Kohler 10REODB User manual

Industrial Generator Sets
Models:
10/15/20REODB/REOZDB
Controller:
KPC 1000
TP-6609 6/08
Installation

TP-6609 6/082
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
WARNING
California Proposition 65
Product Identification Information
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description KPC 1000
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer Yanmar
Model Designation
Serial Number

Table of Contents
TP-6609 6/08 Table of Contents 3
Product Identification Information 2............................................................
Safety Precautions and Instructions 5........................................................
Introduction 11...............................................................................
Service Assistance 12........................................................................
Section 1 Location and Mounting 13..........................................................
1.1 Introduction 13..........................................................
1.2 Location Factors 14......................................................
1.3 Mounting Surface 14.....................................................
1.4 Vibration Isolation 14.....................................................
1.5 Prepare the Site 15......................................................
1.5.1 Indoor Installations, Open Units 15.................................
1.5.2 Outdoor Installations, Enclosed Units 15............................
1.6 Lifting 16...............................................................
1.6.1 Lifting the Generator Set 16.......................................
1.6.2 Lifting the Subbase Fuel Tank 16...................................
Section 2 Exhaust Systems 17................................................................
2.1 Introduction 17..........................................................
2.2 Enclosed Units 17........................................................
2.3 Flexible Exhaust Line 17..................................................
2.4 Condensation Trap 17....................................................
2.5 Piping 18...............................................................
2.6 Double-Sleeved Thimbles 18..............................................
2.7 Exhaust Outlet 19........................................................
2.8 Exhaust System Back Pressure 19.........................................
Section 3 Air and Cooling 21.................................................................
3.1 Air Requirements 21.....................................................
3.1.1 Installation Considerations 21......................................
3.1.2 Air Requirements 22..............................................
3.2 Unit-Mounted Radiator Cooling 22..........................................
3.2.1 System Features 22..............................................
3.2.2 Installation Considerations 22......................................
3.3 Remote Radiator Cooling 24...............................................
3.3.1 General 24......................................................
3.3.2 Radiator Location 25.............................................
3.3.3 Remote Radiator Installation 26....................................
3.3.4 Surge (Expansion) Tank for Horizontal Discharge Radiator 27..........
3.3.5 Procedure to Fill with Deaeration 27................................
3.3.6 Procedure to Fill without Deaeration 27.............................
3.4 Block Heaters 28........................................................
3.5 Startup 28..............................................................
Section 4 Diesel Fuel System 29..............................................................
4.1 Main Tank 30............................................................
4.2 Day Tanks 32............................................................
4.3 Fuel Lines 33............................................................
4.4 Auxiliary Fuel Pumps 33..................................................

Table of Contents, continued
TP-6609 6/08Table of Contents4
Section 5 Electrical System 35................................................................
5.1 Introduction 35..........................................................
5.2 Load Lead Connections 35................................................
5.3 Ground and Neutral Connections 36........................................
5.4 Line Circuit Breakers 36..................................................
5.5 Remote Start Connection 36...............................................
5.6 Automatic Transfer Switches 36............................................
5.7 Engine Starting Battery 37................................................
5.8 Battery Chargers 37......................................................
5.9 Terminal Connector Torque 38.............................................
5.10 Accessories 39..........................................................
5.10.1 Relay and Harness Accessory Kit 39...............................
5.10.2 Remote Serial Annunciator 40.....................................
5.10.3 Remote Emergency Stop Kit 40....................................
Section 6 Reconnection/Adjustments 41.......................................................
6.1 Reconnection 41.........................................................
6.2 Four-Lead Reconnection 41...............................................
6.3 Twelve-Lead Reconnection 42.............................................
Section 7 Diagrams and Drawings 43..........................................................
Appendix A Abbreviations 53..................................................................
Appendix B Exhaust System Back Pressure 55..................................................
Appendix C Common Hardware Application Guidelines 61........................................
Appendix D General Torque Specifications 62...................................................

