Installation

Industrial Generator Set

Models:

KD700 – KD4000,
KD1250-4, KD2500-4, KD3250-4

Controller:

APM802, APM603

TP-7153 5/24i
 WARNING: This product can expose you to chemicals, including carbon monoxide and
benzene, which are known to the State of California to cause cancer and birth defects or
other reproductive harm. For more information go to www.P65warnings.ca.gov

WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel

Product Identification Information

Product identification numbers determine service parts. Record the product identification numbers in the spaces below
immediately after unpacking the products so that the numbers are readily available for future reference.

Engine Identification

Record the product identification information from the engine nameplate.

Model Designation: __________________________

Serial Number: __________________________

Purchase Date

Upon purchase of your Kohler equipment, record the purchase date for reference when communicating with your authorized
Kohler distributor/dealer.

2 TP-7153 5/24
 Table of Contents

Safety Precautions and Instructions ........................................................................................................................................ 5

Introduction .............................................................................................................................................................................. 13
Service Assistance................................................................................................................................................................... 15
Section 1. General ................................................................................................................................................... 17
Section 2. Component Identification ...................................................................................................................... 19
Section 3. Loading and Transporting..................................................................................................................... 27
3.1 Lifting...................................................................................................................................................................... 27
3.1.1 Weight and Center of Gravity ................................................................................................................... 28
3.1.2 Lifting the Generator Set .......................................................................................................................... 28
3.1.3 Lifting the Subbase Fuel Tank ................................................................................................................. 29
3.1.4 Lifting the Generator Set with Attached Enclosure................................................................................... 30
3.1.5 Lifting the Generator Set, Enclosure, and Subbase Fuel Tank Assembly ................................................ 31
3.1.6 Lifting Walk-In Enclosures Components .................................................................................................. 32
3.1.7 Lifting the Radiator (KD2000-KD4000) .................................................................................................... 34
3.2 Generating Set Transporting .................................................................................................................................. 39
Section 4. Location .................................................................................................................................................. 41
4.1 Location Factors ..................................................................................................................................................... 41
4.2 Mounting Surface ................................................................................................................................................... 42
4.2.1 Single-Pad Mounting ................................................................................................................................ 43
4.2.2 Dual-Pad Mounting .................................................................................................................................. 43
4.2.3 Four-Pad Mounting .................................................................................................................................. 44
4.2.4 Mounting Pad Specifications .................................................................................................................... 44
4.3 IBC Seismic Installation.......................................................................................................................................... 45
4.4 Vibration Isolation ................................................................................................................................................... 46
4.5 Dual-Bearing Alternator Alignment ......................................................................................................................... 47
Section 5. Loose Component Installation (KD2000-KD4000) ............................................................................... 49
5.1 Radiator (KD2000-KD4000) ................................................................................................................................... 49
5.1.1 Radiator Hose Installation ........................................................................................................................ 51
5.1.2 Radiator Placement ................................................................................................................................. 53
5.1.3 Radiator Hose Connections ..................................................................................................................... 55
5.2 Air Intake System (KD3500, KD4000) .................................................................................................................... 59
5.2.1 Heavy-Duty Air Filter (KD3500, KD4000) ................................................................................................. 60
5.3 Battery charger (KD3500, KD4000)........................................................................................................................ 65
Section 6. Air and Cooling ...................................................................................................................................... 69
6.1 General .................................................................................................................................................................. 69
6.2 Liquid-Cooled Engines ........................................................................................................................................... 69
6.2.1 System Features ...................................................................................................................................... 69
6.2.2 Installation Considerations ....................................................................................................................... 70
6.2.3 Recommended Coolant ........................................................................................................................... 71
6.3 Unit-Mounted Radiator Cooling .............................................................................................................................. 72
6.3.1 System Features ...................................................................................................................................... 72
6.3.2 Installation Considerations ....................................................................................................................... 72
6.4 Remote Radiator Cooling ....................................................................................................................................... 74
6.4.1 General .................................................................................................................................................... 75
6.4.2 Vent Lines ................................................................................................................................................ 77
6.4.3 Charge Air Cooled Engines...................................................................................................................... 78
6.4.4 Fill Lines (Balance or Static) .................................................................................................................... 78
6.4.5 Location Considerations .......................................................................................................................... 78
6.4.6 Installation Considerations ....................................................................................................................... 79
6.4.7 Surge (Expansion) Tank for Horizontal Discharge Radiator .................................................................... 81

TP-7153 5/24 3
 6.4.8 Procedure to Fill a Remote Cooling System ............................................................................................ 81
6.4.9 Checks after Initial Startup ....................................................................................................................... 83
6.5 City Water Cooling ................................................................................................................................................. 83
6.5.1 System Features ...................................................................................................................................... 83
6.5.2 Installation Considerations ....................................................................................................................... 84
6.6 Cooling Tower ........................................................................................................................................................ 84
6.7 Block Heaters ......................................................................................................................................................... 84
Section 7. Exhaust System ..................................................................................................................................... 85
7.1 Flexible Exhaust Line ............................................................................................................................................. 85
7.2 Condensation Trap ................................................................................................................................................. 86
7.3 Piping ..................................................................................................................................................................... 86
7.4 Double-Sleeved Thimbles ...................................................................................................................................... 87
7.5 Exhaust Outlet ........................................................................................................................................................ 88
7.6 Exhaust System Backpressure .............................................................................................................................. 89
Section 8. Fuel System ............................................................................................................................................ 97
8.1 Main Tank .............................................................................................................................................................. 99
8.1.1 Fuel Tank Monitoring Panel ................................................................................................................... 100
8.2 Day Tanks ............................................................................................................................................................ 104
8.3 Fuel Lines ............................................................................................................................................................. 105
8.4 Auxiliary Fuel Pumps............................................................................................................................................ 106
Section 9. Electrical System ................................................................................................................................. 107
9.1 Electrical Stub-up Areas ....................................................................................................................................... 108
9.2 Generator Set Voltage Reconnection ................................................................................................................... 109
9.3 Electrical Connections .......................................................................................................................................... 109
9.4 Load Lead Connections ....................................................................................................................................... 110
9.5 Grounding and Grounded Conductor (Neutral) Connections ............................................................................... 111
9.6 Terminal Connector Torque ................................................................................................................................. 113
9.7 Batteries ............................................................................................................................................................... 114
9.8 Battery Chargers .................................................................................................................................................. 115
9.9 Component and Accessory Power Source Requirements.................................................................................... 115
9.10 Optional Accessories............................................................................................................................................ 116
9.10.1 Bus Bar Kits/Bus Lugs ........................................................................................................................... 117
9.10.2 Line Circuit Breaker ............................................................................................................................... 117
Section 10. APM603 and APM802 Controller Accessories................................................................................... 119
10.1 Input/Output Modules ........................................................................................................................................... 120
10.1.1 Analog Input/Output and Thermocouple Module.................................................................................... 120
10.1.2 Digital Input/Output Module.................................................................................................................... 122
10.2 Remote Emergency Stop Kit ................................................................................................................................ 126
10.3 Remote Serial Annunciator (RSA III) .................................................................................................................... 127
10.4 Accessory Connections ........................................................................................................................................ 129
Section 11. Remote Adjustment/Control Systems ................................................................................................ 131
11.1 Automatic Transfer Switches ................................................................................................................................ 132
11.2 APM603 Controller Voltage Regulator ................................................................................................................. 132
11.3 APM802 Controller Voltage Regulator ................................................................................................................. 132
Appendix A. Abbreviations ....................................................................................................................................... 133
Appendix B. Common Hardware Application Guidelines ...................................................................................... 137
Appendix C. Torque Specifications ......................................................................................................................... 139

4 TP-7153 5/24
 Safety Precautions and Instructions

Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

IMPORTANT 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.
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 a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE
NOTICE is used to address practices not related to physical injury.

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

WARNING 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.

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 generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.

(APM603 Controller)

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 generator set as follows: (1) Shut down the generator set. (2) Place the controller
in Out of Service mode. (3) Press the emergency stop button. (4) Disconnect the power to the battery charger, if equipped. (5)
Remove the battery cables, negative (–) lead first. Reconnect the negative (–) lead last when reconnecting the battery. Follow
these precautions to prevent the starting of the generator set by the remote start/stop switch.

(APM802 Controller)

TP-7153 5/24 5
Battery

WARNING 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.

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 container with 4 L (1 gal.) of water and 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.

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.

6 TP-7153 5/24
Engine Backfire/Flash Fire

WARNING Risk of fire.

Can cause severe injury or death.
Do not smoke or permit flames or sparks near fuels or the fuel system.

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.

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.

Exhaust System

WARNING Carbon monoxide.

Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.

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:
• Light-headedness, dizziness
• Physical fatigue, weakness in joints and muscles
• Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
• Stomachache, 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.

TP-7153 5/24 7
Fuel System

WARNING 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.

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 in a well-ventilated area away from 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.

Hazardous Noise

CAUTION Hazardous noise.

Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.

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.

8 TP-7153 5/24
Hazardous Voltage/Moving Parts

DANGER Hazardous voltage.

Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.

DANGER Hazardous voltage. Moving parts.

Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.

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.

Servicing the generator set when it is operating. Exposed moving parts will 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.

Grounding electrical equipment. Hazardous voltage will 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 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.

Installing the battery charger. Hazardous voltage will 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 will 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).

Short circuits. Hazardous voltage/current will 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 will 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.

Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and qualified
personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes
and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions
when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch
the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under)

TP-7153 5/24 9
 CAUTION
Welding the generator set.
Can cause severe electrical equipment damage.
Welding on generator set will cause serious damage to engine electronic controls components. Disconnect all engine
electronic control connections before welding.

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.

Heavy Equipment

WARNING Lifting eye failure.

Improper lifting can cause severe injury or death and equipment damage
Do not lift the generator set from the engine or alternator eyes. Never stand under a unit
being lifted. Always maintain a safe distance from the unit being lifted.
See the lifting instructions in the installation manual that was provided with the unit.

Generator set lifting bracket one-time use. Improper lifting can cause severe injury or death. During lifting, the weight of
the generator set adds stress to the lifting brackets. Generator set lifting brackets are only intended for a one-time use. After the
initial installation, replace the lifting brackets before moving the generator set a second time.

Unbalanced weight. An unbalanced load due to separating the radiator from the generator set can cause death or
severe injury. Separating the radiator from the generator set changes the center of gravity and requires different lifting points.
Use appropriate lifting points to prevent unbalanced loads. Additional lifting brackets and lifting eyes are required.

Lifting pin hardware. Improper lifting can cause injury or death. Ensure that the lifting pin is inserted through both keyhole
slots in the frame and is locked into place before lifting. Check the maximum allowable weight stamped on the lifting pin. Store
the lifting pin in a dry location inside the enclosure. Only reuse the lifting pin if properly maintained and periodically inspected
according to OSHA regulations.

Hot Parts

WARNING 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. Fill system before starting unit.

WARNING Hot engine and exhaust system.

Can cause severe injury or death.
Do not work on the generator set until it cools.

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.

Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before
connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to
the heater and allow it to cool before servicing the heater or nearby parts.

10 TP-7153 5/24
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
Parallel Operation. This product includes features intended to support operation in parallel with the utility grid, but these features
have not been evaluated for compliance with specific utility interconnection protection standards or requirements.

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.

NOTICE
Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic
discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits.
An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground.

TP-7153 5/24 11
12 TP-7153 5/24
 Introduction
This manual provides installation instructions for industrial generator sets. Operation manuals and wiring diagram manuals are
available separately.

Some additional model-specific installation information may be included in the respective generator set controller operation
manual.

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.

Abbreviations

This publication makes use of numerous abbreviations. Typically, the word(s) are spelled out along with the abbreviation in
parentheses when shown for the first time in a section. Refer to the Abbreviations section in the Appendices for abbreviation
definitions.

