Related Manuals for Kohler 8.5RMY
Summary of Contents for Kohler 8.5RMY
- Page 1 Operation and Installation Residential/Commercial Generator Sets Models: 8.5RMY 11RMY with Sound Enclosure Controller: Decision-Makert 1 TP-6049 9/02f...
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Page 2: Product Identification Information
California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service parts. Controller Identification Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice. -
Page 3: Table Of Contents
Table of Contents Product Identification Information ..........Inside front cover Safety Precautions and Instructions . - Page 4 Table of Contents, continued Section 6 Installation ..............General .
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Page 5: Safety Precautions And Instructions
Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting WARNING INSTRUCTIONS. Electromechanical equipment, including generator sets, WARNING transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or Explosion. maintained. To prevent accidents be Can cause severe injury or death. - Page 6 Battery gases. Explosion can cause Servicing the air cleaner. A sudden Fuel System backfire can cause severe injury or severe injury or death. Battery gases death. Do not operate the generator can cause an explosion. Do not smoke set with the air cleaner removed. WARNING or permit flames or sparks to occur near a battery at any time, particularly when...
- Page 7 Gas fuel leaks. Explosive fuel Hazardous Voltage/ Installing battery charger. vapors can cause severe injury or Hazardous voltage cause Electrical Shock death. Fuel leakage can cause an severe injury death. explosion. Check the LP vapor gas or ungrounded battery charger may natural gas fuel system for leakage by cause electrical shock.
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Page 8: Hot Parts
Heavy Equipment Moving Parts Notice NOTICE WARNING WARNING This generator set has been rewired from its nameplate voltage Hazardous voltage. Moving rotor. Can cause severe injury or death. Unbalanced weight. Improper lifting can cause severe Operate the generator set only when 246242 injury or death and equipment all guards and electrical enclosures... -
Page 9: Introduction
Information in this publication represents data available at the time of print. The manufacturer may provide this manual for models not listed on the front cover. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. -
Page 10: Service Assistance
Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPowerSystems.com Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product... -
Page 11: Section 1 Features
1.4 Controller 1.2 Generator The generator set has a Decision-Makert 1 relay controller. For a specific description of the controller, The generator uses Kohler’s unique PowerBoostt see Section 2, Operation. Controller features include voltage regulation system, which provides instant the following: response to load changes. -
Page 12: Service Views
1.5 Service Views Figure 1-3 Shows multi-fuel generator sets, which can be identified in two ways: This section includes two generator set service views. Multi-fuel model specification numbers begin with See Figure 1-1 and the descriptions below to determine GM. See the generator set nameplate for the spec which service view applies to your generator set. - Page 13 GM24829A-A 1. Generator set sound enclosure 11. Gas regulator assembly 2. Muffler 12. Fuel solenoid valve 3. Oil check 13. Rodent screens 4. Oil drain hose 14. Engine starting battery location 5. Oil fill 15. Engine oil cooler 6. Spark plugs 16.
- Page 14 Notes Section 1 Features TP-6049 9/02...
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Page 15: Section 2 Operation
Section 2 Operation 2.1 Prestart Checklist Visually inspect for exhaust leaks (blowby). Check for carbon or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. To ensure continued satisfactory operation, perform the Seal leaks as needed. following checks or inspections before or at each startup, as designated, and at the intervals specified in Oil Level. -
Page 16: Decision-Maker 1 Controller Operation
2.3 Decision-Maker 1 Controller Note: The controller provides up to 30 seconds of cyclic cranking before the overcrank shutdown occurs. Operation Name Description For identification of the Decision-Makert 1 controller’s Generator set master Switch functions as the controller reset indicators and controls and their functions, refer to switch and generator set operation switch. -
Page 17: Fault Shutdowns
Model Rating, Amps Overspeed Shutdown occurs immediately when the governed frequency on 50 and 60 Hz models 8.5RMY exceeds 70 Hz. 11RMY Figure 2-3 Fault Shutdowns Figure 2-4 Line Circuit Breakers Controller Fuse. A replaceable 10-amp fuse protects 2.3.5... - Page 18 Notes Section 2 Operation TP-6049 9/02...
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Page 19: Section 3 Scheduled Maintenance
Section 3 Scheduled Maintenance WARNING WARNING Hazardous voltage. Moving rotor. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set. - Page 20 Procedure Visually Check Change Clean Test Inspect System Component or Procedure Frequency Section Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level Daily or before use Crankcase breather* Yearly or 500 hours Change oil Yearly or 100 hours Replace filter*...
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Page 21: Lubrication System
3.3 Lubrication System 3.3.4 Oil Change Procedure Drain the oil while it is still warm. See Section 3.2, Service Schedule, for oil change and oil filter replacement intervals. See Section 1.5, Service 1. Drain the oil. Views, for the oil drain, oil check, oil fill, and oil filter locations. -
Page 22: Spark Plugs
d. Reconnect the generator set engine starting battery, negative (--) lead last. e. Reconnect the power to the battery charger, if equipped. f. Start and run the generator set for a minute to allow the oil pressure to reach the operating range. -
Page 23: Paper Element Service
excess water (do not wring). Allow the precleaner 3.5.2 Paper Element Service to air dry. Use the following procedure to replace the paper 5. Saturate the precleaner with new engine oil. element at the intervals specified in the service Squeeze out all of the excess oil. schedule. -
Page 24: Cooling System
3.6 Cooling System 3.8 Battery The engine fan draws cooling air through the opening in WARNING the base next to the battery. The generator fan draws cooling air through an opening on the rear wall of the enclosure. The cooling air flows to the alternator at the far end of the unit and over the exhaust system. -
Page 25: Cleaning The Battery
Battery short circuits. Explosion can cause severe injury 3.8.1 Cleaning the Battery or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator To prevent dirt and grime buildup, occasionally wipe the set installation or maintenance. Remove all jewelry before battery with a damp cloth. -
Page 26: Checking Electrolyte Specific Gravity
3.8.3 Checking Electrolyte Specific ° ° Correction Gravity 71.1 + .032 + .030 Use a battery hydrometer to check the specific gravity of 65.6 + .028 Example 1: the electrolyte in each battery cell. Use the + .026 ° ° hydrometer’s test instructions, if available, or Figure 3-9 Temperature below 26.7 C (80... -
Page 27: Storage Procedure
3.9 Storage Procedure 3.9.3 Cylinder Lubrication 1. Remove the spark plugs. Perform the following storage procedure before removing the generator set from service for three 2. Pour one tablespoon of engine oil into each spark months or longer. Follow the engine manufacturer’s plug hole. - Page 28 Notes Section 3 Scheduled Maintenance TP-6049 9/02...
