Industrial Generator Sets - Kohler Power

1 Industrial Generator SetsModels:20--400 kWAlternators:Fast-ResponsetII (Permanent Magnet Alternator)TP-6353 3/12bServiceEngineexhaustfromthisproduct containschemicalsknowntotheStateofCalifo rniatocausecancer,birthdefects, Proposition field-installed kit numbers after installing the product identification numbers from thegeneratorsetnameplate(s).ModelDesigna tionSpecificationNumberSerialNumberAcces soryNumber AccessoryDescriptionControllerIdentifica tionRecordthecontrollerdescriptionfromth egeneratorsetoperationmanual,specsheet, the product identification information from 3 20--400 TroubleshootingAlternator, TroubleshootingAlternator, 3/124 Notes5 SafetyPrecautionsandInstructionsTP-6353 3/12 SafetyPrecautionsandInstructionsIMPORTAN T SAFETY equipment,including Generator sets , transferswitches,switchgear,andaccessori es,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained.

2 To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. : Danger,Warning,Caution, indicates the presence of ahazard thatwill cause severepersonal injury, death,orsubstantial property indicates the presence of ahazard thatcan cause severepersonal injury, death,orsubstantial property indicates the presence of ahazard thatwillorcan cause minorpersonal injuryorproperty communicates installation,operation,ormaintenanceinfo rmationthat is safety related but not service technician to thispublication to improve operatorrecognition. Replace missing on the Generator the negative (--) lead firstwhen disconnecting the (--) the Generator starting can causesevere injury or on the Generator set orconnected equipment, disable thegeneratorsetasfollows: (1)MovethegeneratorsetmasterswitchtotheO FFposition. (2)Disconnectthepowertothe battery charger. (3)Remove thebattery cables, negative (--) lead the negative (--) lead lastwhenreconnectingthebattery.

3 Followtheseprecautionstopreventstartingo fthe Generator set by an automatictransfer switch, remote start/stopswitch, protective goggles andclothing. Battery acid may in the battery electrolyte is a dilutedsulfuric acid. Battery acid can cause blindness and burnskin. Alwayswearsplashproofsafetygoggles, rubber gloves, and bootswhen servicing the battery. Do notopen a sealed battery or mutilate eyes or on the skin, immediatelyflushtheaffectedarea for15minuteswith large quantities of clean eye contact. Never add acid to abattery after placing the battery inservice, SafetyPrecautionsandInstructionsTP-6353 3/12 Battery acid cleanup. Battery acidcan cause severe injury or acid is electrically conductiveand corrosive. Add 500 g (1 lb.) ofbicarbonateofsoda(bakingsoda)toacontai nerwith4L(1gal.)ofwaterandmixtheneutrali zingsolution. Pourtheneutralizing solution on the spilledbattery acid and continue to add theneutralizing solution to the spilledbattery acid until all evidence of achemical reaction (foaming) hasceased.

4 Donotsmokeorpermitflamesorsparkstooccurn earabatteryatanytime,particularlywhenit is charging. Do not dispose of abatteryinafire. Topreventburnsandsparksthatcouldcauseane xplosion,avoid touching the battery terminalswith tools or other metal Dischargestaticelectricityfrom your body before touchingbatteries by firsttouching ,donotdisturbthebatterychargerconnection swhilethebatteryis charging. Always turn the batterycharger off before disconnecting thebattery connections. Ventilate thecompartments containing batteries toprevent accumulation of short circuits. Explosioncan cause severe injury or circuits can cause bodily injuryand/or equipment the battery beforegenerator set installation ormaintenance. Remove all jewelrybefore servicing the equipment. Usetoolswithinsulatedhandles. Removethe negative (--) lead first whendisconnectingthebattery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnectthenegative(--)batterycablet othepositive(+)connectionterminalofthest artersolenoid.

5 Donottestthebattery condition by shorting not smoke or permit flames A flashfire can cause severe injury ,fuelline,fuelfilter,fuelpump, fuels in an approved containerwhen removing the fuel line not operate the materials. A fire cancause severe injury or set engine fuels and fuelvapors are flammable and these materials carefully tominimize the risk of fire or a fully charged fire for electrical fires or asrecommendedbythelocalfirecodeoran authorized agency. Train allpersonnel on fire extinguisheroperation and fire cause severe nausea,fainting, exhaust system must set operation. Carbonmonoxide can cause severenausea, fainting, or is an odorless, colorless,tasteless, nonirritating gas that cancausedeathifinhaledforevenashorttime. Avoid breathing exhaust fumeswhenworkingonornearthegeneratorset. Never operate the Generator setinside a building unless the exhaustgas is piped safely outside. Neveroperate the Generator set whereexhaust gas could accumulate monoxide , fainting, or , colorless, tasteless,nonirritatinggasthatcancausede athifinhaledforevenashorttime.

