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Kohler 12RESM1 manual

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Table of contents for the manual

  • Page 1

    Residential/Commercial Generator Sets Models: 12RESM1 12/17/18RESL 12/17/18RESNT 12/18RESHD Controller: DC-RET Digital Control TP-6516 4/09d Installation[...]

  • Page 2

    Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Generator Set Ident ification Numbers Record the product identification numbers from the generator set nameplate(s). Model Designation[...]

  • Page 3

    T able of Contents TP-6516 4/09 T able of Contents 3 Product Identification Information 2 .......................................................... Safety Precautions and Instructions 5 ........................................................ Introduction 9 ............................................................................... Service Ass[...]

  • Page 4

    TP-6516 4/09 4 Notes[...]

  • Page 5

    TP-6516 4/09 5 Safet y Precautions and Instruct ions Safety Precautions and Instructions IMPORT ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear , and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. T o prevent accide[...]

  • Page 6

    TP-6516 4/09 6 Safet y Precautions and Instruct ions 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. T o prevent burns and sparks that could cause an e[...]

  • Page 7

    TP-6516 4/09 7 Safet y Precautions and Instruct ions Hazardous Noise Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. CAUTION Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA[...]

  • Page 8

    TP-6516 4/09 8 Safet y Precautions and Instruct ions Hot Parts Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. W ARNING Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely h[...]

  • Page 9

    TP-6516 4/09 9 Introduction This manual provides installation instructions for 12, 17, and 18 kW residential/commercial generator sets equipped with the Kohler r DC-RET Digital Control. Refer to TP-6517, Operation Manual, for generator set operation and maintenance instructions. The generator set is approved for use in stationary applications in lo[...]

  • Page 10

    TP-6516 4/09 10 12 5 42 0 16 6 3 13 24 17 19 14 15 22 ADV-7341A-B 10 25 23 9 21 18 Control detail, top view 8 11 7 12 1. Muf fler 2. Oil check 3. Oil fill 4. Air cleaner 5. Spark plug locations (bot h sides) 6. Oil filter 7. Oil cooler location 8. DC-RET Digital Cont rol display 9. Generator set m aster switch (RUN-OFF/R ESET - AUTO) 10. Line circu[...]

  • Page 11

    TP-6516 4/09 11 Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KohlerPower .com. D Look at the labels and stickers on y[...]

  • Page 12

    TP-6516 4/09 12 Notes[...]

  • Page 13

    TP-6516 4/09 13 Section 1 I nstallation Section 1 Installation 1.1 General Have an authorized distributor/dealer install the generator set outdoors according to the instructions in this manual. The generator set installation must comply with the National Electrical Code (NEC) and local code requirements. Do not install this generator set indoors. U[...]

  • Page 14

    TP-6516 4/09 14 Section 1 Inst allation Note: Fuel system may differ from drawing. See Section 1.7. Figure 1-2 Generator Set Mounting Details and Dimensions, 12 kW Models, ADV -7466, Sheet 1[...]

  • Page 15

    TP-6516 4/09 15 Section 1 I nstallation Figure 1-3 Generator Set Clearances, 12 kW Models, ADV -7466, Sheet 2[...]

  • Page 16

    TP-6516 4/09 16 Section 1 Inst allation Figure 1-4 Generator Set Mounting Details and Dimensions, 17/18 kW Models, ADV -7341-B, Sheet 1[...]

  • Page 17

    TP-6516 4/09 17 Section 1 I nstallation Figure 1-5 Generator Set Clearances, 17/18 kW Models, ADV -7341-B, Sheet 2[...]

  • Page 18

    TP-6516 4/09 18 Section 1 Inst allation 1.4.1 Exhaust Requirements Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. W ARNING Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritat[...]

  • Page 19

    TP-6516 4/09 19 Section 1 I nstallation 1.6 Fuel Requirements The generator set operates using natural gas or LP vapor fuel. The generator set is EP A-certified for both natural gas and LP vapor fuels. The fuel system installation must comply with the NEC and local codes. 1.6.1 Fuel Supply Because of variable climates and geographical consideration[...]

  • Page 20

    TP-6516 4/09 20 Section 1 Inst allation 1.6.2 Fuel Pipe Size Ensure that the natural gas pipe size and length meet the specifications in Figure 1-13 or Figure 1-14. Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet. Add 2.4 m (8 ft.) to the measured length for each 90 degree elbow[...]