Exhaust Aftertreatment System

For tier 4 models with an exhaust aftertreatment system, additional installation information is required. Refer to the exhaust
afterftreatment system installation and application manual listed under Related Literature. In addition to the assembly and
installation instructions, the exhaust aftertreatment system application and installation manual contains component overviews,
lifting instructions, electrical requirements, structural requirements, and other critical information.

TP-7153 5/24 13
Related Literature
Separate literature contains communication, firmware, and other additional information not provided in this manual. Figure 1 lists
the available literature part numbers.

Manual Description Literature Part No.

Controller Operation Manual, APM603 TP-7141
Controller Operation Manual, APM802 TP-7070
Controller Commissioning Manual, APM603 TP-7131
Maintenance Manual, KD700-KD4000 TP-7143
Tier 4 Exhaust Aftertreatment System Installation and Application Manual,
TP-7186
KD1250-4, KD2500-4, KD3250-4
Controller and Generator Set Service Manual TP-7079
Engine Operation and Maintenance Manual, KD18L06, KD700-KD750 33521059301
Engine Operation and Maintenance Manual, KD27V12, KD800-KD1000 33521029401
Engine Operation and Maintenance Manual, KD36V16, KD1250-KD1350 33521029701
Engine Operation and Maintenance Manual, KD45V20, KD1250-KD1750 33521030001
Engine Operation and Maintenance Manual, KD62V12, KD2000-KD2500 33521030301
Engine Operation and Maintenance Manual, KD83V16, KD2800-KD3250 33521030601
Engine Operation and Maintenance Manual, KD103V20, KD3500-KD4000 33521030901
Alternator, Voltage Regulator, KD700 TP-7271
Alternator, Voltage Regulator, KD700-KD1750 Wye/600 V TP-7073
Alternator, Voltage Regulator, KD1250-KD3250 Wye/600 V/4160 V TP-7075
Alternator, Voltage Regulator, KD2000-KD4000 6600-13800 V TP-7076
Alternator, Voltage Regulator, KD2000-KD2500 Wye/600 V TP-7078
Generator Set/Controller Wiring Diagram Manual w/APM603 Initial Release With Updated I/O Modules
(Before 10/2022) (after 10/2022)
KD700-KD750 (APM603) NA TP-7262
KD800-KD1000 TP-7144 TP-7252
KD1250A-KD1350 (single starter) TP-7145 TP-7253
KD1250A-KD1350 (redundant starter) TP-7145 TP-7254
KD1250-4 (single starter) TP-7182 TP-7253
KD1250-4 (redundant starter) TP-7187 TP-7254
KD1500-KD1750 (single starter) TP-7146 TP-7255
KD1500-KD1750(redundant starter) TP-7146 TP-7256
KD2000-KD2500(single starter) TP-7147 TP-7257
KD2000-KD2500(redundant starter) TP-7147 TP-7258
KD2500-4 (single starter) TP-7183 TP-7257
KD2500-4 (redundant starter) TP-7188 TP-7258
KD2800-KD3250 (single starter) TP-7148 TP-7259
KD2800-KD3250 (redundant starter) TP-7148 TP-7260
KD3250-4 (single starter) TP-7184 TP-7259
KD3250-4 (redundant starter) TP-7189 TP-7260
KD3500-KD4000 TP-7170 TP-7261
Generator Set/Controller Wiring Diagram Manual w/APM802
KD700-KD750 (APM802) NA TP-7263
KD800-KD1000 TP-7106 TP-7242
KD1250A-KD1350 (single starter) TP-7117 TP-7243
KD1250A-KD1350 (redundant starter) TP-7117 TP-7244
KD1500-KD1750 (single starter) TP-7071 TP-7245
KD1500-KD1750(redundant starter) TP-7071 TP-7246
KD2000-KD2500(single starter) TP-7107 TP-7247
KD2000-KD2500(redundant starter) TP-7107 TP-7248
KD2800-KD3250 (single starter) TP-7108 TP-7249
KD2800-KD3250 (redundant starter) TP-7108 TP-7250
KD3500-KD4000 TP-7169 TP-7251
Figure 1 Related Literature

14 TP-7153 5/24
 Service Assistance

For professional advice and conscientious service, please China

contact your nearest Kohler distributor or dealer. North China Regional Office, Beijing
Phone: (86) 10 6518 7950
• Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7951
• Look at the labels and decals on your Kohler product (86) 10 6518 7952
or review the appropriate literature or documents Fax: (86) 10 6518 7955
included with the product.
East China Regional Office, Shanghai
• Call toll free in the US and Canada 1-800-544-2444. Phone: (86) 21 6288 0500
• Outside the US and Canada, call the nearest Fax: (86) 21 6288 0550
regional office. India, Bangladesh, Sri Lanka
Headquarters Europe, Middle East, Africa (EMEA) India Regional Office
Kohler EMEA Headquarters Bangalore, India
Netherlands B.V. Phone: (91) 80 3366208
Kristallaan 1 (91) 80 3366231
4761 ZC Zevenbergen Fax: (91) 80 3315972
The Netherlands Japan, Korea
Phone: (31) 168 331630
Fax: (31) 168 331631 North Asia Regional Office
Tokyo, Japan
Asia Pacific Phone: (813) 3440-4515
Kohler Asia Pacific Headquarters Fax: (813) 3440-2727
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

TP-7153 5/24 15
16 TP-7153 5/24
 Section 1. General

Industrial power systems give years of dependable service if installed using the guidelines provided in this manual and in
applicable codes. Incorrect installation can cause continuing problems. Figure 2 illustrates a typical installation.

Your authorized generator set distributor/dealer may also provide advice about or assistance with your installation.

Supports

Fresh air intake Exhaust thimble

(for wall or ceiling)
Silencer

Plenum (models
KD1250-KD1750) Water trap with drain

Flexible sections Duct work for

cooling air outlet

Electrical conduit
Mounting base

Figure 2 Typical Stationary-Duty Generator Set Installation (KD1250-KD1750 shown)

This manual references several organizations and their codes that provide installation requirements and guidelines such as the
National Fire Protection Association (NFPA) and Underwriter’s Laboratories Inc. (UL).

• NFPA 54 National Fuel Gas Code

• NFPA 70 National Electrical Coder; the National Electrical Code is a registered trademark of the NFPA

• NFPA 99 Standard for Health Care Facilities

• NFPA 101 Life Safety Code

• NFPA 110 Emergency and Standby Power Systems

• UL 486A-486B Wire Connectors

• UL 486E Equipment Wiring Terminals for Use with Aluminum and/or Copper Conductors

• UL 2200 Stationary Engine Generator Assemblies

These organizations provide information specifically for US installations. Installers must comply with all applicable national and
local codes.

Before beginning generator set installation, record the following data from the generator set’s specification sheet and keep this
data accessible for reference during installation:

• Dimensions and weight (verify dimensions and weight using the submittal data)

• Exhaust outlet size and maximum allowable backpressure

• Battery CCA rating and quantity

• Fuel supply line size and fuel pressure requirement (gas models)

• Air requirements

TP-7153 5/24 17
18 TP-7153 5/24
 Section 2. Component Identification

Exhaust outlet Batteries

Fuel return Oil fill

Air filter (standard duty shown)
Fuel return
Alternator voltage regulator location

Customer
connection area

Lifting eye
Fuel Inlet

Lifting eye Fuses

Oil level regulator for automatic

Air restriction replenishment system
Load center gauge
Circuit breaker box Starter

Block heater

Note:
Fuel line material selection is
critical. Refer to the details about
fuel line material in this manual.

Batteries
Radiator drain
Standard battery charger Oil Drain

Figure 3 KD700-KD750, Component Identification

TP-7153 5/24 19
 Lifting eye Lifting eye
Battery rack

Exhaust outlet
Air filter (standard duty shown)

Air restriction Alternator voltage regulator location

gauge

Fuel return

Radiator drain Customer connection area

Fuel Inlet

Note: Oil level regulator for automatic

Fuel line material selection is critical. Refer to the details about replenishment system
fuel line material in this manual.
Air filter (heavy duty shown)
Fuses
Redundant
starter
Circuit breaker box

Standard battery chargers Block heater Redundant battery charger

Oil fill Oil Drain

Figure 4 KD800–KD1000, Component Identification

20 TP-7153 5/24
 Air filter (standard duty shown)
Block
Air restriction gauge heater
Circuit breaker box

Redundant
battery charger

Oil drain
Standard battery chargers Battery rack
Fuses

Exhaust
outlets Lifting eyes
Lifting eyes

Fuel Inlet

Fuel return Radiator drain Customer connection area

Oil level regulator for automatic

replenishment system
Note: Fuel line material selection is critical. Refer to the details
about fuel line material in this manual.

Figure 5 KD1250A–KD1350, Component Identification

TP-7153 5/24 21
 Air filter (standard duty shown)

Circuit breaker box Block heater

Redundant
battery charger

Oil drain
Standard battery chargers
Fuses

Lifting eyes

Battery rack Exhaust outlets

Lifting eyes

Fuel Inlet

Fuel return Radiator drain Customer connection area

Note: Fuel line material selection is critical. Refer to the details
about fuel line material in this manual.

Figure 6 KD1500–KD1750, Component Identification

22 TP-7153 5/24
 Exhaust outlets

Air filter (standard duty shown)

Oil fill
Fuel return

Lifting eyes
Fuel Inlet
Block heater
Oil level regulator for
Oil drain automatic replenishment
system
Battery rack
Circuit breaker box (can be
on either side)
Lifting eyes

Air restriction gauge

Alternator voltage
regulator location

Radiator drains

Standard battery chargers

Redundant battery chargers

Fuses

Customer connection area

Figure 7 KD2000–KD2500, Component Identification

TP-7153 5/24 23
 Exhaust outlets

Air filter (standard duty shown)

Oil fill

Fuel return

Lifting eyes
Fuel Inlet

Block heater Oil level regulator for

automatic replenishment
Battery rack
system

Circuit breaker box (can be

on either side)

Alternator heater
Lifting eyes
threaded inlet

Air restriction gauge

Alternator voltage
regulator location

Radiator drains

Standard battery chargers

Redundant battery chargers

Fuses
Customer connection area

Figure 8 KD2800–KD3250, Component Identification

24 TP-7153 5/24
 Air filter (standard duty shown)
Circuit breaker box

Lifting eyes
Standard battery chargers Oil drain Lifting eyes
Lifting eyes
Alternator voltage
regulator location

Battery rack

Exhaust outlets

Redundant battery charger

Battery charger

Controller

Radiator drains Customer connection area

Lifting eyes
Lifting eyes Fuses

Note: Fuel line material selection is critical. Refer to the details

about fuel line material in this manual.

Figure 9 KD3500–KD4000, Component Identification

TP-7153 5/24 25
26 TP-7153 5/24
 Section 3. Loading and Transporting

The loading and transporting processes expose the generator set to many stresses and the possibility of improper handling.
Therefore, after transporting industrial generator sets:

• Check the alignment of the radiator and supports to ensure that the radiator is evenly spaced from the generator and
that supports are square and of even length. Check the radiator fan for uniform alignment and equal clearance within
the radiator shroud. Adjust if necessary.

• After confirming the correct alignment, tighten the hardware to its specified torque. Reference “Torque Specifications”
in the appendix.

Note:
For lifting instructions about the exhaust aftertreatment system, refer to the exhaust aftertreatment system installation and
application manual.

3.1 Lifting
WARNING Lifting eye failure.
Improper lifting can cause severe injury or death and equipment damage
Do not lift the generator set from the engine or alternator eyes. Never stand under a unit
being lifted. Always maintain a safe distance from the unit being lifted.
See the lifting instructions in the installation manual that was provided with the unit.