TP-6609 6/08 5Safety Precautions and Instructions
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
WARNING
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

TP-6609 6/086 Safety Precautions and Instructions
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. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the fuel injection system,
fuel line, fuel filter, fuel pump, or other
potential sources of spilled fuels or fuel
vapors. Catch fuels in an approved
container when removing the fuel line
or fuel system.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Servicing the air cleaner on a
turbocharged engine. A sudden
engine backfire or turbocharger
compressor failure can cause
severe injury or death. Do not
operate the generator set with the air
cleaner removed. Burns from hot
turbocharger components may occur.
Foreign objects sucked into the
turbocharger can cause mechanical
damage and the potential for high
velocity projectiles.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Using engine starting fluid. A
sudden backfire can cause severe
injury or death. Do not use starting
fluid or similar agents to start an engine
equipped with air preheating (glow
plugs/starter element). The starter
element may cause an explosion in the
inlet manifold.
Engine Fluids and
Chemical Products
Handling caustic engine fluids and
chemical products.
Can cause severe chemical burns,
nausea, fainting, or death.
Most chemicals such as used engine
oil, antifreeze/coolant, rustproofing
agent, inhibiting oil, degreasing
agent, spray paint, and adhesives are
hazardous to health. Read and follow
the user information found on the
packaging. Avoid inhalation and skin
contact. Use only in well-ventilated
areas and use a protective mask
when spraying. Store engine fluids
and chemical products in a locked
cabinet. Contact your local recycling
center for disposal information and
locations.
WARNING
Flammable engine solvents and
cleaners.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near flammable engine
solvents and cleaners. Read and
follow the user information found on
the packaging. Use only in well-
ventilated areas. Never use gasoline
or low flash-point solvents as
cleaning agents.
WARNING
Leaking or accumulated engine
fluids. A fire can cause severe injury
or death. Clean up engine fluids
including fuel, oil, grease, and coolant.
Determine the source of engine leaks
and correct before starting the
generator set. Keep the generator set
area clean and remove combustible
materials.

TP-6609 6/08 7Safety Precautions and Instructions
Used engine oil. Contact with used
engine oil may cause severe skin
irritation. Repeated and prolonged
skin exposure may have other
health risks. Used engine oil is a
suspected carcinogen. Avoid contact
with skin. Thoroughly wash your hands
and nails with soap and water shortly
after handling used engine oil. Wash or
dispose of clothing or rags containing
used engine oil. Dispose of used
engine oil in a responsible manner.
Contact your local recycling center for
disposal information and locations.
Fire-damaged or burned O-rings
may cause the formation of
hydrofluoric acid. Contact with
hydrofluoric acid may cause severe
skin irritation and chemical burns.
O-rings and other fluoroelastomer
seals exposed to fire or temperatures
above 316_C (600_F) (i.e., during
welding) may decompose forming
hydrofluoric acid. Avoid inhalation or
skin contact. Do not incinerate O-rings.
Dispose of O-ring waste material in a
responsible manner.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Generator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building unless the exhaust gas is
piped safely outside. Never operate
the generator set where exhaust gas
could accumulate and seep back inside
a potentially occupied building.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:
DLight-headedness, dizziness
DPhysical fatigue, weakness in
joints and muscles
DSleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
DStomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Fuel System
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
WARNING
Avoid high pressure fluids.
Can cause severe injury or death.
Do not work on high pressure fuel or
hydraulic systems without
protective equipment to protect
hands, eyes, and body. Avoid the
hazard by relieving pressure before
disconnecting fuel injection
pressure lines. Search for leaks
using a piece of cardboard. Always
protect hands, eyes, and body from
high pressure fluids. If an accident
occurs, seek medical attention
immediately.
WARNING
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Fuel tanks. Explosive fuel vapors
can cause severe injury or death.
Gasoline and other volatile fuels stored
in day tanks or subbase fuel tanks can
cause an explosion. Store only diesel
fuel in tanks.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.

TP-6609 6/088 Safety Precautions and Instructions
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. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Electrical Shock
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
WARNING
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
CAUTION
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.
Welding on the generator set. Can
cause severe electrical equipment
damage. Before welding on the
generator set perform the following
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery-
charging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
Installing the battery charger.
Hazardous voltage can cause
severe injury or death. An
ungrounded battery charger may
cause electrical shock. Connect the
battery charger enclosure to the ground
of a permanent wiring system. As an
alternative, install an equipment
grounding conductor with circuit
conductors and connect it to the
equipment grounding terminal or the
lead on the battery charger. Install the
battery charger as prescribed in the
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Servicing the day tank. Hazardous
voltage can cause severe injury or
death. Service the day tank electrical
control module (ECM) as prescribed in
the equipment manual. Disconnect the
power to the day tank before servicing.
Press the day tank ECM OFF
pushbutton to disconnect the power.
Notice that line voltage is still present
within the ECM when the POWER ON
light is lit. Ensure that the generator set
and day tank are electrically grounded.
Do not operate the day tank when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.

