ground connectionclose to the weld location.

Connecting the battery and thebattery charger. Hazardous voltagecan cause severe injury or death.Reconnect the battery correctly,positive to positive and negative tonegative, to avoid electrical shock anddamage to the battery charger andbattery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death. Installa transfer switch in standby powerinstallations to prevent the connectionof standby and other sources of power.Electrical backfeed into a utilityelectrical system can cause severeinjury or death to utility personnelworking on power lines.

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not use lifting eyes.Lift the generator set using lifting barsinserted through the lifting holes onthe skid.

WARNING

Hot Parts

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

Do not work on the generator set untilit cools.

WARNING

Servicing the exhaust system. Hotparts can cause severe injury ordeath. Do not touch hot engine parts.The engine and exhaust systemcomponents become extremely hotduring operation.

Servicing the engine heater. Hotparts can cause minor personalinjury or property damage. Install theheater before connecting it to power.Operating the heater before installationcan cause burns and componentdamage. Disconnect power to theheater and allow it to cool beforeservicing the heater or nearby parts.

NoticeNOTICE

Canadian installations only. Forstandby service connect the output ofthe generator set to a suitably ratedtransfer switch in accordance withCanadian Electrical Code, Part 1.

TP-6879 8/14 9

Introduction

This manual provides installation instructions for Model8/10/12RESV or 8/10/12RESVL generator sets. SeeFigure 1. Refer to TP-6880, Operation Manual, forgenerator set operation and maintenance instructions.

The generator set is approved for use in stationaryapplications in locations served by a reliable utilitypower source.

Have a Kohlerr authorized distributor/dealer install thegenerator set outdoors according to the instructions inthismanual. The generator set installationmust complywith the National Electrical Code (NEC) and local coderequirements. Do not install this generator set indoors.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoidbodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual.

Figure 1 Model RESV Generator Set

List of Related LiteratureFigure 2 identifies related literature available for thegenerator sets covered in thismanual. Only trained andqualified personnel should install or service thegenerator set.

Literature Type Part Number

OperationManual, Generator Set TP-6880

Operation/Installation Manual, ModelRXT Automatic Transfer Switch TP-6807

Service Manual, Generator Set TP-6735

Operation Manual, OnCuer PlusSoftware TP-6928

Operation Manual, SiteTechtSoftware TP-6701

Operation/Installation Manual,Model RDT Transfer Switch TP-6345

Installation Manual, Model RSBTransfer Switch TP-6486

Operation Manual, Model RSBTransfer Switch TP-6487

Installation Instructions, Load ControlModule (LCM) TT-1574

Installation Instructions,Programmable Interface Module (PIM) TT-1584

Installation Instructions, Load Shed Kit TT-1609

Installation Instructions, USB Utility TT-1636

Figure 2 Related Literature

Startup and RegistrationWhen the generator set is installed, complete thestartup and installation checklists supplied with thestartup notification form. Complete the startupnotification form and register the unit using the Kohleronline Warranty Processing System.

TP-6879 8/1410

Service Assistance

For professional advice on generator set powerrequirementsandconscientiousservice, pleasecontactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators�Electric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Lookat the labelsandstickerson your Kohler productor review the appropriate literature or documentsincluded with the product.

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

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

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

Fax: (86) 10 6518 7955

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

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

Latin AmericaLatin America Regional OfficeLakeland, Florida, USAPhone: (863) 619-7568Fax: (863) 701-7131

TP-6879 8/14 11Section 1 Installation

Section 1 Installation

1.1 Introduction



DANGER

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

The exhaust system must beleakproof and routinely inspected.

WARNING

Generator set operation. Carbon monoxide can causesevere nausea, fainting, or death. Carbon monoxide is anodorless, colorless, tasteless, nonirritating gas that can causedeath if inhaled for even a short time. Avoid breathing exhaustfumes when working on or near the generator set. Neveroperate the generator set inside a building. Never operate thegenerator set where exhaust gas could seep inside or bedrawn into apotentially occupiedbuilding throughwindows, airintake vents, or other openings.

Carbon monoxide detectors. Carbon monoxide cancause severe nausea, fainting, or death. Install carbonmonoxide detectors on each level of any building adjacent tothe generator set. Locate thedetectors to adequatelywarn thebuilding’s occupants of the presence of carbon monoxide.Keep the detectors operational at all times. Periodically testand replace the carbon monoxide detectors according to themanufacturer’s instructions.

Have thegenerator set installed byanauthorizedKohlerdistributor/dealer or authorized representative. Installthe equipment in compliancewith theNational ElectricalCode (NEC) and local codes. For Canadianinstallations, refer to the Canadian Electrical Code(CEC).

The generator set must be installed outdoors. Theexhaust systems on enclosed units are designed foroutdoor installation only.

Note: DO NOT install these generator sets inside abuilding.

Note: Install carbon monoxide (CO) detector(s) oneach level of any building adjacent to a generatorset. Locate the detectors to adequately warn thebuilding’s occupants of the presence of carbonmonoxide.

Obtain a building permit and contact your local utilitycompanies to mark the locations of underground pipesand cables.

Read and follow the safety precautions in this manualand observe the decals on the equipment. Refer to thediagrams and drawings in this manual for dimensionsand electrical connections during the installationprocedure. Read the entire installation procedure andobtain the accessories and tools needed beforebeginning installation. Perform the steps in the ordershown.

To install optional accessories, follow the instructionsprovided with each kit.

TP-6879 8/1412 Section 1 Installation

1.2 Lifting

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not use lifting eyes.Lift the generator set using lifting barsinserted through the lifting holes onthe skid.

WARNING

Approximate generator set weights are shown inFigure 1-1. Use lifting bars inserted through the holes inthe skid to lift the unit. See the dimension drawings inSection 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 InspectionComplete a thorough inspection of the generator set.Check for the following:

1. Inspect the generator set for loose or damagedparts or wires. Repair or tighten any loose partsbefore installation.

2. Check the engine oil. Fill, if necessary, with therecommended viscosity and grade of oil. Usesynthetic oil, API (American Petroleum Institute)Service Class SG or higher. See TP-6880,Operation Manual, for additional information.

1.4 Location and MountingInstall the generator set outdoors near the incoming gasservice. The generator set location must allow easyaccess for maintenance and service. Therecommended distance from a structure is dependenton state and local codes. See the dimension drawing inSection 3 for the recommended clearance fromstructures and non-combustible materials.