6 Carbonmonoxidepoisoningsymptomsincludebu tarenotlimitedtothefollowing:DLight-head edness,dizzinessDPhysicalfatigue,weaknes sinjointsandmusclesDSleepiness,mentalfat igue,inabilitytoconcentrateorspeakclearl y,blurredvisionDStomachache,vomiting,nau seaIfexperiencinganyofthesesymptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyandremainactive. Donotsit,liedown,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention 3 extreme care when handling,storing, fuel system. Explosive fuelvapors can cause severe injury fuels are highlyexplosive. Use extreme care whenhandlingandstoringfuels. Storefuelsinawell-ventilatedareaawayfrom spark-producingequipmentandoutofthereach ofchildren. Neveraddfueltothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or not smoke or permit flames orsparkstooccurnearsourcesofspilledfuelo rfuelvapors. Keepthefuellinesand connections tight and in goodcondition.

7 Donotreplaceflexiblefuellines with rigid lines. Use flexiblesections to avoid fuel line set in the presence of fuelleaks, fuel accumulation, or fuel systems before fuel vapors can causesevere injury or :Gasoline Store gasoline only inapproved red containers (LP) Adequate ventilationis mandatory. Because propane isheavier than air, install propane gasdetectors low in a room. Inspect thedetectors per the manufacturer Adequateventilationismandatory. Becausenaturalgasrises,install natural gas detectors high in aroom. Inspect the detectors per themanufacturer tanks. Explosive fuel vaporscan cause severe injury or Explosivefuelvaporscancausesevereinjuryo r fuel can cause fuel leaks. Explosive fuelvapors can cause severe injury leakage can cause anexplosion. ChecktheLPvaporgasornaturalgasfuelsystem forleakagebyusing a soap and water solution withthe fuel system test pressurized to6--8ounces per square inch(10--14incheswatercolumn). Donotuse a soap solution containing eitherammonia or chlorine because depends on the ability of liquid withdrawal fuel fuel vapors can ChecktheLPliquid withdrawal gas fuel system forleakage by using a soap and watersolution with the fuel system testpressurized to at least 90psi(621kPa).

8 Donotuseasoapsolutioncontainingeitheramm oniaorchlorinebecause both prevent bubbleformation. operate the Generator setwithout a muffler or with a Hazardousnoisecancause hearing setsnot equipped with sound Wearhearingprotection when near an guards and electrical property damage, severeinjury, the Generator set is used forstandby Power , install an automatictransferswitchtopreventinadvert entinterconnection of standby SafetyPrecautionsandInstructionsTP-6353 3 cause severe weld components of thegenerator set without firstdisconnecting the battery, controllerwiringharness,andengineelectro niccontrolmodule(ECM).CAUTIONG rounding electrical voltage can possible whenever electricity ispresent. Ensure you comply with allapplicable codes and ground the Generator set,transferswitch, breakers of all Power sourcesbeforeservicingtheequipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these voltage test. Hazardousvoltage can cause severe injury the instructions of thetest equipment manufacturer whenperforming high-voltage tests on therotor or stator.

9 An improper testprocedure can damage equipment the photo transistor circuitboard. Hazardous voltage end cover is removed, do notexpose the photo transistor circuitboard mounted on the Generator setend bracket to any external lightsource, as exposure to light causeshighvoltage. Keepforeignsourcesoflight away from the photo transistorcircuit board during testing. Placeblack electrical tape over the LED onthe circuit board before starting the photo transistorcircuit board. Hazardous voltagecan cause severe injury or that the foil side of the phototransistorcircuitboard,theendofthes haft,andthethreadedholesarecleanand free of metal particles and debris may short-circuit Cancause severe electrical welding on thegenerator set perform the followingsteps: (1)Removethebatterycables,negative(--)le adfirst. (2)Disconnectall engine electronic control module(ECM)connectors. (3)Disconnectallgenerator set controller and voltageregulator circuit board connectors.(4)Disconnect the engine battery-charging alternator connections.

10 (5) the battery voltage can causesevere injury or battery charger maycause electrical shock. Connect thebatterychargerenclosuretothegroundofa permanentwiringsystem. Asanalternative, install an equipmentgrounding conductor with circuitconductors and connect it to theequipment grounding terminal or theleadonthebatterycharger. Installthebattery charger as prescribed in theequipmentmanual. the battery and thebatterycharger. Hazardousvoltagecan cause severe injury or the battery correctly,positive to positive and negative tonegative,toavoidelectricalshockanddama ge to the battery charger andbattery(ies). Have a qualifiedelectricianinstallthebattery(ie s).Short circuits. Hazardousvoltage/current can cause severeinjury or circuits cancause bodily injury and/or not contact electricalconnectionswithtoolsorjewelryw hilemaking adjustments or block heater. Hazardousvoltage can cause severe injury engine block heater cancause electrical shock. Remove theengine block heater plug from backfeed to the backfeed voltage transfer switch in standby backfeed into a utilityelectrical system can cause severeinjury or death to utility live electrical voltage or current and qualified personnel takediagnostic measurements of livecircuits.