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.
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or Explosion. maintained. To prevent accidents be aware of potential dangers and act Can cause severe injury or death.
Engine Backfire/Flash Carbon monoxide symptoms. Fuel tanks. Explosive fuel vapors Carbon monoxide can cause severe can cause severe injury or death. Fire nausea, fainting, or death. Carbon Gasoline and other volatile fuels stored monoxide is a poisonous gas present in in day tanks or subbase fuel tanks can exhaust gases.
Hazardous Voltage/ Installing battery charger. WARNING Hazardous voltage cause Moving Parts severe injury death. ungrounded battery charger may cause electrical shock. Connect the WARNING battery charger enclosure to the ground of a permanent wiring system. As an alternative, install equipment Rotating parts.
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Checking the coolant level. Notice coolant can cause severe injury or death. Allow the engine to cool. NOTICE Release pressure from the cooling Hardware damage. The engine and system before removing the pressure generator set may use both American cap. To release pressure, cover the Standard and metric hardware.
Information in this publication represents data available literature kit information. at the time of print. Kohler Co. reserves the right to change this publication and the products represented Note: The trailer manufacturer includes additional...
East China Regional Office, Shanghai KohlerPower.com. Phone: (86) 21 6288 0500 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.
7. Fuel inlet (opposite side) 10. Oil filter 4. Exhaust outlet Figure 1-14 Generator Set, 400KRP (400REOZDD) 1.5 Electrical Power Panel Figure 1-15 through Figure 1-19 provide electrical power panel specifications and illustrations. 60KRP 100KRP 200KRP 200KRP 400KRP 400KRP (60REOZJB)
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NEMA 5-15P NEMA 5-15P GM45993B-E Figure 1-16 Electrical Power Panel with Ground Fault Protection Receptacles, 60KRP 1. Voltage indicator lamps 2. Two circuit breakers, 15 A, 1-pole for duplex receptacles 3. Power outlet (twistlocks) circuit breakers, 20 A, three pole (qty.
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1. Voltage indicator lamps 2. Two circuit breakers 15 A, 1-pole for duplex receptacles 3. Power inlet, 120 V, 15 A, (NEMA 5-15P) (utility power connection for battery charger) 4. Power inlet, 120 V, 20 A, (NEMA 5-20P) (utility power connection for block heater) 5.
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10 9 NEMA L6-20P NEMA 5-15P E3-15926 1. 24 VDC service light, bulb #F8T5CW 2. GFCI breakers w/shunt trip 3. Main circuit breaker 4. 18-position terminal strip 5. Main breaker 6. Phase ID (A, B, C, NEU, GRD) decal 7. Shore power connection 8.
1.6 Generator Set Accessories The float/equalize battery charger is designed to be used as an on-board battery charger for lead acid batteries (flooded cell or AGM types) and gel-cell type 1.6.1 Battery(ies) batteries. Towable units include a 12-volt, lead-acid engine For 24 VDC systems, use two battery chargers.
1.6.6 Air Cleaner Restriction Gauge The air cleaner restriction gauge mounted on the air 120/208V cleaner helps determine the air cleaner change interval. 3 PH 3 PH 277/480V 120/240V 3 PH 1 PH The air cleaner restriction gauge monitors air flow through the air cleaner.
1.6.11 Fuel Tank and Fuel System The fuel tank location varies by generator set model. The 60--200KRP models have a fuel system with an internal polymer tank below the enclosure. Figure 1-27 for specifications and see Figure 1-29 for an illustration. Item Specification Engine fuel inlet...
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0: System Options 0) Select Temp Option 0) Select Temp Option Degrees Fahrenheit 1) Select Temp Units 1) Select Temp Units Degrees Celsius Vertical 2) Select Tank Orientation 2) Select Tank Orientation Horizontal Rectangular 3) Select Tank Type 3) Select Tank Type Cylindrical Press US gallons...
Section 2 Trailer Hookup, Transport, and Setup 2.1 Introduction Carefully back the tow vehicle to position the tow vehicle hitch below the trailer coupling. Use a trailer tongue jack Section 2 deals with trailer hookup, transport, and setup to lower the trailer coupling onto the hitch. After the hitch at the jobsite.