Locate the generator set so that the hot exhaust doesnot blow on plants or other combustible materials. Noplants, shrubs, or other combustible materials areallowed within 1.2 m (4 ft.) of the exhaust end of thegenerator set.

Donot install the generator setwhereexhaust gas couldaccumulate and seep inside or be drawn into apotentially occupied building. Furnace and other similarintakes must be at least 3 m (10 ft.) from the exhaustend of the generator set.

NoticeDO NOT locate the generator set near patios,decks, play areas, or animal shelters. Keep itemssuch as lawn furniture, toys, sports equipment,and all combustible materials away from thegenerator set exhaust outlet.

Remind family members, children, and visitors tousecautionnear thegenerator set.Generator setsconnected to automatic transfer switches startautomatically during exercise periods and poweroutages. Some generator set componentsbecome hot when the generator set is running andremain hot for a time after the generator set shutsdown.

1.4.1 Mounting Area

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

Note: When installing a concrete mounting pad, thegenerator set must be secured to the mountingpad to prevent shifting or movement caused byengine vibration. Use the screw inserts in themounting pad to secure the generator set. SeeTT--1619 for concrete mounting pad installationinstructions.

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


1.4.2 Exhaust Requirements



WARNING

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.

Figure 1-2 gives the exhaust temperature at rated load.Mount thegenerator set so that thehot exhaust doesnotblow on plants or other combustible materials. Maintainthe clearances shown in the dimension drawing inSection 3.

Exhaust Model

Temperature,

_C (_F)

Exhaust gas exiting theenclosure at rated kW,_C (_F)

8RESV(L) 190 (374)

10/12RESV(L) 106 (224)

Figure 1-2 Exhaust Flow and Temperature

The generator set requires correct air flow for coolingand combustion. The inlet and outlet openings in thesound enclosure provide the cooling and combustionair. Figure 1-3 shows the locations of the cooling airintake and exhaust vents. Inspect the air inlet and outletopenings inside and outside the housing to ensure thatthe air flow is not blocked.

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1. Air intake2. Exhaust outlet

12

FRONT VIEW

Figure 1-3 Cooling Air Intake and Exhaust

1.5 Dimension DrawingsSee the dimension drawings in Section 3 for thegenerator set dimensions, fuel and electric inletlocations, and recommended clearance.

1.6 Access the Air Intake AreaThe battery, fuel system, and electrical connections arelocated in the air intake area. Raise the roof and removethe enclosure panel to access the air intake area duringinstallation as described below.

1. Remove panel screws and remove the panel. Pullthe panel up and off. See Figure 1-4.

2. To make the electrical connections, you will alsoneed to remove the cover panel over the terminalblock.

3. Reinstall the panels after all electrical connectionsare complete and the battery is installed andconnected.

GM801101. Panel screws2. Left side panel3. Electrical cover panel

1

1

23

Figure 1-4 Remove Left Panel


1.7 Fuel Requirements



WARNING

The fuel system. Explosive fuel vapors can cause severeinjury or death. Vaporized fuels are highly explosive. Useextreme carewhen handling and storing fuels. Store fuels in awell-ventilated area away from spark-producing equipmentand out of the reach of children. Never add fuel to the tankwhile the engine is running because spilled fuel may ignite oncontact with hot parts or from sparks. Do not smoke or permitflames or sparks to occur near sources of spilled fuel or fuelvapors. Keep the fuel lines and connections tight and in goodcondition. Donot replace flexible fuel lineswith rigid lines. Useflexible sections to avoid fuel line breakage caused byvibration. Do not operate the generator set in the presence offuel leaks, fuel accumulation, or sparks. Repair fuel systemsbefore resuming generator set operation.

Gas fuel leaks. Explosive fuel vapors can cause severeinjuryor death. Fuel leakage can causean explosion. Checkthe LP vapor gas or natural gas fuel system for leakage byusing a soap and water solution with the fuel system testpressurized to 6--8 ounces per square inch (10--14 incheswater column). Do not use a soap solution containing eitherammonia or chlorine because both prevent bubble formation.A successful test depends on the ability of the solution tobubble.

Explosive fuel vapors can cause severe injury or death.Take additional precautions when using the following fuels:

Propane (LP)�Adequate ventilation is mandatory. Becausepropane is heavier than air, install propane gas detectors lowin a room. Inspect the detectors per the manufacturer’sinstructions.

Natural Gas�Adequate ventilation is mandatory. Becausenatural 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 LPGfuel. The generator set is EPA-certified for both naturalgas and LPG fuels.

The fuel system installation must comply with the NECand local codes.

1.7.1 Fuel Supply

Because of variable climates and geographicalconsiderations, contact the local fuel supplier for fuelsystem planning and installation. Figure 1-5 lists therecommended fuel ratings and other fuel supplyinformation for natural gas and LPG fuels.

Fuel typeNaturalGas LPG

Fuel supply inlet 1/2 NPT

Fuel supply pressure,kPa (in. H2O)

0.87--2.7(3.5-11)

1.7--2.7(7-11)

Fuel flow rate, maximum, Btu/hr.:

8RESV/RESVL 99,200 160,800

10RESV/RESVL 157,100 185,297

12RESV/RESVL 208,550 257,000

Nominal Fuel Rating, Btu/ft.3

Natural gas 1000

LPG 2500

Figure 1-5 Fuel Supply

Verify that the output pressure from the primary gasutility pressure regulator is as shown in Figure 1-5 andthat the utility gas meter flow rate is sufficient to supplythe generator set at rated load plus all othergas-consuming appliances. For LPG tanks, verify thatthe output pressure is as shown in Figure 1-5. SeeFigure 1-8 for fuel consumption. Contact the fuelsupplier for flow rate information or a gas meterupgrade, if necessary.

1.7.2 Fuel Pipe Size

Ensure that the fuel pipe size and length meet thespecifications in Figure 1-6. Measure the pipe lengthfrom the primary gas pressure regulator to the pipeconnection on the generator set fuel inlet. Add 2.4 m(8 ft.) to themeasured length for each 90 degree elbow.Compare the total pipe length with the chart inFigure 1-6 to find the required pipe size.

Contact local LPG provider for LPG installationinformation.


Minimum Gas Pipe Size Recommendation, in. NPT

Pipe Length,m (ft.)