Generator set lifting bracket one-time use. Improper lifting can cause severe injury or death. During lifting, the weight of
the generator set adds stress to the lifting brackets. Generator set lifting brackets are only intended for a one-time use. After the
initial installation, replace the lifting brackets before moving the generator set a second time.

Unbalanced weight. An unbalanced load due to separating the radiator from the generator set can cause death or
severe injury. Separating the radiator from the generator set changes the center of gravity and requires different lifting points.
Use appropriate lifting points to prevent unbalanced loads. Additional lifting brackets and lifting eyes are required.

Follow these general precautions when lifting all generator sets and related equipment.

• Install proper size rigging at the skid lifting eyes providing a direct pull on the skid lifting eye. Make sure the rigging
does not work as a pry bar lever against the lifting eye.

• Do not lift the generator set using the lifting eyes attached to the engine and/or alternator as these lifting eyes cannot
support the total weight of the generator set.

• Generator lifting brackets have a limited lifespan and are only intended for use during the initial placement of the
generator set. If the generator set needs to be moved at a later date, order a lift kit available through Kohler Aftermarket
Parts.

• When lifting an enclosed generator set attached to a subbase fuel tank, use the lifting eyes on the subbase fuel tank.
Do not use the lifting eyes on generator set skid.

• Always protect cables, chains, and straps from sharp edges.

Reinforcing plate

Figure 10 Improper Lifting Hook Placement (above 1000 kW)

TP-7153 5/24 27
 • Generator sets typically above 1000 kW may have reinforcing plates on the skid. Do not attach lifting hooks to the
reinforcing plate. See Figure 10.

• Lifting should only be conducted by those trained and experienced in lifting and rigging to achieve a safe and effective
lift. Consideration needs to be given to, but not necessarily limited to, the following items:

o Weight and center of gravity of the equipment being lifted

o Weight and center of gravity of the lifting device

o Boom angles

o Selection of rated rigging

o Stability of lifting foundation

o Wind and weather conditions

o Local or regional codes that may require or restrict types of rigging.

• Use a spreader bar to prevent lifting cables from contacting air cleaners, shrouds, and other protruding components. If
the cables still do not clear these components, remove the components.

3.1.1 Weight and Center of Gravity

Refer to the respective specification sheet and/or the submittal drawing for the weight and center of gravity of all components
being lifted. The total combined weight and center of gravity must be known to select the proper rigging. If the weight and center
of gravity is not readily available, contact your distributor/dealer.

As applicable, determine the weight and center of gravity of the following components:

• Generator set

• Enclosure system (includes silencer, inlet baffles, louvers, etc.)

• Subbase fuel tank (lift only empty fuel tanks)

3.1.2 Lifting the Generator Set

The distributor/lifting contractor should choose one of the following methods to lift the generator set depending upon the location
circumstances and the generator set’s weight and size. See Figure 11 for the spreader bar and hook methods.

Single Spreader Bar and Hook Method Double Spreader Bar and Hook Method

Spreader bar
Spreader bar
20°
max. 20° max. 20°
20°
max.
max.

Figure 11 Single and Double Spreader Bar and Hook Method

28 TP-7153 5/24
3.1.3 Lifting the Subbase Fuel Tank

This section deals with lifting the subbase fuel tank as a single unit.

• The subbase fuel tank must have lifting eyes in order to use the following methods.

• The subbase fuel tank must be empty. Do not lift a fuel tank containing fuel (or any liquid).

• Remove any vent piping longer than 1 m (3.3 ft.) from the fuel tank. Do not lift a fuel tank with attached vent piping
longer than 1 m (3.3 ft.).

• Attach one or two spreader bars as shown.

Single Spreader Bar Method Double Spreader Bar Method

Spreader bar

Spreader bar

20°
max. 20° max.
20° max.
20°
max.

Lifting eyes
Lifting eyes

Figure 12 Fuel Tank with Single and Double Spreader Bar Method

TP-7153 5/24 29
3.1.4 Lifting the Generator Set with Attached Enclosure

Enclosure Attached Directly to the Enclosure Lifting Base

Lift the assembly by lifting on the skid as shown in the previous section on Lifting the Generator Set. With the subbase fuel tank
detached from the enclosure base, lift only the enclosure and generator set using the enclosure base lifting eyes. Lift using all
of the lifting eyes provided on the enclosure base. Select the procedure based on the matching number of available enclosure
base lifting eyes. Refer to Figure 13.

Do not attach hoisting equipment to the enclosure.

KD1250A-KD2500

KD700-KD1000

Generator Set Skid

Enclosure Base Skid Lifting Eyes Enclosure Base

Lifting Eyes Generator Set Skid Lifting Eyes

Figure 13 Typical Enclosure Attached Directly to the Generator Set Skid

Enclosure Attached to the Enclosure Base and Assembled to the Subbase Fuel Tank

Lift the entire enclosure, generator set, and subbase fuel tank assembly by lifting on the subbase fuel tank lifting eyes. Lift using
all the lifting eyes provided on the subbase fuel tank. Select the procedure from the following illustrations based on the matching
number of available subbase fuel tank lifting eyes. Do not attach hoisting equipment to the enclosure base. Refer to Figure 14.

KD1250A-KD2500

KD700-KD1000

Subbase Fuel Tank Lifting Eyes

Subbase Fuel Tank Lifting Eyes

Figure 14 Typical Enclosure Attached to the Enclosure Base and Assembled to the Subbase Fuel Tank

30 TP-7153 5/24
3.1.5 Lifting the Generator Set, Enclosure, and Subbase Fuel Tank Assembly

When using the subbase fuel tank to lift the generator set and/or enclosure as a package, use ALL of the lifting eyes on the
subbase fuel tank.

3.1.5.1 Four Eye Lifting Method

Hoisting using Four Eye Lifting Method

Apply the same lifting methods using single or double spreader bars as shown in the previous section, Lifting the Generator Set.

3.1.5.2 Eight Eye Lifting Method

Hoisting using Eight Eye Lifting Method

• Apply two spreader bars and four chain falls (Figure 15) for eight eye lifting.

• Install a pair of outer slings up to the maximum angle as shown in Figure 15.

• Remove the slack from the slings in the system but do not lift the unit.
• Install adjustable chain falls and strap or cable them from the spreader bar to the middle lifting eyes. Adjust to remove
the slack.

• Check and remove any slack that has developed in the primary slings and check that all chains/straps/cables are
carrying load.

Spreader bar

20°
max.
20°
max.

Chain fall Lifting eyes

Figure 15 Eight Eyes, Two Spreader Bars, and Four Chain Falls Lifting Method

TP-7153 5/24 31
3.1.6 Lifting Walk-In Enclosures Components

WARNING Lifting eye failure.

Improper lifting can cause severe injury or death and equipment damage
Do not lift the generator set from the engine or alternator eyes. Never stand under a unit
being lifted. Always maintain a safe distance from the unit being lifted.
See the lifting instructions in the installation manual that was provided with the unit.

Lifting the generator set components. Combining any of the generator set components (the enclosure, fuel tank, or
generator set) with another generator set component will exceed weight limits for the lifting points, can create an
unbalanced weight, and can cause severe injury, death, or equipment damage. Do not combine or assemble the enclosure,
fuel tank, or generator set before lifting or moving. Lift and position only one generator set component at a time.

Lifting pin hardware. Improper lifting can cause injury or death. Ensure that the lifting pin is inserted through both keyhole
slots in the frame and is locked into place before lifting. Check the maximum allowable weight stamped on the lifting pin. Store
the lifting pin in a dry location inside the enclosure. Only reuse the lifting pin if properly maintained and periodically inspected
according to OSHA regulations.

Due to the large size and unique construction of walk-in enclosures, the fuel tank, enclosure, and generator set must be lifted
and positioned separately from each other. See the following lifting instructions for the walk-in enclosure and fuel tank. The
generator set for walk-in enclosures follows typical lifting instructions for generator sets found in this section. For installation
instructions for the walk-in enclosure, refer to the walk-in enclosure installation manual.

3.1.6.1 Walk-In Enclosures

To lift the walk-in style enclosure, use the four-point lifting shown in Figure 16.

Note:
The main components (fuel tank, enclosure, and generator set) must be lifted separately.

Spreader bar

20° max. 20° max.

Lifting pins

Lifting pins

Figure 16 Walk-In Enclosure

32 TP-7153 5/24
3.1.6.2 Subbase Fuel Tank for Walk-In Enclosures

To lift the fuel tank for the walk-in style enclosure, use eight-point lifting. See Figure 17.

Note:
The main components (fuel tank, enclosure, and generator set) for the walk-in style components must be lifted separately.

Spreader bar

20° max. 20° max.

Chain fall

Lifting eyes

Figure 17 Fuel Tank for Walk-In Enclosure

TP-7153 5/24 33
3.1.7 Lifting the Radiator (KD2000-KD4000)

WARNING Lifting eye failure.

Improper lifting can cause severe injury or death and equipment damage
Do not lift the generator set from the engine or alternator eyes. Never stand under a unit
being lifted. Always maintain a safe distance from the unit being lifted.
See the lifting instructions in the installation manual that was provided with the unit.

Generator set lifting bracket one-time use. Improper lifting can cause severe injury or death. During lifting, the weight of
the generator set adds stress to the lifting brackets. Generator set lifting brackets are only intended for a one-time use. After the
initial installation, replace the lifting brackets before moving the generator set a second time.

Unbalanced weight. An unbalanced load due to separating the radiator from the generator set can cause death or
severe injury. Separating the radiator from the generator set changes the center of gravity and requires different lifting points.
Use appropriate lifting points to prevent unbalanced loads. Additional lifting brackets and lifting eyes are required.

The following instructions show radiator lifting methods for KD2000 – KD4000. For KD2000 – KD3250, in some instances such
as rooftop installations, the generator set skid and radiator may need to be separated because of dangerous or difficult lifting
conditions. For KD3500 and KD4000, the generator set and radiator are shipped separately and require assembly at the
installation site.

• When lifting a radiator that has been separated from the generator set, lifting eyes, capable of supporting the weight of
the radiator, must be added at the points indicated below (see Figure 18). The generator set lifting locations, used for
lifting the combined generator set and radiator, should not be used when the radiator is separated from the generator
set.

o On KD2000 – KD2500 40˚C ambient radiator, lifting eyes are factory-installed.

• On models KD2000 – KD3250, a lifting bracket kit, GM116198-S, is required to lift the generator set once the radiator
is separated.

o On KD3500 and KD4000, the generator set lifting bracket is standard and is installed at the factory.

Note:
Refer to the section in this manual, Loose Component Installation (KD2000-KD4000), for instructions about the lifting kit
installation and radiator reconnections.

Ø 31.75 mm (1.25 in.)

lifting eye location

Ø 31.75 mm (1.25 in.)

lifting eye location

Ø 31.75 mm (1.25 in.) lifting eye location

Factory-installed lifting bracket

Do not use when radiator skid is
separated from generator set skid.

Figure 18 Radiator Lifting Eye Locations (KD3500 and KD4000 shown)

34 TP-7153 5/24
3.1.7.1 KD2000-KD2500

The following radiator lifting instructions apply only to KD2000 – KD2500. See Figure 19 for radiators with 40˚C ambient
temperature and Figure 20 for radiators with 50˚C ambient temperature.

• On the 50˚C ambient model, four lifting eyes must be installed.

o On the 40˚C ambient radiator, lifting eyes are factory-installed.

• Dry weight of radiator (KD2000 – KD2500):

o 40˚C ambient – 2777 kg (6,122 lbs.)

o 50˚C ambient – 3270 kg (7,210 lbs.)

• Ensure lifting devices have sufficient capacity to account for coolant remaining in the radiator after draining and other
unforeseen loads.

• Attach all four cables from the lifting eyes. Make sure cables do not touch any part of the cooling system other than the
lifting features.