2.3 Pretransport Checklist Check the tightness of the suspension hardware including the hanger bolt, the shackle bolt, and U-bolt Following the rules below in caring for the trailer can add nuts. to its life. Use the following checklist before use. Check Inspect the towing hookup for secure attachment.
2.5 Roadside Emergency Stopping 6. Remove the lug nuts and flat tire. Install the spare tire and lug nuts. Use the lug wrench and tighten prepared possible emergency stopping the lug nuts using a star pattern. See Figure 2-2. situations. The generator set trailer has a higher center of gravity when the fuel tank is empty.
2.7.2 Adequate Air Flow/Heat Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an Dissipation odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust Select a location that provides adequate air flow.
2.8.3 Trailer Tongue Jack 2.9.1 Single-Point Lifting, 60- -200KRP Use a trailer tongue jack to raise the trailer coupling Lift the towable generator set at a single point or bridle. above the tow vehicle hitch. If the ground surface is See Figure 2-3.
2.10 Generator Set Removal from Trailer, 60- -200KRP The following paragraphs describe the method to remove the generator set/weather housing/fuel tank from the trailer. Select moving equipment capable of handling the weight and size of the generator set. See Section 1, Specifications and Features, for weights. Have trained personnel lift and move the generator set.
Section 3 Electrical Connections and Requirements 3.1 Introduction Factory-supplied circuit breakers are sized for maximum generator set output. Have an electrician Section 3 deals with electrical connections and install secondary circuit protection for other current limit requirements. This section may refer to other literature requirements.
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(not shown, located on the generator set junction box) 12. Generator set voltage selector switch (not shown, located on the generator set junction box) NEMA 5-15P NEMA 5-15P GM45993B-E Figure 3-3 Electrical Power Panel with Ground Fault Protection Receptacles, 60KRP Section 3 Electrical Connections and Requirements TP-6376 3/08...
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1. Voltage indicator lamps 2. Two circuit breakers, 15 A, 1-pole for duplex receptacles 3. Power outlet (twistlocks) circuit breakers, 20 A, three pole (qty. 3) 4. Power outlets, twistlock L21-20 receptacles (qty. 3) (not available with 480-volt selection) 5. Power inlet, 120 V, 15 A, (NEMA 5-15P) (utility power connection for block heater) 6.
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10 9 NEMA L6-20P NEMA 5-15P E3-15926 1. 24 VDC service light, bulb #F8T5CW 2. GFCI breakers w/shunt trip 3. Main circuit breaker 4. 18-position terminal strip 5. Main breaker 6. Phase ID (A, B, C, NEU, GRD) decal 7. Shore power connection 8.
7. Place the main circuit breaker(s) in the OPEN If the voltage is incorrect, adjust the voltage using position. the voltage adjustment control on the generator set controller. See Figure 3-9 and the voltage 60- -200KRP. When low wye or single-phase adjustment procedure in the generator set voltage is selected, the 480-volt circuit breaker controller operation manual, as needed.
3.4 Electrical Power Panel 3.4.6 Camlocks, 60- -200KRP One set of five (60/100KRP) or two sets (200KRP) The following information pertains to other available provide convenient attachment of user-supplied power electrical connections beyond the main load lugs. This connections. Camlocks are colored-coded black, red, section shows a complete electrical connection list and blue, white, and green for identification and use with descriptions that may not apply to all models.
3.4.9 Remote Start 2-Terminal The voltage selector switch position determines which voltage lamp, receptacles, and circuit breakers are Connector active. Do not move voltage selector switch while the generator set is running. Section 3 provides the Use this 2-terminal connector to start the generator set remotely.
Section 4 Prestart and Operation 4.1 Introduction Drive Belts. Check the belt condition and tension of radiator fan, water pump, and battery charging Section 4 deals with prestart checks and procedures alternator belt(s). prior to operating the generator set and during generator Enclosure Doors.
4.3 Weather and Climate WARNING Provisions and Operation Limitations Operation and use of a generator set in the outdoors or in unsheltered areas require special attention to Hazardous voltage. weather conditions and environmental surroundings. Backfeed to the utility system can cause property damage, severe Weather conditions may limit the usability where rain or injury, or death.