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

Natural Gas(99,200 Btu/hr.)

LPG(160,800 Btu/hr.)





8 (25) 3/4 3/4 3/4 3/4 3/4 3/4

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

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

46 (150) 1 1 1 1 1 1

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

Figure 1-6 Fuel Pipe Size Recommendations

1.7.3 Connecting the Fuel Supply

The dimension drawing in Section 3 shows the locationof the fuel inlet connection. Have the fuel supplier installrigid gas piping and a manual fuel shut-off valve. Thefuel supply line should line upwith the generator set fuelinlet and end about 12 inches away to allow connectionwith a section of flexible fuel line. Use flexible sections toprevent fuel line breakage caused by vibration.

Note: Do not bend the flexible fuel line to make up formisalignment of the fuel supply line and thegenerator set fuel inlet.

Apply pipe sealant that is approved for fuel connections.Hold the fuel solenoid valve with a wrench whentightening the fuel connections.

Note: Do not hold the fuel solenoid valve coil whentightening the fuel connections. See Figure 1-7for the recommended wrench locations.

Open the manual fuel valves and test all fuelconnections using soapy water. If a leak is found, closethe fuel valves, clean the fittings, and apply freshsealant. Check for fuel leaks again with the generatorset running.

Protect all fuel lines from machinery or equipmentcontact, adverse weather conditions, and environmentaldamage.

2

IMG_0351

1. Hold valve with wrench on flats of valve body2. Alternate wrench location

Note: Do NOT hold the valve coil when tightening connections.

1

Figure 1-7 Holding Fuel Valve to Tighten FuelConnections

Fuel Type % Load

Fuel Consumption, m3/hr. (cfh)

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

60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz

Natural Gas

100% 2.8 (99) 2.5 (88) 4.2 (146) 4.2 (146) 4.2 (149) 4.0 (142)

75% 2.2 (78) 2.0 (70) 3.4 (119) 3.4 (119) 3.6 (125) 2.8 (98)

50% 1.8 (64) 1.6 (57) 2.9 (101) 2.9 (101) 2.7 (95) 2.2 (76)

25% 1.5 (54) 1.3 (45) 2.4 (86) 2.4 (86) 2.0 (70) 1.6 (56)

LPG

100% 1.8 (64) 1.8 (64) 2.0 (72) 2.0 (72) 2.3 (80) 2.0 (70)

75% 1.7 (58) 1.6 (55) 1.7 (60) 1.7 (60) 1.9 (68) 1.7 (58)

50% 1.5 (51) 1.3 (46) 1.4 (51) 1.4 (51) 1.6 (56) 1.3 (46)

25% 1.3 (45) 1.1 (38) 1.2 (42) 1.2 (42) 1.2 (43) 1.0 (36)

LPG conversion factors:8.58 ft.3 = 1 lb.0.535 m3 = 1 kg36.39 ft.3 = 1 gal.

Nominal fuel rating:Natural gas: 37 MJ/m3 (1000 Btu/ft.3)LPG: 93 MJ/m3 (2500 Btu/ft.3)

Figure 1-8 Fuel Consumption


1.8 Fuel ConversionThe multi-fuel system allows conversion from naturalgas (NG) to LPG (or vice-versa) in the field whilemaintaining emissions-standard compliance. A trainedtechnician or an authorized distributor/dealer canconvert the fuel system.

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.



WARNING

Fuel Conversion Procedure

The fuel selector valve allows field-conversion betweennatural gas (NG) and LPG. The valve is factory-set tocomply with applicable emission standards and toprovide the best possible hot and cold starting.

Note: Do not adjust the factory-set screw on theselector valve. Adjusting the screw may violatefederal and state laws. See Figure 1-13.

Use the following procedure to convert the fuel system.The procedure includes removing the side panel,removing the cap from the fuel selector valve, andmaking the fuel selection.

See Figure 1-9 for fuel system components.

1. Gas shutoff valve2. Gas regulator3. Selector valve cap4. Selector valve

1 2

3

4

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Figure 1-9 Fuel System

1. Press the OFF button on the generator setcontroller.

2. Disconnect the power to the battery charger.

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

4. Turn off the fuel supply.

5. Remove panel screws and remove left sidelouvered panel. Figure 1-10.

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1. Panel screws2. Left side panel3. Fuel system. See Figure 1-9 for details.

1

1

2

3

Figure 1-10 Remove Left Panel


6. Remove the cap from the fuel selector valve. SeeFigure 1-11. Insert a flat head screwdriver underthe lip of the capand push it upwards. Keep thecapclose by as it is needed to switch fuels in the nextstep.

tp68791. Fuel selector cap

1

Figure 1-11 Cap Removal

7. See Figure 1-12. Use the cap in the orientationshown to turn the selector valve to NG or LP. SeeFigure 1-13 for valve positions.

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1. Turn selector valve

1

Figure 1-12 Fuel Selection

1. Fully left for LPG2. Fully right for NG3. Factory-set screw (Do not adjust!)

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12

3

Figure 1-13 Valve Positions

8. Replace the cap.

9. Connect and turn on the fuel supply (ensure thatthe fuel supply matches the fuel setting).

10. Reconnect the generator set engine startingbattery leads, negative (--) lead last.

11. Reconnect power to the battery charger.

12. Reassemble the left side panel.

13. Start the generator set by pressing the RUN buttonon the generator set controller.

14. Check for leaks using a gas leak detector.

15. Run the generator set and check the operation.

16. Press theOFFbutton to to shut down thegeneratorset.

Rating

Converting the fuel will change the generator set rating.See thegenerator set specification sheet for ratingswithnatural gas and LPG. When converting to LPG fromfactory settings, order a new nameplate with theupdated rating and fuel information from an authorizeddistributor/dealer, if necessary. Provide the followinginformation from the original nameplate:

D Model Number D kVAD Spec Number D AmpsD Serial Number D VoltsD Fuel (original and new) D HzD kW


1.9 Electrical Connections



DANGER

Grounding electrical equipment. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set, transfer switch, and related equipment andelectrical circuits. Turn off the main circuit breakers of allpower sources before servicing the equipment. Never contactelectrical leads or applianceswhen standing inwater or onwetground because these conditions increase the risk ofelectrocution.

Electrical backfeed to the utility. Hazardous backfeedvoltage can cause severe injury or death. Install a transferswitch in standby power installations to prevent the connectionof standby and other sources of power. Electrical backfeedinto a utility electrical system can cause severe injury or deathto utility personnel working on power lines.