• Ensure that cables do not exceed a 45˚ angle from vertical in any direction.

• Avoid rubbing lifting cables against the radiator. If possible, provide a buffer between the lifting cables and the radiator.

Front View Side View

Lifting beam over the center of gravity

Lifting eye (factory supplied) 634 mm

(24.96 in.)

Center of gravity

Lifting eye
(factory
supplied)

1084 mm
(42.67 in.)

Center of gravity 1419 mm (55.87 in.) 809 mm

(31.85 in.)
1889 mm (74.37 in.)

Figure 19 Radiator Lifting Method (KD2000 – KD2500, 40˚C Ambient Temperature only)

TP-7153 5/24 35
 Front View Side View
Lifting beam over the center of gravity

Use a cable spreader to avoid

damaging the fan guard. Lifting cables 45° max.

Lifting cables 45° max.

Lifting eye (customer supplied) 343 mm (13.50 in.)

Lifting cables 45° max. Ø 31.75 mm

(1.25 in.)
Center of gravity
Center of gravity

3006 mm
(118.36 in.)
709 mm (27.90 in.)
1277 mm (50.28 in.)
1526 mm
(60.06 in.)
457 mm
(18.00 in.)
1371 mm Lifting eye (customer supplied)
(53.96 in.)
Ø 31.75 mm (1.25 in.)

Figure 20 Radiator Lifting Method (KD2000 – KD2500, 50˚C Ambient Temperature only)

36 TP-7153 5/24
3.1.7.2 KD2800-KD3250

The following radiator lifting instructions apply only to KD2800 – KD3250.

• Use four lifting eyes with the following method.

• Dry weight of radiator (KD2800 – KD3250) is 5130 kg (11,310 lbs.).

• Ensure lifting devices have sufficient capacity to account for coolant remaining in the radiator after draining and other
unforeseen loads.

• Attach all four cables from the lifting eyes. Make sure cables do not touch any part of the cooling system other than the
lifting features.

• Ensure that cables do not exceed a 45˚ angle from vertical in any direction.

• Avoid rubbing lifting cables against the radiator. If possible, provide a buffer between the lifting cables and the radiator.

Front View Side View

Lifting beam over the center of gravity

Use a cable spreader to avoid

damaging the fan guard. Lifting cables 45° max.

Lifting cables 45° max.

Lifting eye (customer supplied) 377 mm (14.84 in.)

Lifting cables 45° max. Ø 31.75 mm

(1.25 in.)
Center of gravity
Center of gravity

3200 mm
(126.00 in.)
663 mm (26.11 in.)
1427 mm (56.17 in.)
1620 mm
(63.77 in.)
457 mm
(18.00 in.)
1568 mm (61.74 in.) Lifting eye (customer supplied)
Ø 31.75 mm (1.25 in.)

Figure 21 Radiator Lifting Method (KD2800 – KD3250)

TP-7153 5/24 37
3.1.7.3 KD3500-KD4000

The following radiator lifting instructions apply only to KD3500 and KD4000.

• Use four lifting eyes with the following method.

• Dry weight of radiator (KD3500 and KD4000) is 5448 kg (12,010 lbs.).

• Ensure lifting devices have sufficient capacity to account for coolant remaining in the radiator after draining and other
unforeseen loads.

• Attach all four cables from the lifting eyes. Make sure cables do not touch any part of the cooling system other than the
lifting features.

• Ensure that cables do not exceed a 45˚ angle from vertical in any direction.

• This lifting method only applies to the radiator for KD3500 and KD4000.

• Avoid rubbing lifting cables against the radiator. If possible, provide a buffer between the lifting cables and the radiator.

Front View Side View

Lifting beam over the center of gravity

Use a cable spreader to avoid

damaging the fan guard. Lifting cables 45° max.

Lifting cables 45° max.

Lifting eye (customer supplied) 416 mm (16.38 in.)

Lifting cables 45° max. Ø 31.75 mm

(1.25 in.)
Center of gravity
Center of gravity

3200 mm
(126.00 in.)
711 mm (28.01 in.)
1432 mm (56.38 in.)
1672 mm
(65.81 in.)
457 mm
(18.00 in.)
1601 mm (63.04 in.) Lifting eye (customer supplied)
Ø 31.75 mm (1.25 in.)

Figure 22 Radiator Lifting Method (KD3500 and KD4000 only)

38 TP-7153 5/24
3.2 Generating Set Transporting
Follow these guidelines when transporting the generator set:

• Select the transporting vehicle/trailer based on the dimensions and weight of the generator set as specified in the
generator set dimension drawing or specification sheet. Ensure that the gross weight and overall height of the generator
set and vehicle/trailer in transport does not exceed applicable transportation codes.

• Use low boy-type trailers that meet clearance requirements when transporting units larger than 1000 kW. Load large
(unboxed) radiator-equipped generator sets with the radiator facing the rear to reduce wind resistance during transit.
Secure fans to prevent fan rotation in transit.

• Securely fasten the generator set to the vehicle/trailer. Even the heaviest of generator sets can move during shipment
unless they are secured. Fasten the generator set to the vehicle/trailer bed with a correctly sized chain routed through
the mounting holes of the generator set skid (or tank, if equipped). Use chain tighteners to remove slack from the
mounting chain. Do not use strapping over the top of an enclosed generator set as damage to the enclosure may occur.

• Always cover a non-enclosed unit with a heavy-duty canvas or tarpaulin secured to the generator set or trailer.

TP-7153 5/24 39
40 TP-7153 5/24
 Section 4. Location

4.1 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 determines whether the structure can support
the weight of the generator set.

The location of the generator set must meet the following criteria.

General:

• Mounting surface is square and horizontally level at all four edges.

• Support the weight of the generator set and related equipment such as fuel storage tanks, batteries, radiators, and
mounting pad(s). Keep in mind that the mounting pad weight may exceed the weight of the generator set.

• Mounting pad should be designed to prevent the vibration of a running unit from causing mounting pad distortion and
affecting engine/alternator alignment.

• Meet applicable fire rating codes and standards.

• Install the unit so that the risk of contact by people with the hot generator set surfaces is minimized.

• Position the generator set over a noncombustible surface. If the mounting surface directly under or near the generator
set is porous or deteriorates from exposure to engine fluids, construct a containment pan for spilled fuel, oil, coolant,
and battery electrolyte. Do not allow accumulation of combustible materials under the generator set.

• Permit vibration isolation and dampening to reduce noise and prevent damage.

• Be clean, dry, and not subject to flooding.

• Provide easy access for service and repair.

Indoor Installations:

• Allow adequate ventilation with a minimum amount of ductwork. Refer to the generator spec sheet.

• Allow safe expulsion of exhaust.

• Allow for storage of sufficient fuel to sustain emergency operation. See the generator set specification sheet for fuel
consumption.

• Allow for locating the fuel tank within the vertical lift capabilities of the fuel pump and any auxiliary pumps. See the
section on Fuel Systems.
• Minimize the risk of public or unauthorized access.

• Provide adequate protection to prevent injury in the stub-up area. If the stub-up area opening is exposed, provide a
cover or fill in the area to avoid the risk of tripping or falling into the stub-up opening.

TP-7153 5/24 41
Outdoor Installations:

• Select a location that provides adequate air flow. Avoid locations next to tall buildings that block normal air flow and
cause air vacuum pockets. Avoid areas that are subject to high winds, excessive dust, or other airborne contaminants.
High dust areas may require more frequent air cleaner maintenance. High temperature conditions affect generator set
efficiency. Select a shaded area away from direct sunlight and/or other heat-producing equipment when practical.

• Avoid areas with combustible materials, including but not limited to building materials as well as natural surroundings.
Keep dry field grass, foliage, and combustible landscaping materials a safe distance from the exhaust system.

• The subsoil location must have a bearing strength capable of supporting the generator set and mounting pad combined
weight. Analysis by a qualified technician or engineer is recommended to determine the proper excavation material
required.

• If the generator set enclosure is mounted on multiple pads where it is elevated above the main surface it may cause
discharge air recirculation underneath the unit. A typical location could be a building roof where the main surface is
uneven for a single pad. In the following section on Air and Cooling, refer to “Installation Considerations” under Liquid-
Cooled Engines for information to minimize discharge air recirculation.

• Select a location that provides adequate space to access and service the unit. Allow for adequate clearance to open
and close access doors. Avoid locations on a hill or steep embankment unless provision is made to include a servicing
platform.

4.2 Mounting Surface

Figure 23 shows typical mounting surface details for sizing the concrete surface beyond the generator set and allowing for
clearances during generator set service. Follow the dimensional details for single-pad, dual pad, or four-pad mounting depending
upon the mounting method. Refer to the following sections for the applicable mounting method.

Note:
Refer to respective seismic installation ADV drawing(s) for seismic isolator requirements and for seismic information about
anchors, concrete pads, enclosures, and positioning.

Extend the concrete

Battery rack
Generator set skid surface a minimum of
Allow at least 1219 mm (48 in.)
152 mm (6 in.) beyond
between the generator set and
the generator set
Engine end adjacent walls or other
obstructions on all sides for ease
of servicing the generator set

Extend the concrete

surface a minimum of Alternator end
152 mm (6 in.) beyond
the generator set

Building wall
Extend the concrete surface a minimum of Mounting pad
152 mm (6 in.) beyond the generator set (concrete surface)

Figure 23 Mounting Surface Detail (top view)

42 TP-7153 5/24
4.2.1 Single-Pad Mounting

The manufacturer recommends a single, level concrete mounting pad as shown in Figure 24. 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 24 Single-Pad Mounting

4.2.2 Dual-Pad Mounting

The two-pad arrangement shown in Figure 25 provides easy access to conveniently drain the oil. Follow the oil draining
considerations outlined in the previous section, Single-Pad Mounting.

Figure 25 Dual-Pad Mounting

TP-7153 5/24 43
4.2.3 Four-Pad Mounting

The four-pad arrangement shown in Figure 26 provides more room under the engine for service than the previous two methods.
Follow the oil draining considerations outlined in the previous section, Single-Pad Mounting.

Figure 26 Four-Pad Mounting

4.2.4 Mounting Pad Specifications

Mounting pad weight.

The weight of the single mounting pad or combined weight of multiple mounting pads should equal or exceed the combined
weight of the generator set and attached accessories.

To determine the weight of the mounting pad(s), determine the volume (length x width x height) of each pad in cubic meters
(cubic feet). Multiply this result by 2400 kg/cm3 (150 lb./ft.3) to determine a pad’s weight. In multiple-pad installations, add the
weights of all pads to determine the total mounting pad weight.

Mounting pad specifications.

Mounting pad composition should follow standard practice for the required loading. Typical specifications call for
17238-20685 kPa (2500-3000 psi) concrete reinforced with eight-gauge wire mesh or No. 6 reinforcing bars on 305 mm (12 in.)
centers. The top surface of the mounting pad on which the generator set mounts should be within a flatness of 3 mm (1/8 in.).

The recommended concrete mixture by volume is 1:2:3 parts of cement, sand, and aggregate, respectively. Surround the pad
with a 200-250 mm (8-10 in.) layer of sand or gravel for proper support and isolation of a pad located at or below grade.

Anchor the generator set to the concrete using bolts cast into the surface of the pad. Otherwise, drill holes in the mounting pad
prior to generator set placement and use expansion anchor bolts. Anchor the generator set skid or fuel tank (if equipped) using
all of the provided anchor holes on the bottom of the skid.

Note:
Refer to the generator set and accessory dimension drawings for conduit and fuel-line placement. The drawings give dimensions
for electrical and fuel connection rough-ins and stub-ups including model specific clearances.

44 TP-7153 5/24
4.3 IBC Seismic Installation
International Building Code (IBC) seismic installations involve additional mounting and installation considerations. Refer to
respective seismic installation ADV drawing(s) for seismic isolator requirements and for seismic information about anchors,
concrete pads, enclosures, and positioning.