4.4.1 KPC 1000 Controller Use the emergency stop switch for emergency shutdowns only. Use the generator set master switch for The controller is externally accessible on the trailer normal shutdowns. enclosure. See Figure 4-1 and Figure 4-2. The unit shuts down and the controller fault lamp lights if an operator activates the emergency stop switch.
4.4.4 Engine Idle Switch The engine idle switch is located with the KPC 1000 controller. See Figure 4-1 and Figure 4-5. This feature allows the generator set engine to run at a lower rpm. When the engine idle switch is in the IDLE mode, the engine uses less fuel and makes less noise.
Section 5 General Maintenance 5.1 Introduction Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator Section 5 deals with general maintenance of the set as follows: (1) Move the generator set master switch to the generator set, trailer, and accessories.
5.4 Service Schedule Action System—Component Visually Inspect Check Change Clean Test Interval Fuel System Flexible lines and connections Fuel level switch Main tank supply level Weekly Weekly Solenoid valve operation Transfer pump operation Water in system, remove Filter(s) Quarterly Fuel piping Yearly Yearly Tank vents and return lines for obstructions...
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Service Schedule, continued Action System—Component Visually Inspect Check Change Clean Test Interval AC Electrical System, continued Safety and alarm operation Six Months Tighten control and power wiring connections Yearly Transfer switch main contacts[ Yearly Yearly Voltage-sensing device/relay adjustment[ 3 Years or Wire-cable insulation breakdown 500 Hours Engine and Mounting...
5.5 Engine Oil Makeup System 5.6 Fuel/Water Separator Bypass Kit This feature provides a means to replenish the engine The fuel/water separator bypass kit provides the ability oil level during generator set operation. An engine will the change the engine fuel/water separator element normally use a small amount of oil over time and when while the generator set is running allowing uninterrupted left unchecked will cause an engine shutdown.
5.7 Fuel/Water Separator Fuel/Water Separator Element Replacement with Units Equipped with Bypass Kit The fuel/water separator collects accumulated water The bypass kit allows fuel/water separator element and traps fuel oil sediment. At the specified interval and replacement while the unit is running. Be aware that the without the unit running, open the water drain valve at fuel and engine temperatures are higher when the unit is the bottom of the water separator and allow water to flow...
14. Rotate the fuel supply three-way valve handle 180_ 5.9 Axle/Hub Bearing Service until the marker points toward the fuel/water separator. Use the supplied axle and related component manual for all required axle, hub, drum, and/or bearing 15. Check and repair any fuel leaks. inspection and service maintenance.
5.11.1 Wheel Installation Procedure Check tire wear frequently because once a wear pattern becomes firmly established in a tire, uneven wearing is It is important to maintain correct wheel lug nut mounting difficult to stop even after correcting the cause. Use the torque and use a torque wrench whenever possible to chart in Figure 5-5 to help determine causes and establish correct wheel torque.
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Notes Section 5 General Maintenance TP-6376 3/08...
Section 6 Troubleshooting and Wiring Diagrams 6.1 Introduction As a general aid to diagnosing common problems, refer to Figure 6-1, Trailer Troubleshooting Chart. If the Section 6 deals with troubleshooting the trailer. This trouble cannot be corrected through routine servicing, section may refer to other literature for procedures and contact an authorized service distributor/dealer for additional information.
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Problem Possible Cause Corrective Action Main circuit breaker(s) Circuit breaker overloaded Reduce circuit load. Reset circuit breaker. tripped or trips when reset Electrical circuit shorted Check electrical circuit wiring and load connections. Circuit breaker shunt trip activated Circuit breaker unavailable based on voltage selector switch position. See Section 3, Electrical Connections and Requirements, for further information.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E-Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
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Motoren-und Turbinen-Union read only memory kilobyte (2 bytes) megawatt rot. rotate, rotating KBus Kohler communication protocol milliwatt revolutions per minute μF kilogram microfarad right side kg/cm kilograms per square N, norm. normal (power source) remote terminal unit...
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KOHLER CO. Kohler, Wisconsin 53044 Phone 920-459-1634, Fax 920-459-1846 TP-6376 3/08a For the nearest sales and service outlet in the US and Canada, phone 1-888-769-3794 KohlerRental.com E 2006, 2008 by Kohler Co. All rights reserved.
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