TP-6609 6/08 9Safety Precautions and Instructions
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage.Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
Heavy Equipment
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
WARNING
Hot Parts
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Hot engine oil.
Can cause severe injury or death.
Avoid skin contact with hot oil. Do not
start or operate the generator set with
the engine oil filler cap removed, as
hot oil can spray out. Ensure that the
lubrication system is not under
pressure when servicing. Do not
work on the generator set until it
cools.
WARNING
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 hot
during operation.
Moving Parts
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
WARNING
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.

TP-6609 6/0810 Safety Precautions and Instructions
Notice
NOTICE
This generator set has been
rewired from its nameplate voltage
to
246242
NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
NOTICE
Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.

TP-6609 6/08 11Introduction
Introduction
This manual provides installation instructions for model
10/15/20REODB/REOZDB generator sets equipped
with the KPC 1000 controller. The generator set
specification sheet also contains data that may be
required during the installation process. Operation
manuals are available separately.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The generator set and accessories must be installed by
an authorized generator set distributor/dealer. The
installation must comply with all applicable national and
local codes.
Note: These instructions outline one procedure for
installing the generator set. Local codes may
require different procedures. Install the
equipment in compliance with the National
Electrical Code (NEC) and local codes.
Obtain the accessories and tools needed before
beginning installation. Refer to the wiring diagrams in
the generator set Operation Manual for electrical
connections during the installation procedure. See the
List of Related Literature.
To install optional accessories, follow the instructions
provided with each kit.
List of Related Literature
Figure 1 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.
Literature Type Part Number
Specification Sheets:
10REODB/REOZDB G5-318
15REODB/REOZDB G5-319
20REODB/REOZDB G5-320
Operation Manual (Engine) TP-6596
Operation Manual (Generator) TP-6427
Parts Catalog* TP-6395
Service Manual (Engine) TP-6597
Service Manual (Generator) TP-6394
* Includes the generator and engine information.
Figure 1 Generator Set Literature

TP-6609 6/0812 Service Assistance
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
DConsult the Yellow Pages under the heading
Generators—Electric.
DVisit the Kohler Power Systems website at
KohlerPower.com.
DLook at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
DCall toll free in the US and Canada 1-800-544-2444.
DOutside the US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East,Africa
(EMEA)
Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]

TP-6609 6/08 13Section 1 Location and Mounting
Section 1 Location and Mounting
1.1 Introduction
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
WARNING
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Generator set operation. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Avoid breathing exhaust
fumes when working on or near the generator set. Never
operate the generator set inside a building unless the exhaust
gas is piped safely outside. Never operate the generator set
where exhaust gas could accumulate and seep back inside a
potentially occupied building.
Enclosed generator sets include a factory-supplied
weather or sound housing. Enclosed units must be
installed outside. The exhaust systems on enclosed
units are designed for outdoor installations.
Note: Do not install enclosed units inside a
building.
Open generator sets do not include a factory-supplied
weather or sound enclosure. Open units may be
installed inside an unoccupied structure only if the
exhaust is piped safely outside and adequate air for
combustion and cooling is provided. The generator set
location must be safe, secure (locked), and
well-ventilated. See Figure 1-1 for a typical open-unit
installation.
Note: Do not install open generator sets in
residential applications.
1. Air inlet opening
2. Ductwork mounting flange
3. Air outlet duct
4. Support legs
5. Flexible section with radiator duct flange
6. Pusher fan
TP-5700-4
1
2
3
4
5
6
Figure 1-1 Typical Open Generator Set Installation

