Industrial Generator Sets - Kohler Power

1 Industrial Generator SetsModels:10-1000kWController:Decision- Makerr3000 Software(Code) 7/11cOperationEngineexhaustfromthisprodu ctcontainschemicalsknowntotheStateofCali forniatocausecancer,birthdefects, Proposition field-installed kit numbers after installing Set Identification NumbersRecord the product identification numbers from thegeneratorsetnameplate(s).ModelDesigna tionSpecificationNumberSerialNumberAcces soryNumber AccessoryDescriptionEngine IdentificationRecord the product identification information from ,specsheet,orsalesinvoice. Recordthe Controller Serial Number from the the manufacturer. Determine the ApplicationProgram Version Number as shown in Menu the Personality Profile Reference the version number upgrade/updates 7/11 TableofContents Stopping(UserStoppingandFaultShutdown) ControllerResetting(FollowingSystemShutd ownorWarning) GeneratorMetering(andCalibration) ,continuedTP-6694 7/11 TableofContents4 Section3 300--1000kWModelswith4M/5M/7 MSingle-BearingAlternator GasFuelSystemConcept(SingleFuel) FuelSystemChangeoverKits(DualFuel) CrankcaseVentilation(CCV)

2 InternalEngineComponents(Gas-FueledEngin es) VoltageReconnectionProcedure( ) VoltageReconnectionProcedure( ) CommonFault/Failure(32A) Input/Output(I/O) LowFuel(Level/Pressure) 7/11 SafetyPrecautionsandInstructionsIMPORTAN T SAFETY equipment,including Generator sets , transferswitches,switchgear,andaccessori es,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. : 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.

3 Replace missing on the Generator the negative (--) lead firstwhen disconnecting the (--) the Generator starting can causesevere injury or on the Generator set orequipment connected to the set,disable the Generator set as follows:(1)Press the Generator set off/resetbuttontoshutdownthegeneratorset .(2)Disconnectthepowertothebatterycharge r,ifequipped. (3)Removethebattery cables, negative (--) lead the negative (--) lead lastwhenreconnectingthebattery. Followthese precautions to prevent thestarting of the Generator set by protective goggles andclothing. Battery acid may in the battery electrolyte is a cause blindness and burn wear splashproof safetygoggles, rubber gloves, and bootswhen servicing the battery.

4 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, 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. SafetyPrecautionsandInstructionsTP-6694 7/11 Batterygases.

5 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.

6 Remove all jewelrybefore servicing the equipment. Usetoolswithinsulatedhandles. Removethe negative (--) lead first whendisconnectingthebattery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnectthenegative(--)batterycablet othepositive(+)connectionterminalofthest artersolenoid. Donottestthebattery condition by shorting not smoke or permit flames A not smoke or permit flames orsparks near the carburetor, fuel line,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.

7 Train allpersonnel on fire extinguisheroperation and fire cause severe nausea,fainting, exhaust system must set operation. Carbonmonoxidecancauseseverenausea,faint ing, an odorless, colorless, tasteless,nonirritatinggasthatcancausede athifinhaled for even a short time. Avoidbreathingexhaustfumeswhenworkingon or near the Generator set. Neveroperate the Generator set inside abuilding unless the exhaust gas ispiped safely outside. Never operatethe Generator set where exhaust monoxide , fainting, or , colorless, tasteless,nonirritatinggasthatcancausede athifinhaledforevenashorttime. Carbonmonoxidepoisoningsymptomsincludebu tarenotlimitedtothefollowing:DLight-head edness,dizzinessDPhysicalfatigue,weaknes sinjointsandmusclesDSleepiness,mentalfat igue,inabilitytoconcentrateorspeakclearl y,blurredvisionDStomachache,vomiting,nau seaIfexperiencinganyofthesesymptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyandremainactive.

8 Donotsit,liedown,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention 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. Donotreplaceflexiblefuellines with rigid lines.

9 Use flexiblesections to avoid fuel line set in the presence of fuelleaks, fuel accumulation, or fuel systems before 7/11 Explosive fuel vapors can causesevere injury or :Propane (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.

10 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). 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 electrical voltage can possible whenever electricity ispresent.