Skid Mounted Directly to Concrete (KD700 to KD1750)

Anchor detail

Concrete pad

Anchor location Concrete pad

Refer to the seismic installation ADV.

Mounted with Vibration Isolators (KD2000 to KD4000)

Vibration Isolator detail

Concrete pad

Anchor location Concrete pad

Refer to the seismic installation ADV.

Figure 27 Seismic Installation Requirements

TP-7153 5/24 45
4.4 Vibration Isolation
The KD700–KD4000 generator sets use one of the vibration isolation types detailed in the following paragraphs. Also,
connections between the generator set or its skid and any conduits, fuel lines, or exhaust piping must include flexible sections
to prevent breakage and to isolate vibration. These connections are detailed in subsequent sections.

• KD700–KD1750 use neoprene vibration isolators

• KD2000–KD4000 use spring-type vibration isolators

The two primary types of isolators are neoprene and spring-type. See Figure 28.

Generator sets with integral vibration isolation (neoprene isolators)

Neoprene isolators are located between the engine-generator and the skid, referred to as integral vibration isolation mounting.
Integral vibration isolation units come from the factory with neoprene vibration isolation. Neoprene isolators provide 90%–95%
vibration isolation efficiency and are often sufficient for installations at or below grade. KD700–KD1750 use C section-fabricated
steel.

Neoprene Vibration Isolators Spring-Type Vibration Isolators

(KD700 to KD1750) (KD2000 to KD4000 – GM84038, GM84954, 11808000100,
11808000200, and 11808000300)
Ø 6 x 21 (0.81) hole for 4 X (base plate) Ø 19 (0.75)
To engine-generator attachment to concrete hole for attachment to steel
29 (View cut away for clarity)
(1.13)
305 (12)
Neoprene
vibration
isolator

159
(6.25)
57
(2.25)

73
(2.88)

Skid crossmember 181 (7.13)

22 38 286 (11.25)
(0.88) (1.5)
19 (0.75) removable
adjusting bolt

156 (6.13)
free and
operating
height

Note: Dimensions shown

are in mm (inches).

Figure 28 Neoprene and Spring-Type Vibration Isolators

46 TP-7153 5/24
Generator sets with direct mounting (spring-type isolators)

The spring-type isolator kit is installed with direct-mounted units. Direct-mounted units have no factory vibration isolation.
Spring-type isolators provide 98% vibration efficiency and are recommended for above grade installations and other locations
where vibration sensitivity could be an issue.

KD2000–KD4000 typically mount directly to a structural steel base. For these units, install the recommended spring-type
vibration isolators between the base and the mounting pad in the holes provided. Because of the reduced mounting surface area
of these individual mounts, the static load on the mounting surface increases to the range of 345–690 kPa (50–100 psi).

With spring-type vibration isolators, mounting positions depend upon the combination of the generator set model and alternator.
The skid has dedicated mounting position holes for spring-type vibration isolators.

Note:
For spring-type isolator positioning and locations, refer to the spring-type isolator kit placement document shipped with the
product (KD2000–KD2500: 118080000XX with KD62V12, 118080006XX with KD62V12A, KD2800–KD3250: 118080004XX
with KD83V16, 118080008XX with KD83V16A, KD3500–KD4000: 118080005XX).

Dedicated radiator position when mounted

to the generator set.

Locate accessory spring-type vibration isolators Concrete mounting pad

according to 118080000XX, 118080004XX,
118080005XX, 118080006XX, or 118080008XX.

Figure 29 Spring-Type Vibration Isolators

Generator sets mounted on subbase fuel tanks

Do not install vibration spring isolators under the subbase fuel tank.

4.5 Dual-Bearing Alternator Alignment

Generator sets equipped with dual-bearing alternators require alignment after mounting the generator set skid to a mounting
pad. Refer to Service Bulletin SB-566 for details.

TP-7153 5/24 47
48 TP-7153 5/24
 Section 5. Loose Component Installation (KD2000-KD4000)

Due to the size, shipping constraints, or placement of larger generator sets (KD2000–KD4000), several components may require
onsite installation. Follow the instructions in this section to install the radiator, air intake system, and battery chargers. Refer to
the section on Loading and Transporting for instructions on Lifting the Radiator.

Note:
The following radiator installation covers models KD2000–KD4000; air intake and battery charger instructions apply specifically
to the KD3500 and KD4000.

5.1 Radiator (KD2000-KD4000)

WARNING 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.

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 generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.

(APM603 Controller)

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 generator set as follows: (1) Shut down the generator set. (2) Place the controller
in Out of Service mode. (3) Press the emergency stop button. (4) Disconnect the power to the battery charger, if equipped. (5)
Remove the battery cables, negative (–) lead first. Reconnect the negative (–) lead last when reconnecting the battery. Follow
these precautions to prevent the starting of the generator set by the remote start/stop switch.

(APM802 Controller)

WARNING 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. Fill system before starting unit.

DANGER Hazardous voltage. Moving parts.

Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.

Servicing the generator set when it is operating. Exposed moving parts will 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-7153 5/24 49
 WARNING Lifting eye failure.
Improper lifting can cause severe injury or death and equipment damage
Do not lift the generator set from the engine or alternator eyes. Never stand under a unit
being lifted. Always maintain a safe distance from the unit being lifted.
See the lifting instructions in the installation manual that was provided with the unit.

Generator set lifting bracket one-time use. Improper lifting can cause severe injury or death. During lifting, the weight of
the generator set adds stress to the lifting brackets. Generator set lifting brackets are only intended for a one-time use. After the
initial installation, replace the lifting brackets before moving the generator set a second time.

Unbalanced weight. An unbalanced load due to separating the radiator from the generator set can cause death or
severe injury. Separating the radiator from the generator set changes the center of gravity and requires different lifting points.
Use appropriate lifting points to prevent unbalanced loads. Additional lifting brackets and lifting eyes are required.

The radiator for larger models, KD2000–KD4000, may require installation depending on the installation site or the shipping
requirements.

• For models KD3500 and KD4000, the radiator will always ship loose from the rest of the generator set.

• For models KD2000–KD3250, the radiator skid ships installed to the generator set skid and, if needed, can be separated
at the site.

Once the radiator is separated (models KD2000–KD3250 only), a lifting bracket kit, GM116198-S, must be installed to lift the
generator set. Secure the lifting bracket kit in the same location that the radiator skid was secured. Contact Kohler Aftermarket
Parts to order the lifting bracket kit. See Figure 30.

Note:
KD3500 and KD4000 ships with the lifting bracket secured to the generator set skid. The radiator skid aligns with the generator
skid next to the lifting bracket; so, the lifting bracket does not need to be removed after the radiator and generator skids are
combined.

Note: Tighten the lifting bracket bolts to 731 Nm (539 ft. lbs.).

Lifting bracket kit

Lifting bracket kit

Figure 30 Lifting Bracket Kit Installation (KD2000–KD3250)

50 TP-7153 5/24
5.1.1 Radiator Hose Installation

Radiator belt guard

Figure 31 Remove the Belt Guard

1. Remove the radiator belt guard. See Figure 31.

Insulated clamp Vent lines Insulated clamp Deaeration tank

High temperature
overflow hose
Insulated clamp
Insulated clamp
Low temperature
overflow hose

High temperature
outlet from engine

High temperature
inlet to engine

Low temperature
outlet from engine

Low temperature
inlet to engine

Figure 32 High and Low Temperature Cooling Circuit Connections

TP-7153 5/24 51
 2. To mount the overflow hoses, use the following steps.

For the high-temperature overflow hose:

a. Fit the high temperature overflow hose over the fitting on the deaeration tank and secure with a hose clamp. See
Figure 32.

b. Route the high temperature overflow hose through the insulated clamps on the radiator guard. Tighten the clamps
to secure.

c. Fit the end of the overflow hose over the fitting on the high-temperature inlet tube. Use the hose clamp to secure
the hose.

d. Route the coolant sensor wiring harness under the supports for the deaeration tank and connect the wiring harness
to the sensors.

For the low-temperature overflow hose:

e. Fit the low temperature overflow hose over the fitting on the deaeration tank and secure with a hose clamp. See
Figure 32.

f. Route the low temperature overflow hose through the insulated clamps on the radiator guard. Tighten the clamps
to secure.

g. Fit the end of the low temperature overflow hose over the fitting on the low-temperature inlet tube. Use the hose
clamp to secure the hose.

h. Route the wiring harness up the front of the radiator and connect the wiring harness to the coolant temperature
sensor.

High temperature outlet from engine

Low temperature outlet from engine

High temperature inlet to engine

Low temperature inlet to engine

Figure 33 Engine Cooling Circuit Caps

3. Remove the caps from the high and low temperature inlets and outlets. Figure 33.

52 TP-7153 5/24
5.1.2 Radiator Placement

WARNING Lifting eye failure.

Improper lifting can cause severe injury or death and equipment damage
Do not lift the generator set from the engine or alternator eyes. Never stand under a unit
being lifted. Always maintain a safe distance from the unit being lifted.
See the lifting instructions in the installation manual that was provided with the unit.

Generator set lifting bracket one-time use. Improper lifting can cause severe injury or death. During lifting, the weight of
the generator set adds stress to the lifting brackets. Generator set lifting brackets are only intended for a one-time use. After the
initial installation, replace the lifting brackets before moving the generator set a second time.

Unbalanced weight. An unbalanced load due to separating the radiator from the generator set can cause death or
severe injury. Separating the radiator from the generator set changes the center of gravity and requires different lifting points.
Use appropriate lifting points to prevent unbalanced loads. Additional lifting brackets and lifting eyes are required.

Radiator skid

Lifting eye, radiator skid

Generator set skid

Lifting eye (remove on KD2000 – KD3250)

Figure 34 Position the Radiator (KD3500-KD4000 shown)

Note:
After the lifting eyes are removed, use the bolt holes for the lifting eye locations to secure the radiator skid (KD2000 –
KD3250 only).

1. For KD2000–KD3250 only, remove the lifting eyes from each side of the generator set.

2. Lift and position the radiator. Align the radiator skid with the engine and generator set skid. See Figure 34. Refer to the
previous section, Loading and Transporting for radiator lifting locations.

Important!
Engine damage can result when positioning the radiator. Use caution when aligning the generator set skid and radiator
skid. Loop the radiator belts on the engine extension so that, after the generator set skid and radiator skid are joined
together, the belts can be repositioned on the radiator.

TP-7153 5/24 53
 Side Front

Shims
Washer

Bolt

Bolt

Bolts and washers

Washer
Bolt plate
Top
Support plate
Shims

Washer

Nut

Figure 35 Radiator Skid Bolts (KD3500-KD4000 shown)

3. To secure the radiator skid to the generator set skid:

Note:
Tighten the skid bolts to 731 Nm (539 ft. lbs.).

a. On each side of the skid, use four bolts and washers, two bolt plates, and shims to secure the radiator. See Figure
35.

Note:
Position the bolt plates behind the generator set skid and the shims between the generator set skid and radiator
skid.

Important:
To ensure appropriate bolt preload, add shims until the gaps between the radiator skid and generator set skid are
filled. The number of shims varies with each installation.

b. In the front of the skid, tighten the twelve bolts and washers (six each side) through the generator set skid and into
the threaded holes in the radiator skid.

c. On the top of the skid, align the support plate with the holes in the generator set skid and radiator skid. Use four
bolts, eight washers, and four nuts (on each side) to secure the radiator.

54 TP-7153 5/24
5.1.3 Radiator Hose Connections

WARNING 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.

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 generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.