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

Have an authorized distributor/dealer or a licensedelectrician make the following electrical connections.The electrical installationmust comply with the NationalElectrical Coder (NEC) class 1 wire designation and allapplicable local codes. Canadian installations mustcomply with the Canadian Electrical Code (CEC) andapplicable local codes.

AC circuit protection. All AC circuits must includecircuit breaker or fuse protection. The circuit breakermust be rated for a maximum of 125% of the ratedgenerator set output current. The circuit breaker mustopen all ungrounded connectors. The generator set isequipped with a factory-installed circuit breaker.

For customer-supplied wiring, select the wiretemperature rating in Figure 1-14 based upon thefollowing criteria:

D Select row 1, 2, 3, or 4 if the circuit rating is110 amperes or less or requires #1 AWG (42.4 mm2)or smaller conductors.

D Select row 3 or 4 if the circuit rating is greater than110 amperes or requires #1 AWG (42.4 mm2) orlarger conductors.

Row Temp. Rating Copper (Cu) Only Cu/Aluminum (Al) Combinations Al Only

1 60_C (140_F)or

75_C (167_F)

Use No. * AWG, 60_C wire oruse No. * AWG, 75_C wire

Use 60_C wire, either No. * AWG Cu, or No. *AWG Al or use 75_C wire, either No. * AWGCu or No. * AWG Al

Use 60_C wire, No. * AWG oruse 75_C wire, No. * AWG

2 60_C (140_F) Use No. * AWG, 60_C wire Use 60_C wire, either No. * AWG Cu or No. *AWG Al

Use 60_C wire, No. * AWG

3 75_C (167_F) Use No. *[ AWG, 75_C wire Use 75_C wire, either No. *[ AWG Cu or No.*[ AWG Al

Use 75_C wire, No.*[ AWG

4 90_C (194_F) Use No. *[ AWG, 90_C wire Use 90_C wire, either No. *[ AWG Cu or No.*[ AWG Al

Use 90_C wire, No.*[ AWG

* The wire size for 60_C (140_F) wire is not required to be included in the marking. If included, the wire size is based on ampacities for thewire given in Table 310-16 of the National Electrical Coder, in ANSI/NFPA 70, and on 115% of the maximum current that the circuit carriesunder rated conditions. The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.

[ Use the larger of the following conductors: the same size conductor as that used for the temperature test or one selected using theguidelines in the preceding footnote.

Figure 1-14 Terminal Markings for Various Temperature Ratings and Conductors

The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.


1.9.1 Grounding

Ground the generator set. The grounding method mustcomply with NEC and local codes. Connect thegrounding strap to the generator set ground lug,terminal GND inside the controller compartment.

Generator sets are shipped with the generator neutralbonded (connected) to the generator ground in thejunction box. The requirement for having a bonded(grounded) neutral or ungroundedneutral is determinedby the type of installation. At installation, the neutral canbe grounded at the generator set or lifted from theground stud and isolated if the installation requires anungrounded neutral connection at the generator. Thegenerator setwill operateproperlywith theneutral eitherbonded to ground or isolated from ground at thegenerator.

Various regulationsandsiteconfigurations including theNational Electrical Code (NEC), local codes, and thetype of transfer switch used in the application determinethe grounding of the neutral at the generator. NECSection 250 is one example that has a very goodexplanation of the neutral grounding requirements forgenerators.

1.9.2 Electrical Lead Entry

Drill or punch holes in the enclosure for the electricalconduit in the locations shown in Figure 1-15.

1. 1/2 NPT female fuel inlet2. Utility voltage electrical lead entry point3. ATS signal electrical lead entry point

ADV--8539

1

2 3

Figure 1-15 Electrical Lead Entry Locations

1.9.3 Field-Connection Terminal Block

The generator set is equipped with a field-connectionterminal block located in the air inlet area inside thejunctionbox. Leadshavebeen factory-installed from thejunction box to the terminal block for easy field wiring.

SeeFigure 1-16 for terminal block location.Remove thecover panel for access to the field connections.

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1. Electrical cover panel

1

Figure 1-16 Field-Connection Terminal BlockLocation

See Figure 1-17 for terminal block details. Refer to theterminal block decal for connections and cable sizes.Also see the wiring diagram in Section 3.

RouteAC leads through flexible conduit. Ensure that theleads and conduit do not interfere with the operation ofthe generator set or obstruct the service areas. Routelow-voltage communication leads through separateconduit.


Procedure

1. Drill holes for the conduit fittings. See Figure 1-15for the recommended electrical inlet locations.Feed the cables through the openings.

2. Connect the leads from the transfer switchemergency source lugs to the L1 and L2connections on the generator set terminal block.

3. Connect the neutral (L0) and ground (GRD) leadsfrom the ATS and the main panel to thecorresponding connection points on the terminalblock. See Section 1.9.1, Grounding.

4. Connect utility power leads to the terminal blockconnections labelled UTILITY. Connect to a circuitthat is supplied by the utility source and backed upby the generator. See Section 1.9.4 for moreinformation about the utility power requirement.

5. For connection of optional transfer switches, theprogrammable interface module (PIM), and/or aloadcontrolmodule (LCM),or the loadshedkit, seeSection 1.10.

6. To connect the OnCuer Plus GeneratorManagement System to your generator, runnetwork cable from the generator set to thecustomer’s router or modem.

a. Route the network cable with other low-voltagesignal wiring (for example, the RBUScommunication leads or engine start leads tothe transfer switch), in separate conduit fromtheAC load leads. If the network cable is longerthan 100 meters (328 ft.), use a repeater orswitch.

b. Test the internet connection for the generatorby connecting a laptop to the network cable.

(1) Turn OFF any wireless connections to thelaptop.

(2) Connect the network cable to the laptop.Connect the other end of the network cableto the customer’s router or modem.

(3) Verify the Internet connection by openingyour web browser and going towww.kohlerpower.com or any knownwebsite.

(4) Disconnect the network cable from thelaptop.

c. Use an RJ45 inline coupler to connect theEthernet cable to the cable in the customerconnection box. See Figure 1-17. The inlinecoupler is included with the OnCue Plus kit.