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Page 29: Section 4 Troubleshooting
Section 4 Troubleshooting This section contains generator set troubleshooting, If the procedures in this manual do not explain how to diagnostic, and repair information. correct the problem, contact an authorized distributor/ dealer. Maintain a record of repairs and adjustments Use the following chart to diagnose and correct common performed on the equipment. - Page 30 Notes Section 4 Troubleshooting TP-6049 9/02...
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Page 31: Section 5 Wiring Diagrams
RESET/ AUTO substitute for a manual under development. Controller Model No. Spec. No. Fault Lamp F1 10 AMP F2 10 AMP 8.5RMY PA-195021 FAULT TYPE ABC TYPE ABC 8.5RMY PA-195025 8.5RMY GM16902-GA1 8.5RMY... - Page 32 Notes Section 5 Wiring Diagrams TP-6049 9/02...
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Page 37: Section 6 Installation
Section 6 Installation 6.1 General 6.4 Weight WARNING Installation must comply with these installation instructions. Install the generator set to comply with state and local code requirements. Use the specifications provided here only in the initial planning. Use the respective spec sheets, dimension drawings, and wiring diagrams for installation. - Page 38 Figure 6-2 Generator Set Mounting Details and Dimensions Section 6 Installation TP-6049 9/02...
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Page 39: Fuel System
6.7 Fuel System Generator Set Model Generator Set Model Gas Flow Rate Btu/hr Gas Flow Rate, Btu/hr. 8.5RMY 132,000 The generator set operates using natural gas or LP 11RMY 192,000 vapor fuel. The multi-fuel system allows conversion 12RMY 202,000 from natural gas to LP vapor (or vice-versa) in the field Figure 6-3 Natural Gas Flow Rate while maintaining emissions-standard compliance. -
Page 40: Multi-Fuel Systems
Single-fuel generator sets that Note: Do not adjust the factory-sealed fuel-metering adjustments on the fuel block. Changing the emission-certified do not have the emission decal. An fuel-metering adjustments on multi-fuel units authorized distributor/dealer can convert the fuel may violate federal or state laws. system from natural gas to LP vapor (or vice-versa) on a non-certified unit. -
Page 41: Electrical Connections
Fuel Conversion Procedure for Multi-Fuel 10. Connect the new fuel supply. Systems 11. Turn on the fuel supply and check for leaks using a 1. Place the generator set master switch in the OFF gas leak detector. position. 12. Check that the generator set master switch is in the 2. -
Page 42: Ac Load Lead Connections
6.8.2 AC Load Lead Connections Have an authorized distributor/dealer or a licensed electrician make the following load connections. Connect the AC output leads in the controller compartment to the AC circuit breaker. Route AC and DC leads through the bottom of the generator set or through flexible conduit directly to the AC circuit breaker box. -
Page 43: Battery Charger
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. -
Page 44: Carburetor Heater
charger into a 110 or 120-volt outlet connected to the Figure 6-11 shows the blower housing covers installed. utility power. The covers are not used on all units. A DC version of the carburetor heater is available. Refer 6.8.5 Carburetor Heater to the installation instructions provided with the DC carburetor heater kit. -
Page 45: Generator Reconnection
6.9 Generator Reconnection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator The generator set can produce a variety of voltages at set as follows: (1) Move the generator set master switch to the either 50 or 60 Hz. -
Page 46: Factory Connections, 110/220 Volt 50 Hz Or 120/240 Volt 60 Hz
6.9.2 Factory Connections, 110/220 Volt 6.9.3 Reconnection Options 50 Hz or 120/240 Volt 60 Hz The following reconnections can be made using the factory two-pole circuit breaker provided. It is the Generator sets are available from the factory connected responsibility individual performing for 110/220 Volt 50 Hz or 120/240 Volt 60 Hz. -
Page 47: 220 And 240 Volt Configuration
Return the form to the distributor/dealer or mail it directly L0-L1 100--120 volt 110--120 volt Note: The existing ammeter lower scale indicates Kohler Power Systems half of the actual L1 current. DO NOT PUT Generator Warranty Administrator THE CT ON L1. Either label the ammeter M.S. 072... - Page 48 Notes Section 6 Installation TP-6049 9/02...
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Page 49: Appendix A Abbreviations
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per hour E-Stop emergency stop ABDC after bottom dead center cubic feet per minute etc. et cetera (and so forth) alternating current center of gravity exh. - Page 50 International Organization for military standard round head Standardization m/sec. meters per second round head machine (screw) joule MTBF mean time between failure rly. relay Japanese Industry Standard MTBO mean time between overhauls root mean square kilo (1000) mtg. mounting rnd. round kelvin megawatt...
- Page 52 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-6049 9/02f 7 Jurong Pier Road Singapore 619159 E 1999, 2000, 2001, 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...