TP-6609 6/0814 Section 1 Location and Mounting
1.2 Location Factors
Ideally, the generator set should be mounted on
concrete at ground level. For above-ground installations,
including roof installations, weight considerations are
especially important. The building engineer must
determine whether the structure can support the weight
of the generator set.
The location of the generator set must:
DSupport the weight of the generator set and related
equipment such as batteries, radiators, and mounting
pad(s). Keep in mind that the mounting pad weight
may exceed the weight of the generator set.
DMeet applicable fire rating codes and standards.
DPosition the generator set over a noncombustible
surface. Do not allow accumulation of combustible
materials under the generator set.
DPermit vibration isolation to reduce noise and prevent
damage.
DBe clean, dry (open units), and not subject to flooding.
DAllow ventilation with a minimum amount of ductwork.
(open units)
DProvide clearance for cooling air flow and access for
service. See Section 1.5 for required clearances
around the generator set.
DAllow safe expulsion of exhaust.
DMinimize the risk of public or unauthorized access.
1.3 Mounting Surface
The manufacturer recommends a single, level concrete
mounting pad as shown in Figure 1-2. This method
provides maximum stability for the generator set;
however, draining the oil and servicing the generator set
may require raising the set from the pad.
Use an oil drain pump if clearance below the oil drain or
extension is insufficient for a pan large enough to hold all
the engine’s oil.
Figure 1-3 shows typical mounting surface details for
sizing the concrete surface beyond the generator set
and allowing for clearances during generator set
service. Refer to the generator set dimension drawings
for conduit and fuel-line placement.
TP-5700-3
Figure 1-2 Typical Single-Pad Mounting
12
3
4
5
6
7
3
3
TP-5700-3
1. Engine end
2. Generator set
3. Extend the concrete surface a minimum of 152 mm (6 in.)
beyond the generator set
4. Battery rack
5. Allow at least 457 mm (18 in.) between the generator set
and adjacent walls or other obstructions on all sides for
ease of servicing the generator set
6. Alternator end
7. Mounting pad (concrete surface)
3
Figure 1-3 Mounting Surface Detail (top view)
1.4 Vibration Isolation
The generator set is equipped with neoprene vibration
isolators. Connections between the generator set or its
mounting base and any conduits, fuel lines, or exhaust
piping must include flexible sections to prevent
breakage and to isolate vibration.

TP-6609 6/08 15Section 1 Location and Mounting
1.5 Prepare the Site
See Section 1.2 for important factors to consider in
choosing the generator set location.
1.5.1 Indoor Installations, Open Units
Maintain a minimum of 457 mm (18 in.) between the
generator set and any adjacent walls or obstructions to
allow access for maintenance and service. See
Figure 1-1 for a typical open-unit installation.
1. Prepare an area for mounting the generator set.
a. Clear all combustible materials from the
generator set location.
b. Lay a concrete pad that extends at least
152 mm (6 in.) beyond the generator set on all
sides. See Figure 1-3. Include mounting bolts
at the locations shown on the dimension
drawing.
c. Provide air intake and outlet openings as
described in Section 3.1.
1.5.2 Outdoor Installations, Enclosed
Units
Choose a location that is at least 0.9 m (3 ft.) from any
building or structure. Allow a minimum of 2.4 m (8 ft.)
clearance beyond the exhaust end of the generator set.
Plan the installation so that the exhaust end of the
generator set is not directed toward the building or any
openings where exhaust gas could be drawn into the
building.
1. Obtain a building permit and contact your local
utility companies to mark the locations of
underground pipes and cables.
2. Prepare an area for mounting the generator set.
a. Clear all combustible materials, including
plants and shrubs, building materials, and lawn
furniture, from an area at least 2.4 m (8 ft.)
beyond the exhaust end of the generator set.
b. Spread a 76-mm (3-in.) thick layer of gravel to
support the concrete mounting pad.
c. Lay a concrete pad that extends at least
152 mm (6 in.) beyond the generator set on all
sides. See Figure 1-3. Include mounting bolts
at the locations shown on the dimension
drawing.