  • Page 21

    TP-6516 4/09 21 Section 1 I nstallation Procedure to Convert from NG to LP 1. Place the generator set master switch in the OFF position. 2. Disconnect the power to the battery charger . 3. Disconnect the generator set engine starting battery , negative ( - - ) lead first. 4. T urn off the fuel supply . 5. Remove the hose clamp and fuel hose from th[...]

  • Page 22

    TP-6516 4/09 22 Section 1 Inst allation 9. Connect and turn on the new fuel supply . 10. Check that the generator set master switch is in the OFF position. 1 1. Reconnect the generator set engine starting battery leads, negative ( - -) lead last. 12. Reconnect power to the battery charger . 13. Start the generator set by moving the generator set ma[...]

  • Page 23

    TP-6516 4/09 23 Section 1 I nstallation 1. Junction box 2. Field connection term inal block location (see Figure 1-20) 3. Suggested elect rical inlet ADV-7341 2 1 3 12 kW 17/18 kW ADV-7466 1 2 3 Figure 1-19 Field Wiring Figure 1-20 Field-Connection T erminal Block 1.8.2 Remote Start Connection Connect engine start leads from terminals 3 and 4 to th[...]

  • Page 24

    TP-6516 4/09 24 Section 1 Inst allation 1.9 Battery Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. W ARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area[...]

  • Page 25

    TP-6516 4/09 25 Section 1 I nstallation Note: The generator set will not start and circuit board damage may occur if the battery is connected in reverse. Figure 1-22 shows the location of the engine starting battery . Standard battery cables provide easy connection to the battery . Use the following procedure to install and connect the battery . AD[...]

  • Page 26

    TP-6516 4/09 26 Section 1 Inst allation 1.10 Carburetor Heater (optional) Have accessories installed by an authorized distributor/ dealer or a licensed electrician. F ollow the installation instructions provided with each kit. U se s eparate conduit for AC and DC leads to reduce the possibility of electrical interference. V erify that the leads and[...]

  • Page 27

    TP-6516 4/09 27 Section 1 I nstallation GM19463 1 1. Thermostat 2. Connector 3. Heater 3 12 kW Carburetor Heater 1 3 17/18 kW Carburetor Heater GM57968 2 Figure 1-26 Carburetor Heaters 1.1 1 Prestart Installation Check Review the entire installation section. Inspect all wiring and connections to verify that the generator set is ready for operation.[...]

  • Page 28

    TP-6516 4/09 28 Section 1 Inst allation Notes[...]

  • Page 29

    TP-6516 4/09 29 Section 2 Wiring Diagram s Section 2 Wiring Diagrams Figure 2-1 lists the wiring diagram drawing numbers and drawing references. Wiring Diagram Description Drawing Number Reference Page Schematic Diagram, 12 kW Models ADV -7351 Figure 2-2 30 Point-to-Point Wiring Diagram, 12 kW Models GM52471 Figure 2-3 31 Schematic Diagram, 17/18 k[...]

  • Page 30

    TP-6516 4/09 30 Section 2 Wiring Diagrams - Figure 2-2 Schematic Diagram, 12 kW Models, ADV -7351[...]

  • Page 31

    TP-6516 4/09 31 Section 2 Wiring Diagram s - Figure 2-3 Point-to-Point Wiring Diagram, 12 kW Models, GM52471[...]

  • Page 32

    TP-6516 4/09 32 Section 2 Wiring Diagrams - Figure 2-4 Schematic Diagram, Single Phase, 17/18 kW Models, ADV -7353[...]

  • Page 33

    TP-6516 4/09 33 Section 2 Wiring Diagram s Figure 2-5 Point-to-Point Wiring Diagram, Single Phase, 17/18 kW Models, GM52541[...]

  • Page 34

    TP-6516 4/09 34 Section 2 Wiring Diagrams Notes[...]

  • Page 35

    TP-6516 4/09 Appendix 35 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC aft er bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital convert er adj. adjust, adjustm ent ADV advertising dimensional drawing Ah amp-hour[...]

  • Page 36

    TP-6516 4/09 36 Appendix k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 10 bytes) KBus Kohler comm unication protocol kg kilogram kg/cm 2 kilogram s per square centimet er kgm kilogram-met er kg/m 3 kilogram s per cubic meter kHz kilohertz kJ kilojoule km ki lome ter kOhm, k Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A [...]

  • Page 37

    TP-6516 4/09 37 Notes[...]

  • Page 38

    TP-6516 4/09 38 Notes[...]

  • Page 39

    [...]

  • Page 40

    E 2007, 2008, 2009 by Kohler Co. A ll rights reserved. TP-6516 4/09d KOHLER CO. Kohler , Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower .com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (6[...]