Kohler 7ER Installation Manual
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Kohler 7ER Installation Manual

Kohler 7ER Installation Manual

Commercial mobile generator sets
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Installation
Commercial Mobile Generator Sets
Model:
7ER
TP-6034 10/02a

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Summary of Contents for Kohler 7ER

  • Page 1 Installation Commercial Mobile Generator Sets Model: TP-6034 10/02a...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Section 1.
  • Page 4 Notes Table of Contents TP-6034 10/02...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...

  • Page 6: Exhaust System

    Battery short circuits. Explosion Combustible materials. A fire can Carbon monoxide symptoms. cause severe injury or death. Carbon monoxide can cause severe can cause severe injury or death. Generator set engine fuels and fuel nausea, fainting, or death. Carbon Short circuits can cause bodily injury vapors are flammable and explosive.

  • Page 7: Fuel System

    Fuel System Hazardous Noise Grounding electrical equipment. Hazardous voltage cause severe injury or death. Electrocution CAUTION is possible whenever electricity is WARNING present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment...

  • Page 8: Hot Parts

    Testing live electrical circuits. Servicing the exhaust system. Hot WARNING Hazardous voltage or current can parts can cause severe injury or cause severe injury or death. Have death. Do not touch hot engine parts. trained and qualified personnel take The engine and exhaust system diagnostic measurements live...
  • Page 9 Notice NOTICE NOTICE Hardware damage. The engine and Canadian installations only. generator set may use both American standby service connect the output of NOTICE Standard and metric hardware. Use the generator set to a suitably rated the correct size tools to prevent transfer switch in accordance with This generator set has been rounding of the bolt heads and nuts.
  • Page 10 Notes VI Safety Precautions and Instructions TP-6034 10/02...

  • Page 11: Section 1 Introduction

    Section 1 Introduction All information in this publication represents data 1.3 Generator Set Operation available at the time of print. Kohler Co. reserves the right After the installer attaches the generator set to the to change this literature and the products represented vehicle’s frame and connects the hoses, do the following...
  • Page 12 Notes 2 Introduction TP-6034 10/02...

  • Page 13: General Considerations

    2.1 General Considerations 2.3 Vehicle-Floor Mounting Consider the following items concerning the generator Install the Kohler 7ER mobile generator set on an open set and Section 2.2 for the proposed location. vehicle’s floor or truck bed. Follow the guidelines below.

  • Page 14: Extended-Shaft Mounting

    ADV-6450-E Figure 2-1 Extended Shaft Dimensions Figure 2-2 shows a Kohler mobile generator set mounted to a hydraulic pump. The generator set equipped with the extended-shaft option can power external equipment to the limit of the engine’s capacity.

  • Page 15: Air Requirements

    Section 3 Cooling System 3.1 Air Requirements 3.2 High Water Temperature Switch Air flow around the generator set is necessary for adequate cooling. See the current generator set Each generator set includes a high water temperature specification sheet for air requirements. The air intake shutdown switch that automatically shuts down the set if silencer/cleaner provides combustion air to the engine.
  • Page 16 Notes 6 Cooling System TP-6034 10/02...
  • Page 17 Section 4 Exhaust System Installing the exhaust tail pipe. Carbon monoxide can WARNING cause severe nausea, fainting, or death. Install the exhaust system tail pipe to prevent the drawing of discharged exhaust gases into the vehicle interior through windows, doors, air conditioners, and other openings.

  • Page 18: Planning

    Adding Kohler Co. recommends a clearance of 38 mm exhaust-pipe extensions to the unit-mounted muffler (1 1/2 in.) between the exhaust system parts and the may cause excessive vibration and noise transmitted to fuel system, the electrical system, and all combustible the vehicle.

  • Page 19: Section 5 Fuel System

    Design the generator set gasoline fuel system to operate independently of the vehicle engine fuel system if the operator may operate both engines simultaneously. Kohler Co. recommends using separate fuel tanks, if possible; using separate Explosive fuel vapors. fuel tanks is usually impractical because of space Can cause severe injury or death.