7. When connections to the terminal block arecomplete, replace the cover plate.

1. Ground connection for communication cable shield.2. Low voltage communication and engine start

connections3. AC power connections4. Ethernet cable for OnCue Plus connection5. AC load connections

GM8835451 2 3 4

Figure 1-17 Electrical Connections

1.9.4 AC Power Supply

The installer must connect AC power for the batterycharger (which is integral to the RDC2 controller) andthe optional accessories shown in Figure 1-18. Thepower source must comply with state and local codes.The power to the battery charger and accessories mustbebackedupby thegenerator so that power is availableat all times.

Be sure to disconnect power at the distribution panelbeforemaking the connections. Connect power leads tothe utility power connectionpoints on the terminal block.See Section 1.9.3 and the wiring diagrams in Section 3for connection details.

Equipment

Power Requirement, Max.

Watts Amps Volts

Battery charger(standard) 50 0.4

100--250 VAC50/60 Hz

Carburetor heater *37 0.3

120 VAC50/60 Hz

* Optional accessory

Figure 1-18 Power Requirements


1.10 ATS and AccessoryConnections

Hazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.

If the generator set is used forstandby power, install an automatictransfer switch to prevent inadvertentinterconnection of standby andnormal sources of supply.

WARNING

The following sections cover electrical connections ofthe automatic transfer switches andRBUSaccessories,including theprogrammable interfacemodule (PIM), theload control module (LCM), or the load shed kit.

1.10.1 Transfer Switch Connection

Connect the ATS or remote start/stop switch. Connectthe load leads from the generator set to the Emergencysource lugs on the ATS. Route low-voltagecommunication leads throughseparateconduit from theAC power and load leads. All connections must complywith applicable state and local codes.

Note: Do not use the Kohlerr Model RRT transferswitch with the RESV or RESVL generator set.

Communication connections for a KohlerrModel RXT transfer switch

OneModel RXT transfer switch can be connected to thegenerator set. See Figure 1-19. Use shielded,twisted-pair communication cable to connect P10-1throughP10-4on the transfer switch interfacemodule tothegenerator set terminal blockconnectionsA,B,PWR,and COM.

Note: Connections 3 and 4 on the generator set are notused with the Model RXT transfer switch.

1. Generator set terminal block TB3. See Figure 3-4 for location. Check the decal on the generator set for terminal block connections.2. Connect one end of each cable shield to GROUND at the generator set.3. Communication cable Belden #9402 or equivalent 20 AWG shielded, twisted-pair cable. Section 1.10.24. Leave one end of each cable shield disconnected. If accessory modules (PIM, LCM, or load shed kit) are connected, see Section

1.10.3.

Interface Board on theModel RXT Transfer Switch

Note: Generator set terminal block (TB3) connections 3 and 4 are NOT USED with the Model RXT ATS.

Generator Set

COM

PWR

B

A RXT

COM

PWR

B

A

GND

TB3

RBUS

12 VDC

3

1

2

4

4

A

B

COM

PWR

3

4

Figure 1-19 Model RXT Transfer Switch Communication Connection to Generator Set Terminal Block


Engine start connection for other transferswitches or a remote start/stop switch

Connect the engine start leads from the transfer switchor remote start switch to terminals 3 and 4 on the

terminal block. See Figure 1-20. Route the engine startleads through separate conduit from the AC power andload leads.

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1. Generator Set Terminal Block. See the dimension drawings in Section 3 for location. Check the decal on the generator set for terminalblock connections.

2. Engine start leads 3 and 4. See the ATS manual for cable size specifications.

Generator Set ATS(with enginestart contacts)

12

A

B

COM

PWR

3

4

TB3

Figure 1-20 Engine Start Connections with Transfer Switch Models RDT or RSB


1.10.2 Communication CableSpecifications

RBUS Connections A and B

For the RBUS communication connections A and B tothe Model RXT transfer switch, optional PIM and/oroptional LCM or load shed kit, use 20 AWG shielded,twisted-pair communication cable. Belden #9402(two-pair) or Belden #8762 (single-pair) or equivalentcable is recommended.

For outdoor installations, including those with buriedcables and/or conduit, use outdoor-rated Belden#1075A or equivalent 20 AWG shielded, twisted-paircommunication cable.

PWR and COM Connections

For the PWR and COM connections from the generatorset to theRXT, PIM and/or LCMor load shed kit, use thesecond pair in the two-pair communication cable forshort runs, or use 12--14 AWG cable for longer runs asshown in Figure 1-21.

The maximum cable length depends on the number ofoptional modules connected. A module can be a ModelRXT transfer switch, a load control module (LCM) or aload shed kit or a programmable interface module(PIM). See Figure 1-21 for the maximum cable lengthswith 1, 2, or 3 modules per cable run. Note the shieldconnections shown in Figure 1-23.

Cable Size for PWR and COM Connections

Indoor orOutdoor

Installation

Maximum length per run, meters (ft.)

Number of Modules (ATS, PIM and LCM, or LoadShed Kit) per Run

1 Module 2 Modules 3 Modules

20 AWG Belden #9402 or equivalent, two-pair Indoor 61 (200) 31 (100) 21 (67)

20 AWG Belden #1075A or equivalent, two-pair Outdoor 61 (200) 31 (100) 21 (67)

14 AWG * � 152 (500) 152 (500) 122 (400)

12 AWG * � 152 (500) 152 (500) 152 (500)

* Use 12 or 14 AWG cable for PWR and COM connections only. For RBUS connections A and B, use shielded, twisted pair communicationcable specified in Section 1.10.2.

Figure 1-21 Total Cable Lengths for PWR and COM Connections


1.10.3 System Connections withAccessory Modules

See Figure 1-23 through Figure 1-26 for connectionoptions with accessory modules. Accessory modulescan include one Model RXT transfer switch, one

programmable interface module (PIM) and/or one loadcontrol module (LCM) or load shed kit.

SeeFigure 1-21 for themaximum total cable lengthwith1, 2, or 3 accessory modules per cable run.

Generator Set

GND

A

B

COM

PWR

3

4

RBUS

12 VDC

TB3

PIM

LCM or Load Shed Kit

COM

COM

PWR

COM

PWR

PWR

B

A

B

A

B

A

COM

PWR

B

A

RXT

COM

PWR

B

A

COM

PWR

B

A

4

1. Customer connection terminal block. See Figure 1-17 for location. Check the decal on the generator set for terminal block connections.2. Connect one end of each cable shield to GROUND at the generator set.3. See Figure 1-21 for cable specifications, including maximum total cable length per run (1 run shown).4. Connect shields together as shown.5. Leave the end of each cable shield disconnected at the last device.