TP-6609 6/0816 Section 1 Location and Mounting
1.6 Lifting
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
WARNING
1.6.1 Lifting the Generator Set
Use equipment that is rated for the generator set’s
weight to lift the unit into place. Refer to the specification
sheet for generator set weights.
Follow these general precautions when lifting all
generator sets. When lifting housed units, lift the
weather enclosure and generator set together as one
unit.
DDo not lift the generator set using the lifting eyes
attached to the engine and/or alternator. These eyes
cannot support the generator set’s weight. Instead,
insert lifting hooks or lifting bars through the holes in
the mounting skid. The placement of the holes
prevents the lifting cables from damaging the
generator set components and maintains balance
during lifting.
DIf the lifting cables contact the air cleaner, guards, or
other protruding components, use spreader bars on
the cables. If the cables still do not clear the
protruding component(s), temporarily remove the
component(s).
1.6.2 Lifting the Subbase Fuel Tank
Lift the subbase fuel tank as one unit if the tank is not
installed on the generator set. When lifting the fuel tank,
use the subbase fuel tank’s lifting eyes, if equipped;
otherwise use chains or cables wrapped around the
subbase fuel tank. If using lifting straps, protect the
straps from the sharp edges of the fuel tank.
If the fuel tank is empty and does not extend outside the
perimeter of the generator set skid, lift the generator set
and the subbase fuel tank together.
If the tank is not empty or extends outside the perimeter
of the skid, uninstall the subbase fuel tank by removing
the mounting hardware and wiring between the
generator set and the subbase fuel tank. Lift the
generator set and subbase fuel tank separately. It is not
necessary to drain the fuel tank when lifting only the fuel
tank.

TP-6609 6/08 17Section 2 Exhaust Systems
Section 2 Exhaust Systems
2.1 Introduction
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Generator set operation. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an
odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Avoid breathing exhaust
fumes when working on or near the generator set. Never
operate the generator set inside a building unless the exhaust
gas is piped safely outside. Never operate the generator set
where exhaust gas could accumulate and seep back inside a
potentially occupied building.
Satisfactory generator set performance requires proper
exhaust system installation. The following sections
detail exhaust system components.
2.2 Enclosed Units
Enclosed units use an engine-mounted silencer. The
exhaust systems on units with factory-installed
enclosures are complete and designed for outdoor
installation only.
2.3 Flexible Exhaust Line
For units without enclosures or with separately mounted
exhaust systems, install a flexible exhaust line onto the
engine exhaust outlet. See Figure 2-1. The flexible line
limits stress on the engine exhaust manifold or
turbocharger. Never allow the engine manifold or
turbocharger to support the exhaust piping.
Note: Do not bend the flexible section or use it to
compensate for misalignment between the
engine exhaust and the exhaust piping.
3
7
6
1
2
9
8
TP-5700-5
1. Exhaust wall thimble
2. Muffler
3. 45°Y fitting
4. Water trap
5. Drain petcock
6. Outer diameter adapter and clamp
7. Flexible section
8. Manifold
9. 45°elbow
4
5
Figure 2-1 Exhaust System, Side-Inlet Silencer
2.4 Condensation Trap
Install a wye- or tee-type condensation trap with a drain
plug or petcock between the engine and the exhaust
silencer as shown in Figure 2-2. The trap prevents
condensed moisture in the engine exhaust from
draining into the engine after shutdown. Periodically
drain collected moisture from the trap.
1
TP-5700-5
1. Condensation trap
Figure 2-2 Condensation Trap