  • Page 20: Fuel Lines

    5.2 Fuel Lines 5.3 Fuel Pump Lift and Fuel Consumption Note: Keep fuel lines away from the exhaust system. See Figure 5-2 for the fuel pump lift capability. Consult Routing fuel lines. Take care when routing the fuel line the current generator set specification sheet for the from the fuel tank to the generator set.

  • Page 21: Ac Load Lead Connections

    Section 6 Electrical System 6.2 AC Load Lead Connections WARNING Routing. Each generator set has four color-coded load leads. The black leads (L1 and L2) are hot, the white lead (L0) is neutral, and the green lead is the hazard ground.
  • Page 22 Note: Transfer switch. Use a triple-pole, double-throw Note: For standby service connect output of the transfer switch rated for the calculated load of the generator to a suitably rated transfer switch in vehicle to transfer the load from one source to the accordance with the Canadian Electrical Code, other.

  • Page 23: Circuit Protection

    6.3 Circuit Protection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the The AC circuit breakers protect the generator set from generator set as follows: (1) Place the generator set start/stop extreme overload.

  • Page 24: Circuit Breaker Installation

    6.3.2 Circuit Breaker Installation 7. Make the recommended connections for the following three reconnection systems using circuit (Only Required for Changing breakers. from Factory-Installed and -Wired, 120 Volt, 2 Wire) Two-pole circuit breaker with a single-voltage system (example: 120 volt, 3 wire). Note: Wire material.

  • Page 25: Battery And Connections

    6.4 Battery and Connections Lengths and sizes. See Figure 6-3 for the lengths and recommended sizes of the battery cables. WARNING Cable Size (AWG) Distance between Distance between At -18°C At 0°C At 24°C Generator Set (0°F) (32°F) (75°F) and Battery, m (ft. ) 12.2 (40) (30)

  • Page 26: Remote Switch Connection

    6.5 Remote Switch Connection View A Using a Separate Battery Controllers include an accessory plug (P3) for easy for the Generator Set connection of the remote switch to the following: Oil pressure gauge, if equipped Water temperature gauge, if equipped Battery voltage Hourmeter Start/Stop switch including run light...
  • Page 27 Section 7 Installation Drawing ADV-6450-E Figure 7-1 Dimension Drawing TP-6034 10/02 Installation Drawing 17...
  • Page 28 Notes 18 Installation Drawing TP-6034 10/02...

  • Page 29: Four-Lead Reconnection

    Section 8 Reconnection/Adjustments 8.1 Four-Lead Reconnection L0 (Neutral) The following drawings illustrate the reconnection of four-lead generator sets. In all cases, conform to the GRD. Ground National Electrical Code (NEC). Load NOTICE Side Voltage reconnection. Affix a notice to the generator set after Two-Pole reconnecting the set to a voltage different from the voltage on Line...
  • Page 30 100- -120/200- -240-Volt Configurations 200- -240-Volt Configurations The 100--120/200--240-volt configuration does not use The 200--240-volt configuration does not use a jumper a jumper lead. If the unit was originally wired for straight lead. If the unit was originally wired for straight 100--120 volt, 3 wire, remove the jumper lead (see 100--120 volt, 3 wire, remove the jumper lead (see Figure 8-1 for location).

  • Page 31: Voltage Regulator Adjustment

    8.2 Voltage Regulator Adjustment WARNING Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage is present at the TT-875-11 voltage regulator heat sink.
  • Page 32 See Figure 8-5 to identify the potentiometers on the 6. Rotate the stability pot clockwise to minimize light flicker. PowerBoostt IIIE voltage regulator. 7. Readjust the voltage adjustment pot, if Stabilizer Potentiometer (Pot)—Fine-tunes necessary. regulator circuitry to reduce light flicker. 8.
  • Page 33 Appendix A Generator Selection and Wattage Requirements General Wattage Requirements Appliance Loads Generator sets often furnish AC for appliances such as Consider the total wattage requirements (lights, motors, TVs, stereos, and electric water heaters. Except for the appliances) when selecting a generator set, or when resistance-type loads such as the water heater, the sizing wattage usage in which available space and requirements for appliances are usually low.
  • Page 34 Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 35 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat. gas natural gas right side kilojoule...
  • Page 40 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-6034 10/02a 7 Jurong Pier Road Singapore 619159 E 1998, 2001, and 2002 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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