5

21

3

5

Figure 1-22 Accessory Module Communication Connection Details


RXT

4

PIM

LCM or a Load Shed Kit

Generator Set

COM

PWR

COM

PWR

B

A

B

A

COM

PWR

B

A

COM

PWR

B

A

1. Generator set terminal block. See Figure 3-4 for location. Check the decal on the generator set for terminal block connections.2. Connect one end of each cable shield to GROUND at the generator set.3. Communication cable Belden #8762 or equivalent 20 AWG shielded, twisted-pair cable (one pair).4. Connect shields together as shown.5. Leave one end of each cable shield disconnected at the last device.6. 12 AWG or 14 AWG leads for PWR and COM.

GND

1

2

5

6

Note: See Section 1.10.2, Cable Specifications.

COM

PWR

B

A

COM

PWR

B

AA

B

COM

PWR

3

4

RBUS

12 VDC

TB3

3

Figure 1-23 Accessory Module Communication Connection Details


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PIM

RXT ATSGenerator Set

NOTES:

D See Figure 3-4 for terminal block location on generator set. Checkthe decal on the generator set for terminal block connections.

D See Figure 1-21 for maximum total cable length per run (3 runswith 1 module each shown).

D See Figure 1-23 for communication connection detail (A and B,PWR and COM).

D Use splices or wire nuts to collect multiple leads for connection tothe generator set terminal block. See Figure 1-25.

TB3

LCM or LoadShed Kit

Figure 1-24 Accessory Module Connections (three cable runs with one module each)

A

B

COM

PWR

3

4

2

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1. Generator Set Terminal Block TB3. See Figure 3-4 for location. Check the decal on the generator set for terminal block connections.2. Splice3. Connect all of the shield leads on this end to GROUND at the generator set.

Generator Set COMPWR

BA

3

9402 CABLE

9402 CABLETB3

RBUS

12 VDC

1

3

COMPWR

B

A

Figure 1-25 Multiple Connections to the Generator Set


tp6809

PIM

RXT ATSGenerator Set

Notes:

D See Figure 3-4 for terminal block location on generatorset. Check the decal on the generator set for terminal blockconnections.

D See Section 1.10.2, Cable Specifications.

D See Figure 1-23 for communication connection detail (Aand B, PWR and COM). Connect the cable shield toground at the generator set.

D Use splices or wire nuts to collect multiple leads forconnection to the generator set terminal block. SeeFigure 1-25.

TerminalBlock

LCM or LoadShed Kit

Figure 1-26 Accessory Module Connections (two cable runs with one and two modules shown)


1.11 Battery

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

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

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

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid can causeblindness and burn skin. Always wear splashproof safetygoggles, rubber gloves, and boots when servicing the battery.Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediatelyflush the affected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case of eyecontact. Never add acid to a battery after placing the battery inservice, as this may result in hazardous spattering of batteryacid.

Battery acid cleanup. Battery acid can cause severeinjury or death. Battery acid is electrically conductive andcorrosive. Add 500 g (1 lb.) of bicarbonate of soda (bakingsoda) to a container with 4 L (1 gal.) of water and mix theneutralizing solution. Pour the neutralizing solution on thespilled battery acid and continue to add the neutralizingsolution to the spilled battery acid until all evidence of achemical reaction (foaming) has ceased. Flush the resultingliquid with water and dry the area.

Battery gases. Explosion can cause severe injury ordeath. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur near a battery at any time,particularly when it is charging. Do not dispose of a battery in afire. To prevent burns and sparks that could cause anexplosion, avoid touching the battery terminals with tools orother metal objects. Remove all jewelry before servicing theequipment. Discharge static electricity from your body beforetouching batteries by first touching a grounded metal surfaceaway from the battery. To avoid sparks, do not disturb thebattery charger connections while the battery is charging.Always turn the battery charger off before disconnecting thebattery connections. Ventilate the compartments containingbatteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injuryor death. Short circuits can cause bodily injury and/orequipment damage. Disconnect the battery before generatorset installation or maintenance. Remove all jewelry beforeservicing the equipment. Use tools with insulated handles.Remove the negative (--) lead first when disconnecting thebattery. Reconnect the negative (--) lead last whenreconnecting the battery. Never connect the negative (--)battery cable to the positive (+) connection terminal of thestarter solenoid. Do not test the battery condition by shortingthe terminals together.

Connecting the battery and the battery charger.Hazardous voltage can cause severe injury or death.Reconnect the battery correctly, positive to positive andnegative to negative, to avoid electrical shock and damage tothe battery charger and battery(ies). Have a qualifiedelectrician install the battery(ies).

Starting batteries are usually the lead-acid type. Use a12-volt group 51 battery with a minimum rating of 500cold cranking amps at 0_F. The generator set uses anegative groundwith a 12-volt engine electrical system.SeeFigure 1-27 for battery connections.Make sure thatthe battery is correctly connected and the terminals aretight.

Note: The generator set will not start and circuit boarddamage may occur if the battery is connected inreverse.

See the dimension drawing in Section 3 for the enginestarting battery location on the air intake side of thegenerator set. Standard battery cables provide easyconnection to the battery.


EZ-273000-J

1

1. To positive (+) terminal on starter solenoid.2. To ground (--) terminal on or near starter motor.

2

Figure 1-27 Typical Battery Connection

Use the following procedure to install and connect thebattery.

Battery Installation Procedure

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

2. Clean the battery posts and/or adapters ifnecessary.

3. Install the battery post adapters, if needed.

4. Place the battery in the housing.

5. Connect the positive (+) lead to the engine startingbattery.

6. Connect thenegative (--) lead to the engine startingbattery.

Refer to the generator set operation manual and thebattery manufacturer’s instructions for batterymaintenance instructions.

Whenpower is applied to theRDC2/DC2controller (thatis, when the battery is connected), you will be promptedto set the date and time, and then to set the exerciser.See Section 1.13 and the generator set operationmanual for instructions.

If thebattery is disconnected for service or replacement,the exercise settings on the RDC2/DC2 controller arelost. Set theexerciser after installing and connecting thebattery. See Section 1.13, Set Exerciser.