TP-6609 6/0818 Section 2 Exhaust Systems
2.5 Piping
Note: Select piping with a diameter that is the same size
as or larger than the manifold outlet’s inside
diameter.
DKeep exhaust lines as short and straight as possible.
DUse schedule 40 black-iron pipe.
DUse sweep elbows with a radius of at least three times
the pipe diameter.
DUse exhaust piping that conforms to applicable
codes.
DSupport the exhaust piping securely, allowing for
thermal expansion.
DInsulate the exhaust piping with high-temperature
insulation to reduce the heat rejected by exhaust
piping and consequently the amount of ventilating air
required.
Exhaust temperatures measured at the engine’s
exhaust outlet are listed on the generator set
specification sheets.
Route the exhaust piping a minimum of 914 mm (36 in.)
from combustible material, including building materials
and natural surroundings.
When planning exhaust silencer and piping placement,
consider the location of combustible materials. If the
proximity of the exhaust system to the combustible
materials cannot be avoided, follow a regular
maintenance schedule to ensure that combustible
materials are kept away from the exhaust pipes after
installation. Combustible materials include building
materials as well as natural surroundings. Keep dry field
grass, foliage, and combustible landscaping material a
safe distance from the exhaust system.
2.6 Double-Sleeved Thimbles
If the exhaust pipe passes through a wall or roof, use a
double-sleeved exhaust thimble to prevent the
transmission of exhaust pipe heat to the combustible
material. Figure 2-3 shows construction details of a
typical double-sleeved thimble in which exhaust piping
passes through a combustible structure. Sheet metal
shops usually fabricate thimbles using installation
engineer’s specifications and drawings.
Construct the thimble so it extends at least 254 mm
(10 in.) both inside and outside the structure’s surface.
Openings at both ends of the thimble allow cooling air to
circulate through the thimble. If screening is used on the
outer end to keep birds and animals from entering the
thimble, use a mesh large enough to allow unrestricted
air circulation through the thimble. See Section 2.7 for
additional exhaust outlet location and protection
considerations.
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8
12
3
4
9
7
6
10 11
15
12
13
14
TP-5700-5
6
1. Rain cap (or gradual U bend)
2. Rain shield
3. 254 mm (10 in.) minimum
4. 25 mm (1 in.) minimum
5. Exhaust pipe
6. Ventilation holes at both ends
7. 254 mm (10 in.) minimum
8. 25 mm (1 in.) minimum
9. Flashing
10. Inner sleeve
11. Outer sleeve
12. Thimble outer diameter
13. 254 mm (10 in.) minimum outside
14. 254 mm (10 in.) minimum inside
15. Exhaust pipe diameter
Figure 2-3 Double-Sleeved Thimbles and Rain Cap

TP-6609 6/08 19Section 2 Exhaust Systems
2.7 Exhaust Outlet
Outlet location. Engine performance and efficiency
depend on the location of the exhaust outlet. Direct the
exhaust outlet away from the air inlet to prevent exhaust
gases from entering the air inlet and clogging the
dry-type air filter elements. Hot exhaust drawn through
the radiator adversely affects engine cooling. Locate
the exhaust outlet to prevent exhaust fumes from
entering a building or enclosure. See Figure 2-4 for
exhaust temperatures.
Noise reduction. The exhaust outlet configuration
affects the apparent noise level for people or animals in
the vicinity. An upward-directed outlet seems quieter
than one directed downward or horizontally.
Additionally, a 30- to 45-degree angled cut at the end of
a horizontal exhaust outlet pipe reduces turbulence at
the outlet, thereby reducing the noise level.
Rain cap. To prevent precipitation from entering the
exhaust pipe, install a rain cap on vertical outlets. See
Figure 2-3. In a climate where freezing is common, do
not use a rain cap. Instead, extend the exhaust piping at
least 610 mm (24 in.) beyond the roof line and create a
gradual U bend at the end to direct the exhaust outlet
downward. Keep the pipe outlet at least 457 mm (18 in.)
from the roof to prevent hot exhaust from igniting the
roof material.
Note: Avoid using a rain cap in areas subject to freezing
temperatures.
Exhaust Temperatures, _C(_F)
Model, kW 50 Hz 60 Hz
10 490 (914) 550 (1022)
15 570 (1058) 570 (1058)
20 550 (1022) 560 (1040)
Figure 2-4 Exhaust Temperatures
2.8 Exhaust System Back
Pressure
Exhaust back pressure limits engine power and
excessive back pressure causes serious engine
damage. Excessive back pressure usually results from
one or more of the following reasons:
DThe exhaust pipe diameter is too small.
DThe exhaust pipe is too long.
DThe exhaust system has too many sharp bends.
DThe exhaust silencer is too small.
DThe exhaust silencer is not the correct design for the
application.
The engine’s maximum exhaust back pressure limit is
shown in Figure 2-5. Use the procedure in Appendix B
to verify that the planned exhaust system does not
exceed the maximum exhaust back pressure limit.
Model, kW
Maximum Exhaust Back Pressure
kPa (in. water)
10 12.75 (51.3)
15 7.85 (31.6)
20 9.81 (39.4)
Figure 2-5 Silencer and Engine Exhaust Pipe Back
Pressures

TP-6609 6/0820 Section 2 Exhaust Systems
Notes