(APM603 Controller)

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 generator set as follows: (1) Shut down the generator set. (2) Place the controller
in Out of Service mode. (3) Press the emergency stop button. (4) Disconnect the power to the battery charger, if equipped. (5)
Remove the battery cables, negative (–) lead first. Reconnect the negative (–) lead last when reconnecting the battery. Follow
these precautions to prevent the starting of the generator set by the remote start/stop switch.

(APM802 Controller)

DANGER Hazardous voltage. Moving parts.

Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.

Servicing the generator set when it is operating. Exposed moving parts will 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-7153 5/24 55
 3/4" undercarriage bolt
locations

Tension pulley Tension adjustment bolt

Figure 36 Belt Tension Adjustment

1. Install the radiator belts and adjust the belt tension. See Figure 36. Refer to the generator set maintenance manual for
the belt tensioning procedure and tension tolerances.

Low temperature
inlet tube

Drain valve

Drain valves

Figure 37 Drain Valve

56 TP-7153 5/24
 High temperature outlet tube

High temperature inlet tube

Low temperature outlet tube

Low temperature inlet tube

Figure 38 Inlet and Outlet Tube Connections

Note:
In the following procedure, tighten the flange nuts to 50 Nm (37 ft. lbs.).

2. To mount the low temperature inlet tube to the engine low temperature inlet:

a. Apply thread sealant to the drain valve and antiseize compound to the hose clamps. See Figure 37.

b. Apply sealant to both sides of the flange gasket.

c. Position the flange gasket over the four inlet flange studs.

d. Align the low temperature inlet tube with the engine inlet flange. See Figure 38.

e. Secure the low temperature inlet tube with four 10 mm nuts and washers.

3. To mount the low temperature outlet tube to the engine low temperature outlet:

a. Apply sealant to both sides of the outlet flange gasket.

b. Position the flange gasket over the four outlet flange studs.

c. Align the low temperature outlet tube with the engine outlet flange.

d. Secure the engine inlet flange with four 10 mm nuts and washers.

e. Use the four hose clamps and the hose coupler to secure the engine outlet tube to the radiator outlet tube.

4. To mount the high temperature inlet tube to the engine high temperature inlet:

a. Apply thread sealant to the drain valves and antiseize compound to the hose clamps.

b. Apply flange sealant to both sides of the gasket.

c. Position the flange gasket over the four inlet flange studs.

d. Secure the engine inlet flange with four 10 mm nuts and washers.

TP-7153 5/24 57
 5. To mount the high temperature outlet tube to the engine high temperature outlet:

a. Apply thread sealant to the drain valves and antiseize compound to the hose clamps.

b. Apply sealant to both sides of the flange gasket.

c. Position the flange gasket over the four outlet flange studs.

d. Position the high temperature outlet tube. Use the four hose clamps and the hose coupler to secure the engine
outlet tube to the radiator outlet tube.

e. Use the hose clamp to secure the overflow hose to the high temperature outlet tube.

f. Secure the engine inlet flange with four 10 mm nuts and washers.

Radiator connections

Vent lines

Engine connections

Figure 39 Vent Line Connections

6. Connect the vent lines from the radiator to the ports on the engine. Refer to Figure 39.

7. Connect the coolant sensors to the wiring harness. Refer to the generator set wiring diagram.

8. Reinstall the belt guard.

58 TP-7153 5/24
5.2 Air Intake System (KD3500, KD4000)
This section covers the installation of the air intake system. Because of the relative simplicity of the standard-duty air intake
system installation, only the heavy-duty air filter and intake system is covered in detail.

Note:
On more recent KD3500-KD4000 models, the generator sets ship with the air intake system and battery chargers installed.
When applicable, use the following instructions, as needed, to install any components that were removed due to shipping
requirements.

Note:
For the standard-duty air intake system, position the filter and tighten the filter clamp. See Figure 40.

Standard-Duty Heavy-Duty

Filter element

Clamp

Air intake elbow

Figure 40 Standard-Duty and Heavy-Duty Air Intake Systems

TP-7153 5/24 59
5.2.1 Heavy-Duty Air Filter (KD3500, KD4000)

Bolt
Flanged inlet pipe
Washer
Clamp
Air-cleaner bracket
Inlet-air-pipe bracket

Air-cleaner
bracket

Clamp Left
(controller)
side

Nuts

Right side
Nut

Figure 41 Flanged Inlet Pipe and Air-Cleaner Brackets

1. Position the two air-cleaner brackets on the inlet-air-pipe brackets. Secure with the bolts, washers, and nuts. See
Figure 41.

Mounted inlet pipe

Bolts
Washers Bolts
Nuts
Angle Washers
Cross brace
brace

Bolts Nuts

Washers Nuts

Spacer

Figure 42 Cross Braces and Angle Braces

2. Secure the cross brace to the air-cleaner brackets. See Figure 42.

3. Secure the angle braces. Use the spacer blocks as shown in Figure 42.

4. Secure the two mounted inlet pipes to the air-cleaner brackets.

60 TP-7153 5/24
 Spacer
Washers
Air-cleaner support beam Bolts
Nuts

Cross brace

Bolts

Washers

Cross brace

Figure 43 Air Cleaner Support Beams

5. Secure the air-cleaner support beams to the generator set frame.

6. Secure the cross braces to the support beams. Use the hardware and spacers as shown in Figure 43.

Bolts

Top support beam

Washers

Air cleaner clamps

Nuts
Bolts

Nuts
Washers

Figure 44 Air Cleaner Support and Clamps

7. Secure the top support beam to the air-cleaner support beams. See Figure 44.

8. Position and secure the air cleaner clamps to the top support beam.

TP-7153 5/24 61
 Weep cover (should face down;
swap with weep cap if needed)

Air cleaner

Weep cap (should be on top of the

air cleaner; swap with weep cover
if needed)

Figure 45 Air Cleaner Positioning

9. Position the air cleaners. See Figure 45.

Note:
If needed, swap the weep cover and the weep cap so the weep cover is on the bottom.

Coupling
Pipe
Clamps

45˚ elbow Pipe

Clamps Coupling

Clamps

45˚ coupling

Clamp
Air intake
elbow

Figure 46 Interior Pipe

10. Connect the interior pipe to the middle air cleaner and the air intake elbow. Secure with clamps. See Figure 46.

62 TP-7153 5/24
 Coupling

Pipe
Coupling

Pipe
Clamp
Coupling
Clamp
45˚ coupling
Clamp

Clamps Air intake

elbow
Pipe

Clamp
Air intake elbow
Coupling

Clamps
Coupling

Figure 47 Right-Side Exterior Pipes

11. Connect the right-side exterior pipes to the right-side air cleaners and the air intake elbows. Secure with clamps. See
Figure 47.

Coupling Clamp

Pipe

Pipe

Clamp

Clamp

Clamp
45˚ coupling
Air intake elbow

Clamp

Air intake elbow

Figure 48 Left-Side Exterior Pipes

12. Connect the left-side exterior pipes to the left-side air cleaners and the air intake elbows. Secure with clamps. See
Figure 48.

TP-7153 5/24 63
 Left Side Right Side

Wiring harness connection

ZIP ties

ZIP ties

Figure 49 Air Intake Wiring Harness Connections

13. Connect the wiring harness to the left-side intake elbows. Use ZIP ties to secure the harness. See Figure 49.

14. Connect the wiring harness to the right-side intake elbows. Use ZIP ties to secure the harness.

64 TP-7153 5/24
5.3 Battery charger (KD3500, KD4000)
DANGER Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.

Grounding electrical equipment. Hazardous voltage will 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 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.

Installing the battery charger. Hazardous voltage will 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 will 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).

Short circuits. Hazardous voltage/current will 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.

Note:
On more recent KD3500-KD4000 models, the generator sets ship with the air intake system and battery chargers installed.
When applicable, use the following instructions, as needed, to install any components that were removed due to shipping
requirements.

Grommet

Vibromount

Lock washer

Standard battery chargers

Redundant battery chargers

Figure 50 Grommets and Vibromounts

TP-7153 5/24 65
 1. Insert grommets into the holes in the generator set skid to prevent damage to the wiring harness.

2. Place a lock washer onto the vibromount studs and tighten the vibromounts in the threaded holes in the generator set
skid. See Figure 50.

Standard Battery
Chargers
Oil cooler

Standoffs Redundant Battery

Chargers
Washer

Support bracket

Bolt (M933-12020-60)
Bolt (M933-08016-60)

Washer
Vibromount
Lock washer

Figure 51 Support Bracket Installation

3. Use the bolts (M933-08016-60), washers, and lock washers to mount the vibromounts to the support brackets. Tighten
to 25 Nm (18 ft. lbs.). See Figure 51.

4. Align the support brackets with the standoffs on oil cooler and secure with the bolts (M933-12020-60) and washers.
Tighten to 53 Nm (39 ft. lbs.).

Bolt (M933-08016-60)
Lock washer

Washer
Nut (M6923-08-80)

Lock washer

Vibromount

Figure 52 Support Bracket and Battery Charger Mounting Bracket

Note:
Apply lock washers to both sides of the vibromounts.

5. To secure the battery charger mounting bracket:

66 TP-7153 5/24
 a. Place a lock washer over the bottom vibromounts. Position the battery charger mounting brackets and loosely
secure to the bottom vibromounts with washers and bolts (M933-08016-60). Tighten to 25 Nm (18 ft. lbs.). See
Figure 52.

b. Use a washer and nut (M6923-08-80) to secure the battery charger mounting bracket to the support bracket.
Tighten to 25 Nm (18 ft. lbs.).

Stud

Battery charger

Nut (M934-04-50)

Standard battery chargers

Redundant battery chargers

Figure 53 Battery Charger Installation

6. Route the wiring harness, battery cables, and power supply plug through the skid.

7. To secure the battery charger to the battery charger mounting bracket:

a. Position the battery charger onto battery charger mounting brackets. Refer to Figure 53.

b. Align the threaded studs on the battery charger mounting brackets with the holes in the battery charger flanges.

c. Tighten the nuts (M934-04-50) to 2.9 Nm (2.1 ft. lbs.).

TP-7153 5/24 67
 Standard Battery Chargers Redundant Battery Chargers

ADV-9203/ADV-9204

Figure 54 Wiring Harness Connections

8. Connect the wiring harness from the battery charger to the generator set wiring harness. Refer to Figure 54 and the
generator set wiring diagram.

9. Connect the positive and negative cables to the engine starter motor.

10. Plug each battery charger into a 120 VAC power supply. Refer to the section on “Component and Accessory Power
Source Requirements.”

68 TP-7153 5/24
 Section 6. Air and Cooling

6.1 General
Combustion and heat dissipation require an ample flow of clean, cool air regardless of whether the generator set is air- or liquid-
cooled. Approximately 65% of the heat value of fuel consumed by an engine is lost through the cooling and exhaust systems.

Battery compartment ventilation.

To prevent the accumulation of explosive gases, ventilate compartments containing batteries.

6.2 Liquid-Cooled Engines

6.2.1 System Features

Generator sets designed for interior installation feature liquid cooling systems. The three most common liquid cooling systems
are unit-mounted radiator, remote radiator, and city-water cooling. Observe the common installation considerations outlined
below as well as the installation considerations for your generator set’s cooling system as detailed in subsequent sections.

TP-7153 5/24 69
6.2.2 Installation Considerations

Intake and outlet openings

Provide air intake and air outlet openings for generator sets located in a building or enclosure. Keep air inlets and outlets clean
and unobstructed. Position the air inlet into the prevailing wind and the air outlet in the opposite direction. The recommended
airflow path should flow over the engine and generator set, passing over the alternator first and then the engine.

Elevated outdoor installations

If the generator set enclosure is mounted on multiple pads, in cases where a single pad is not practical such as an uneven
building roof, it may cause discharge air recirculation under the unit. Enclosures are constructed with the intent of single pad
mounting where the unit is sealed to prevent discharge air recirculation. If multiple pad installation is unavoidable, use a single
pad above the multiple pads and fabricate flashing/skirting around the multiple pads to minimize unwanted discharge air
recirculation.