1.12 Prestart Installation CheckReview the entire installation section. Inspect all wiringand connections to verify that the generator set is readyfor operation. Check all items in the following PrestartChecklist.

Prestart Checklist

Air Cleaner. Check that a clean air cleaner element isinstalled to prevent unfiltered air from entering theengine. See the generator set operation manual forinstructions.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consultthe battery manufacturer’s instructions regardingbattery care and maintenance.

Enclosure.Check that all enclosure panelsand internalbaffling are in place.

Exhaust System. Check for exhaust leaks andblockages. Check the muffler condition.

D Inspect the exhaust system components for cracks,leaks, and corrosion. Check for tight exhaust systemconnections.

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check that the exhaust outlet is unobstructed.

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

Operating Area. Check for obstructions that couldblock the flow of cooling air. Keep the air intake areaclean. Do not leave rags, tools, or debris on or near thegenerator set.


1.13 Set the ExerciserSet the exerciser to automatically run the generator seton the desired day and time every week or every twoweeks. See the generator set Operation Manual fordetailed descriptions of the unloaded and loadedexercise operation.

Note: Your generator will use either the RDC2 (RESVmodels) or theDC2 (RESVLmodels) controller.Determine which controller your generator setuses and follow the directions to set that specificcontroller. See Figure 1-28.

RDC2 (RESV) DC2 (RESVL)

Figure 1-28 Controller Identification

1.13.1 RDC2 Controller

Whenpower is applied to theRDC2controller (when thebattery or the utility power for the battery charger isconnected), you will be prompted to set the date andtime, and then to set the exerciser.

The first setting will flash. Press theUp and Down arrowbuttons to change the setting. Press Select to save thesetting and move on to the next. Repeat until the date,time, and exercise are set and the controller displayshows themainmenu. See the generator set OperationManual formoredetailed instructions to set the dateandtime and set the exerciser.

Press AUTO to place the generator set controller intoautomatic mode.

tp6803

Date:

05Dec2011

Time:

08:31am

Next Exercise:

08:31a 12Dec2011

Setting will flash.

Press the up and down arrowbuttons to change the setting.

Press Select to save thesetting.

Figure 1-29 Set Time, Date, and Exercise (RDC2)

1.13.2 DC2 Controller

To set the exerciser on the DC2 controller, first pressAUTO to place the controller into automatic (standby)mode. Then press and hold the Exercise button. Thegenerator set will start and run a 20-minute unloadedcycle exercise. The generator set will run automaticallyfor 20 minutes at the same time every 7 days. See thegenerator set Operation Manual for more information.

1.13.3 Loaded Exercise

In order to set a loaded exercise using theRDC2orDC2controller, a KohlerrModelRXT transfer switchmust beconnected. See the generator set operation manual forinstructions to set a loaded exercise.

Toset a loadedexercise onagenerator set connected toa transfer switch other than a Model RXT, use thetransfer switch controller to set theexercise.Refer to thetransfer switch operation manual for instructions.

1.14 Operation Test

1. Verify that all guards and enclosure panels are inplace.

2. Check the items in the Prestart Checklist inSection 1.12.

3. Press the RUN button on the generator setcontroller to start the generator set. Verify that theengine starts and runs.

4. Press OFF to stop the engine. Then press AUTOon the RDC2 controller.

5. Verify that the enclosure door is closed and that thepanels are installed. Lock the enclosure to preventunauthorized access.


1.15 OnCue Plus GeneratorManagement System

The OnCuer Plus Generator Management System isincluded with the 8RESV(L), 10RESV(L), and12RESV(L) and allows monitoring and control of yourgenerator set from a personal computer, smart phone,or tablet. OnCue Plus can also be configured to sendemail or text message notifications in the event of agenerator set fault. SeeG18-247,QuickStartGuideandTP--6928, OnCue Plus Operation Manual, forinstructions.

To use OnCue Plus, you must have the followingminimumrequirements for connecting your generator tothe Internet:

D “Always-on” Internet service for generator setconnection (for example, cable, DSL, or phone linemodem connected 24 hours)

D Unused Ethernet port on a switch, router,or modem

D Anuninterruptiblepowersupply (UPS) for themodemand router is recommended.

D 5E customer-supplied network cable for connectionof the generator set to the customer’s Ethernet router(see installation instructions in Section 1.9.3)

D USB cable, male USB A to male mini-B, for updatingthe controller firmware.

For instructions on connecting the network cables to thegenerator set, see instructions in Section 1.9.3.


Notes

TP-6879 8/14 33Section 2 Accessories

Section 2 Accessories

2.1 IntroductionThis section describes someof the accessories that areavailable for the generator sets. Have accessoriesinstalled by an authorized distributor/ dealer or alicensed electrician. This document does not containinstallation instructions for accessories. Follow theinstallation instructions provided with each kit.

Use separate conduit for ACandDC leads to reduce thepossibility of electrical interference. Verify that the leadsand conduit do not interfere with the operation of thegenerator set or obstruct the service areas. Verify thatthe electrical installation complies with the NationalElectrical Code (NEC) and all applicable local codes.See the wiring diagrams in Section 3 for moreinformation regarding generator set electricalconnections.

2.2 Connect OptionalProgrammable InterfaceModule (PIM)

The optional programmable interface module (PIM)provides two programmable inputs and six dry contactoutputs, four of which are programmable. See TT-1584for PIM installation and connection instructions. Alsosee Section 1.10 of this manual for connection to thegenerator set.

The default settings for the inputs and outputs areshown in Figure 2-2. To change the input and outputsettings, use a personal computer running KohlerSiteTechr software. See TP-6701, SiteTech SoftwareOperation Manual, for instructions.

KohlerOnCuerPlus can beused to actively control PIMoutputs. See the OnCue Plus Operation Manual forinstructions.

1. Output connections (3 terminal blocks, 6 outputs)2. Input connections (2 inputs)3. RBUS communication connection to generator set terminal

block TB2

2

ADV-8199

1

3

1

1

Figure 2-1 Optional PIM

PIM Connection Factory Default Setting

Input 1 None

Input 2 None

Output 1 (Relay 1) Run

Output 2 (Relay 2) Common Fault

Output 3 (Relay 3) Low Battery Voltage(Programmable)

Output 4 (Relay 4) Not in Auto (Programmable)

Output 5 (Relay 5) Cooldown (Programmable)

Output 6 (Relay 6) Normal Source Failure(Programmable)

Figure 2-2 PIM Inputs and Outputs

TP-6879 8/1434 Section 2 Accessories

2.3 Load Control Module (LCM)The optional LoadControlModule (LCM) is available forsingle-phase generator sets only. The LCM provides anautomatic load management system to comply withSection 702.5 of NEC 2008. The installer is responsiblefor ensuring that the power system installation complieswith all applicable state and local codes.

With the Load Control Module (LCM), less criticalappliances can be powered by the generator set whenthemore important appliances are not running, allowingthe use of a smaller generator set thanwould be neededto run all of the building’s electrical equipment at thesame time.

The LCM receives commands from the RDC2 or DC2generator controller and energizes or de-energizes theappropriate load relays to add or shed non-critical loadsaccording to their priority.

Note: Connect only non-essential loads to the loadcontrol module.

The load control module automatically manages up tosix residential loads:

D Four power relays are provided for management ofnon-essential secondary loads. 120 VACpowermustbe provided for operation of the power relays.

D Two relays are available to control two independentair conditioner loads.

The LCM is available with either a prewired harness forload relay connection, or a terminal block. The prewiredharness requires installation of the LCM within0.6 meters (2 feet) of the distribution panel. The loadcontrol module with the optional wire harness is shownin Figure 2-3. If the harness is not used, connect to theterminal blocks inside the LCM enclosure. Figure 2-4shows the load control module without the optionalharness.

Refer to TT-1574, providedwith the LCM, for installationand connection instructions.

Figure 2-3 Load Control Module (shown withoptional wire harness)

Figure 2-4 Load Control Module (cover removed toshow field-connection terminal blocks)

TP-6879 8/14 35Section 2 Accessories

2.4 Load Shed KitA load shed kit can be used on single-phase systemsthat include a Model RDT or RXT transfer switch. Theload shed kit mounts inside the Model RDT or ModelRXT transfer switch enclosure. Figure 3 shows the loadshed assembly.

The optional load shed kit provides an automatic loadmanagement system to comply with Section 702.5 ofNEC 2008. The installer is responsible for ensuring thatthe power system installation complies with allapplicable state and local codes.

Note: Do not install both a load shed kit and a loadcontrol module (LCM) on the same system.

The load shed kit provides the same load shed and addfunctionsas the loadcontrolmodule (LCM).SeeSection2.3.

Note: Connect only non-essential loads to the loadshed kit.

The load shed kit automatically manages up to sixresidential loads:

D Up to four customer-supplied power relays can beconnected through normally open relay contacts onthe circuit board. See TT-1609 for relay coil voltagespecifications.

D Two relays are included to control two independentheating, ventilation, and air conditioning (HVAC)loads.

An adequate electrical supply is required for operationof the customer-supplied power relays connected to theload shed kit. Check the electrical requirements of thecustomer-provided equipment prior to installation todetermine the wire size and circuit protection required.Verify that customer-provided equipment complies withapplicable local and national electrical codes.

See TT-1609, provided with the kit, for detailedinstallation and connection instructions.

1. Terminal block TB102. Load control circuit board3. Mounting bracket

Note: Kit includes current transformer (CT), not shown.

2

GM88281

1

3

Figure 3 Load Shed Assembly GM88281-1

TP-6879 8/1436 Section 2 Accessories

2.5 Carburetor Heater



WARNING

Servicing the engine heater. Hot parts can cause minorpersonal injury or property damage. Install the heaterbefore connecting it to power. Operating the heater beforeinstallation can cause burns and component damage.Disconnect power to the heater and allow it to cool beforeservicing the heater or nearby parts.

An optional carburetor heater is recommended forimproved cold starting in locations where the ambienttemperature drops below 0_C (32_F). The carburetorheater prevents condensation and carburetor icing. Theheater turns on when the temperature at the thermostatfallsbelowapproximately4_C(40_F) and turns offwhenthe temperature rises above approximately 16_C(60_F). The carburetor heater is shown in Figure 2-6.

To install the carburetor heater, follow the instructionsprovided with the kit. Figure 2-7 shows the installedcarburetor heater kit.

Verify that AC power is connected to the generator setas described in Section 1.9. The circuit must be backedup by the generator set to provide power at all times.

The heater thermostat is installed in the cord. Figure 2-6shows the location of the thermostat on the power cord.Theheater power cordand thermostat are located in thegenerator set housing air intake area/ batterycompartment.

The heater requires a continuous source of power. Plugthe carburetor heater into the 120 VAC receptacleprovided.

Kit Number 120 Volt Kits

Voltage 120 VAC50/60 Hz

Thermostat ON 4 4_C (40 7_F)

Thermostat OFF 16 3_C (60 5_F)

Figure 2-5 Carburetor Heater Specifications

2 3

GM57968

1

1. Power plug2. Thermostat3. Heater

Figure 2-6 Carburetor Heater

8RESV(L)

10/12RESV(L)GM57969

1. Carburetor heater2. Carburetor heater power cord

1

2

1

2

Figure 2-7 Carburetor Heater Location

TP-6879 8/14 37Section 3 Drawings and Diagrams

Section 3 Drawings and Diagrams

Figure 3-1 lists the wiring diagram numbers and pagenumbers.

Dimension Drawing Drawing Number Page

Dimension Drawing ADV--8539, Sheet 1 38

ADV--8539, Sheet 2 39

ADV--8539, Sheet 3 40

Wiring Diagram Description Drawing Number Page

Schematic Diagram ADV--8552 41

Point-to-Point Wiring Diagram GM89012 42

Figure 3-1 Wiring Diagrams and Schematics

TP-6879 8/1438 Section 3 Drawings and Diagrams

Figure 3-2 Dimension Drawing ADV-8539, Sheet 1


-

Figure 3-5 Schematic Diagram, ADV-8552


-

Figure 3-6 Point-to-Point Wiring Diagram, GM89012

TP-6879 8/14 Appendix 43

Appendix A Abbreviations

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

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)

exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupterGND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6879 8/1444 Appendix

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, m milliohmMOhm, M megohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gasNBS National Bureau of Standards

NC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRBUS RS-485 proprietary

communicationsRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d�unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

E 2014 by Kohler Co. All rights reserved.

TP-6879 8/14

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455

For the nearest KOHLER authorizedinstallation, service, and sales dealer inthe US and Canada:Call 1-800-544-2444 or visitKOHLERPower.com

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