Ventilating fans

Some buildings tend to restrict airflow and may cause generator set overheating. Use ventilating fans and/or ductwork to increase
airflow in the building if the generator set’s cooling fan does not provide adequate cooling. See Figure 55. Remote radiator and
city-water cooled models require ventilating fans. When using ductwork and ventilating fans, check the exhaust fan capacity in
m3/min. (cfm). If using exhaust fans, install fan-operated louvers with exhaust fans to regulate airflow. Follow the fan
manufacturer’s recommendations to determine the size of the inlet and outlet openings.

Ventilating Fans Exhaust Fan-Operated Louvers

Figure 55 Ventilating Fan and Exhaust Fan-Operated Louvers

Thermostatically-controlled louvers

Do not allow uncontrolled recirculation of air within an enclosure. The ventilation system must provide a temperature differential
sufficient to prevent high engine temperature shutdown on even the hottest days.

In areas of great temperature variation, install movable louvers to thermostatically regulate airflow and room temperature. See
Figure 56. In the following subsection, Unit-Mounted Radiator Cooling, refer to “Louver use” under Installation Considerations
for further information.

Stationary Air Inlet Louvers Moveable Air Inlet Louvers

Figure 56 Stationary Air Inlet Louvers and Moveable Air Inlet Louvers

70 TP-7153 5/24
In cold climate interior installations using controlled recirculation to recover heat, install thermostatically activated louvers and
fans to prevent the generator set and engine room from overheating.

Electric louvers are usually connected to the optional generator set run relay. Typically, the louvers are energized to open when
the generator set is operating. However, some louvers are energized to close and when deenergized are spring-actuated to
open when the generator set is operating.

Filters

Install a furnace-type or similar filter in the inlet opening if the generator set operates in an atmosphere highly contaminated with
impurities such as dust and chaff.

Air restrictions

When using a filter, screen, or other air restriction, increase the inlet opening size by the following amounts as a general principle
to compensate for diminished airflow:

• Louvers: Enlarge the opening 50%.

• Window screening: Enlarge the opening 80%.

• Furnace-type filters: Enlarge the opening 120%.

Engines have maximum air intake restrictions. Refer to the respective generator set specification sheet for specific requirements.

6.2.3 Recommended Coolant

All applications require antifreeze/coolant protection. Refer to the Kohler engine operation manual for engine antifreeze/coolant
specifications, concentration levels, and inhibitor selection recommendations.

Add antifreeze/coolant before starting the generator set or energizing the block heater(s). The antifreeze/ coolant and additive
mixture reduces corrosion, sludge formation, and cavitation erosion and provides boil and freeze protection.

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6.3 Unit-Mounted Radiator Cooling
The unit-mounted radiator is the most common cooling system for engine-driven generator sets.

6.3.1 System Features

The system’s major components include an engine-driven fan and circulating water pump, a radiator, and a thermostat. The
pump circulates water through the engine until it reaches operating temperature. Then the engine thermostat opens, allowing
water circulation through the radiator. The thermostat restricts water flow as necessary to prevent overcooling. The fan blows
air from the engine side of the radiator across the cooling surface.

6.3.2 Installation Considerations

Figure 57 shows a typical unit-mounted radiator installation. Note the direction of airflow and refer to the figure as needed during
installation.

Air inlet opening

Ductwork mounting flange

Air outlet duct

Support legs

Flexible section with

Pusher fan radiator duct flange

Figure 57 Radiator-Cooled Generator Set Installation

Avoid suction fan use.

The alternator airflow should move in the same direction as the engine’s standard pusher fan. Using a suction fan to reverse
airflow is not recommended because it may interfere with the alternator cooling airflow. This in turn reduces the maximum engine
power available because higher temperature combustion air is drawn into the air cleaner

Use ductwork to direct airflow.

Direct the radiator air outside the room or enclosure using sheet metal ductwork with structural supports. Keep ductwork as
short, straight, and unobstructed as possible. Combined static pressure restrictions greater than 0.12 kPa (0.5 in. water column)
on the radiator inlet and outlet openings cause reduced airflow and contribute to overheating especially in high ambient air
temperatures. Use heavy canvas, silicone rubber, or similar flexible material for the connection between the radiator duct flange
and the ductwork to reduce noise and vibration transmission.

72 TP-7153 5/24
Outlet and inlet location and sizing.

Consult TIB-118 for cooling system capability and size the intake and discharge louver to correlate to the desired room restriction.
If the pressure drop is not available, size the outlet duct area to at least 50% larger than the radiator duct flange area. Size the
inlet air opening to at least 100% larger than the radiator duct flange area.

If screens, louvers, or filters are used on either the inlet or outlet, increase the inlet or outlet size according to the
recommendations given in the previous section on Installation Considerations.

Since the exhaust air of larger units is both high volume and high velocity, direct the exhaust flow away from areas occupied by
people or animals.

Louver use.

Design temperature-controlling louvers to prevent air inlet restrictions and air pressure reductions inside the building. Low
building pressure can extinguish pilot lights on gas-fired appliances or cause problems with the building ventilation system.

Additionally, bringing large quantities of winter air into a building wastes building heat and risks frozen water pipes in normally
heated spaces. Use dampers and controlled air outlet louvers as shown in Figure 58 to eliminate these problems and allow
recovery of engine heat to reduce building heat loss. Close the louvers to the exterior and open the interior louvers when the
outdoor temperature is below 18°C–21°C (65°F–70°F). Reverse the louver settings when the outdoor temperature is above
21°C–24°C (70°F–75°F).

Interior
Exterior
Air outlet duct

Generator set

Controlled air
outlet louvers

Dampers

Figure 58 Air Control Louvers

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6.4 Remote Radiator Cooling
A remote radiator system allows installation of generator sets in locations where it would otherwise be difficult to bring the volume
of air required to cool a unit-mounted radiator. In these systems, the engine water pump pushes coolant through a radiator
mounted remotely from the generator set and, typically, in an open area. An electric motor-driven fan mounted on the radiator
circulates air across the radiator’s cooling fins.

The remote radiators have a Secondary Expansion Deaeration and Drawdown (SEDD) tank. This SEDD tank can be connected
to the radiator either as an open or closed tank system. Closed SEDD tanks are typically used when the remote radiator is in
close proximity to the generator set and open SEDD tanks are typically used when the remote radiator is located further away.

In order to assess a remote radiator cooling system, the cooling system designer needs the following data. From the respective
generator set or engine specification sheet, obtain the:

• Engine jacket water flow, Lpm (gpm).

• Cooling air required for generator set based on 14°C (25°F) rise.

• Maximum static (vertical) head allowable above engine, kPa (ft. H2O).

• Heat rejection to coolant.

• Maximum water pump inlet restriction kPa (psi).

• Maximum allowable coolant pressure differential external to engine kPa (psi).

o For KD27V12, KD36V16, and KD45V20 engines:

- Charge air cooler off engine system restriction should not exceed 10 kPa (1.45 psi).

- High temperature (jacket water) off engine system restriction should not exceed 70 kPa (10.15 psi).

o For KD62V12, KD83V16, and KD103V20 engines:

- The low temperature (water cooled charge air) and high temperature (jacket water) off engine system
restriction should not exceed 70 kPa (10.15 psi).

• Maximum top tank temperature for all KD engines is 100°C (212°F).

o For KD EPA certified engines:

- The KD27V12, KD36V16, and KD45V20 engines air circuit is charge air cooled and the charge air circuit
temperature exiting the charge air cooler and returning to the engine should be sized such that the air
temperature will not exceed a 20°C (36°F) rise over the ambient temperature at rated load.

- The KD62V12, KD83V16, and KD10320 engines air circuit is water cooled through an on-engine heat
exchanger and the water temperature exiting the off engine radiator and returning to the engine should be
sized such that the water temperature will not exceed a 20°C (36°F) rise over the ambient temperature at
rated load.

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6.4.1 General

System limitations.

Cooling systems are limited by radiator cap ratings. The maximum radiator operating pressure is 138 kPa (20 psi); however, the
maximum engine operating temperature typically dictates the top tank temperature. Radiators are available for vertical or
horizontal discharge. See Figure 59 and Figure 60.

Air requirements.

Refer to the generator set specification sheet for radiator air and engine/alternator air requirements. Cooling air required for
generator sets equipped with a remote radiator is based on a 14°C (25°F) rise and an ambient temperature of 25°C (77°F). The
amount of air required to ventilate the generator set room or enclosure determines the size of the air inlet and outlet. Configure
the ventilation air inlet and outlet so that air flows across the generator set.

Use a ventilating fan to dissipate alternator and engine heat loss.

Note:
All remote radiators are sized for mounting in an open area with no additional external devices attached. Attached devices,
confined installation, louvers, dampers, ductwork, or other inlet or outlet air restriction require resizing the radiator to compensate
for reduced airflow.

Pressure cap Surge tank/expansion tank

Fill line
Remote vertical radiator Radiator inlet
(horizontal discharge)
Vent line

Shutoff Valve
Engine outlet

Engine water pump

Maximum allowable
static (vertical) head
(varies with engine)
Shutoff valve

Radiator outlet
Suction side
Fill/drain (lowest point of engine)

Figure 59 Remote Vertical Radiator (Horizontal Discharge) System

Horizontal radiator
(vertical discharge) Radiator outlet
Pressure cap Vent line(s)
Shutoff valve
Surge tank/expansion tank Fill line

Radiator inlet Engine outlet

Shutoff valve Engine inlet

Fill/drain (lowest point of engine)

Figure 60 Remote Horizontal Radiator (Vertical Discharge) System

TP-7153 5/24 75
Static (vertical) head.

If the vertical distance from the engine water pump to the radiator (known as static head) is within the engine manufacturer’s
recommendations, and the pressure drop through the piping and remote radiator does not exceed the engine manufacturer’s
limits, use the engine water pump to circulate water through the remote radiator. Check the generator set specification sheet for
the maximum allowable static head. Exceeding the allowable static head causes excessive pressure on engine components
resulting in problems such as leaking water pump seals.

Note:
Size the pressure relief valve or cap to remain under the engine pressure limit.

Hot well tank/heat exchanger.

When the static (vertical) head exceeds the distance stated in the specification sheet, use a hot well tank or heat exchanger and
auxiliary circulating pump as shown in the following section, Vent Lines. Always wire the circulating pump in parallel with the
remote radiator fan so that both operate whenever the generator set operates.

A partial baffle divides a hot well tank into two or more compartments. The engine pump forces heated coolant into the hot side,
and the auxiliary pump then draws the water off and forces it into the radiator. After circulating through the radiator, coolant
drains back to the cold side of the well where the engine water pump removes it. A hot well or heat exchanger also isolates head
pressures from the engine.

Note:
The water in the hot well tank drains into the radiator when the generator set is not running.

Note:
Determine the size requirements of the remote radiator and hot well tank/heat exchanger for each application. Do not use a
standard remote radiator with a hot well tank/heat exchanger.

76 TP-7153 5/24
6.4.2 Vent Lines

Route the vent lines at a continuous upward slope from the engine connection exit to the expansion tank. Port all vent lines
individually into the expansion tank above the coolant level.

Locate the vent lines in the expansion tank to prevent splash on the coolant level sensor. Thoroughly vent the systems by
installing vent lines to all the vent points on the engine and the charge air cooler water circuits including the radiator core(s).
Refer to the installation drawings for vent points.

Size the vent line to 10 mm diameter.

Vacuum relief check valve

Remote radiator

High volume breather

Baffles Expansion space

Vent line (s)
Auxiliary water pump
Shutoff valve

Generator set

Hot well tank

Shutoff valve

Fill/drain (lowest
point of engine)

Figure 61 Compound Remote Radiator/Hot Well Tank Cooling System

Expansion/surge tank
Expansion/surge tank
Remote radiator
Vent line(s)
Vent line
Fill line

Shutoff valve

Generator set
Shutoff valve

Auxiliary water pump

Heat exchanger Fill/drain (lowest point of engine)

Figure 62 Compound Remote Radiator/Heat Exchanger Cooling System

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6.4.3 Charge Air Cooled Engines

KD700 – KD1750 generator sets have charge-air-cooled engines. The charge air pressure drop from the turbocharger to the
intake manifold must comply with the engine limits. Because of this, most remote applications for the charge air cooler will require
an air-to-water heat exchanger mounted locally to minimize the charge air pressure drop.

6.4.4 Fill Lines (Balance or Static)

Connect the fill line(s) close to the water pump inlet. Make the lines as short as possible, continuously descending, and connected
directly before the engine water pump(s). To provide a positive head pressure to the engine water pump inlet, properly locate
the fill line (or makeup line). See the installation drawings for the fill line connection points.

Connect the vent and fill lines to the expansion tank at the greatest possible distance from each other to prevent aeration and
preheating of the coolant returning down the fill line.

6.4.5 Location Considerations

When choosing the radiator’s location:

• For economical installation and operation, locate the radiator as close as practical to the engine and at the same
elevation to reduce piping, coolant, and wiring costs.

• Locate the radiator surge tank fill opening and vent line(s) at the highest point in the cooling system.

• Position the radiator no closer than one fan diameter from a wall, another radiator, or any other obstruction that would
restrict air movement and future service access.

• Locate the radiator to prevent recirculation of the heated exhaust air back into the intake stream.

• Mount the radiator in an area where prevailing winds do not hamper free airflow.

• Locate the radiator where it is not subject to deep snow or ice accumulation, flooding, industrial fallout, leaf
accumulation, heavy dust and chaff, or other detrimental seasonal or environmental conditions.

• For rooftop installations, do not locate the radiator near critical sound areas, building ventilation, or hood exhausts.

78 TP-7153 5/24
6.4.6 Installation Considerations

When installing the remote radiator:

• Use a remote radiator setup kit, if available, to aid installation. See Figure 64.

• Wire the cooling fan motor to the generator set output so that the fan operates whenever the generator set operates.
There is no need for a thermostatic control of the fan motor because the engine thermostat prevents overcooling as it
does on generator set- mounted radiator systems unless noise and power consumption reduction dictate the need.
Follow all applicable national and local codes when wiring the cooling fan.

• Follow the wiring diagram on the remote radiator’s fan motor. The motor rotation must match the fan blade design. The
manufacturer supplies most units with counterclockwise fan rotation as viewed from motor side. The fan is typically a
blower type, moving air from the fan side of the radiator, through the core, and out the front side.

• Preferably, connect no devices to either side of the radiator. Resize the radiator if adding louvers or duct work to the
radiator to compensate for reduced airflow.

• Ensure that the radiator is level and securely bolted to a firm, solid foundation.

• Brace the radiator as needed, especially in areas with strong winds.

• Use isolators to keep area vibration from affecting the radiator or to keep vibration produced by the radiator from
affecting surrounding areas.

• Use hose clamps on all non-threaded connections.

KD700 – KD750

Charge-air-cooled pipe

Belt guard
Jacket water tube

Remote radiator guard

Pulley guard

Charge-air-cooled pipe Jacket water tube

Figure 63 Remote Radiator Setup Kits, KD700 – KD750

TP-7153 5/24 79
 KD800 – KD1000 KD2000 – KD4000

Mounting flange cover

Vent lines

Engine outlet tube,

high temperature circuit

Wire insert hose

Jacket water tube Vent lines

Charge-air-
cooled pipes
Jacket water
Belt guard tube

Pulley guard

Engine outlet tube, low

temperature circuit
Belt guard

Engine inlet tube,

high temperature
Engine inlet tube, circuit
low temperature circuit

Remote radiator guard

Figure 64 Remote Radiator Setup Kits, Typical

80 TP-7153 5/24
6.4.7 Surge (Expansion) Tank for Horizontal Discharge Radiator

A horizontal discharge remote radiator requires the use of a surge (expansion) tank. Locate the tank at the highest point in the
cooling system. The surge tank provides venting, surge/ expansion protection, and filling/makeup functions.

• The cooling system top tank should be designed to include a drawdown volume of 5-8%, a deaeration volume greater
than 10% and an expansion volume that is typically 8-10% of the system volume (thus a typical top tank is ~25% of the
total system volume). See Figure 65.

Drawdown Volume Typical 5-8%

Deaeration Volume Typical >10%
Expansion Volume Typical 8-10% fluid
Total Tank Approximately 25% total system volume
Figure 65 Recommended Cooling System Top Tank Sizing
• Locate the coolant level sender at a height that is above the drawdown level so the coolant level sender activates
before air is ingested into the coolant.

• Locate the coolant level sender in a location where there is minimal agitation to prevent splashing on the coolant level
sender.

• Equip the surge tank with a sight-glass gauge, overflow tube, and pressure cap.

• Connect the main line from the surge tank to the highest point of the remote radiator. Most vertical core radiators have
the surge tank as part of the radiator top tank. The setup illustrated in the previous figure provides for radiator and
engine deaeration and a positive pressure at the pump suction inlet.

• Use a strainer to filter dirt, scale, and core sand from the coolant line.

Piping

Size water piping between the engine and the remote radiator large enough to eliminate the need for a booster pump. If the
cooling system requires a booster pump, contact your distributor/dealer.

Use piping of ample size and with as few short sweep bends or elbows, tees, and couplings as possible. Use long sweep elbows
or long bends, if bends are required.

Installation

Support piping externally, not from the radiator or engine.

On standard remote radiators, connect radiator bottom outlets only to the suction side of the pump. Plumb the lines to prevent
air from becoming trapped in the lines. Route piping in one general direction, either upward or downward. A combination of both
upward and downward piping creates air pockets in the piping. Route vent lines to the expansion/surge tank without creating
low spots in the lines.

Flexible connections

Provide flexible connections when connecting piping to the radiator assembly. Use hose clamps at all non-threaded connections.

Shutoff valves

Locate shutoff valves between the engine and cooling system to allow for isolation of both the radiator and the engine. A shutoff
valve eliminates the need to drain the entire cooling system during service.

6.4.8 Procedure to Fill a Remote Cooling System

1. For radiators designed for full deaeration:

a. Fill the cooling system from the bottom when possible. Otherwise, fill the radiator at the filler neck.

b. Continue filling the system to cover the filler neck bottom until coolant appears in the sight glass located in the
radiator top tank.

TP-7153 5/24 81
 2. For radiators designed without deaeration:

a. Initially, fill the radiator through one of the top tank inlets located before the final hose connection for faster and
more complete fillup.

b. Fill the cooling system from the bottom when possible. Otherwise, fill the radiator at the filler neck with coolant
covering the filler neck bottom until coolant appears in the sight glass located in the radiator top tank.

3. For models KD2000-KD4000, use the manual engine venting ports to bleed trapped air from the system. Refer to the
engine operation manual for the venting locations on the water pumps, thermostat housing, and engine block. See
Figure 66.

Note:
To open the venting ports, thread the venting tool into the port.

4. Leave the radiator cap off and run for 5 minutes with no load.

5. Stop the engine and allow it to cool.

6. Check and repair any coolant leaks.

7. After initial startup, check coolant levels and add coolant as necessary.

Engine block, above the flywheel Oil cooler, near the oil filters Water pumps

Engine Control Units, ECUs

Figure 66 Engine Coolant Venting or Bleeding, KD2000-KD4000

82 TP-7153 5/24
6.4.9 Checks after Initial Startup

If any problems arise during startup, immediately shut down the generator set. See Figure 67, Cooling System Checklist. Even
after a successful startup, shut down the generator set after 5-10 minutes and recheck the belt tension to make sure no hardware
has loosened during operation. Perform another recheck after 8-12 hours of operation.

 Operation
Verify the cooling fan’s position in the fan shroud.
Check the mounting hardware.
Check the fan motor for free rotation.
Check V-belts for alignment and tension.
Fill the system with coolant and check all connections for tightness and leaks.
Verify that all electrical connections are secure and that the power source matches the motor nameplate.
Verify that no loose foreign material is in the fan’s air
With the unit running, check for:
fan clearance
excessive vibration
excessive noise
coolant leaks
Figure 67 Cooling System Checklist

6.5 City Water Cooling

6.5.1 System Features

City water-cooling systems use city water and a heat exchanger for cooling. They are similar to remote radiator systems because
they require less cooling air within the generator set room than unit-mounted radiator systems. Figure 68 shows some of the
elements of a typical installation.

The heat exchanger limits the adverse effects of city water chemistry to one side of a heat exchanger, which is relatively easy
to clean or replace, while engine coolant circulates in a closed system similar to the radiator system. The heat exchanger allows
engine temperature control, permits the use of antifreeze and coolant conditioners, and is suited to the use of an engine block
heater as a starting aid.

Coolant expansion
Coolant tank pressure cap
expansion tank Ventilation fan (for heat rejected
from exhaust and engine)

Connect heat
exchanger inlet to
city water supply
Flexible section

Manual shutoff valve

City water supply

Side View End View

Connect heat exchanger Heated city water
Solenoid valve outlet to floor drain into floor drain
Heat exchanger

Figure 68 City-Water Cooling System with Heat Exchanger

TP-7153 5/24 83
6.5.2 Installation Considerations

Vibration isolation requirements

Use flexible hose sections at all times between the engine coolant parts and coolant pipes.

Shutoff valve location

A solenoid valve mounted at the inlet connection point automatically opens when the generator set starts, providing the engine
cooling system with pressurized water from city water mains. This valve automatically closes when the unit shuts down. Use an
additional customer-supplied valve ahead of the entire system to manually shut off city water for generator set service.

6.6 Cooling Tower

A cooling tower system is a variation of a city water cooling with heat exchanger system. In warm, dry climates, a cooling tower
is a suitable source of generator set cooling water.

A cooling tower system consists of the engine cooling system plus a raw-water system. The engine cooling system usually
includes the engine water pump, a heat exchanger, a surge tank, and the engine water jacket. The raw-water system consists
of the cooling tower, a raw-water pump, and the tube portion of the heat exchanger. A typical system is shown in Figure 69.
The engine cooling system circulates coolant through the heat exchanger outer shell. Raw water circulates through the heat
exchanger tubes absorbing heat from the engine coolant. The heated raw water flows into a pipe at the top of the cooling tower
and sprays down into the tower to cool by evaporation. Because some water is constantly being lost through evaporation, the
system must provide makeup water.

Makeup water connection

Surge tank

Engine water
pump

Cooling tower

Auxiliary water pump Cooling tower drain

Heat exchanger drain
Heat exchanger

Figure 69 Cooling Tower System

6.7 Block Heaters

Block heaters are available as installed accessories on all generator sets. Generator sets installed in NFPA applications
generally require use of a block heater. Equip generator sets with block heaters on all standby applications where the generator
set is subject to temperatures below the value stated on the respective generator set specification sheet. Connect the block
heater to a power source that is energized when the generator set is not running. The block heater thermostat temperature is
set for optimum operation based on the respective engine cooling characteristics.

Note:
Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Before energizing
the block heater, fill the cooling system, run the engine until it is warm, and refill the radiator to purge the air from the system.

84 TP-7153 5/24
 Section 7. Exhaust System

Satisfactory generator set performance requires proper exhaust system installation. The following sections detail arrangements
of typical exhaust systems and exhaust system components.

7.1 Flexible Exhaust Line

Install a section of steel flexible exhaust line at least 305 mm (12 in.) long within 610 mm (2 ft.) of the engine exhaust outlet. See
Figure 70 and Figure 71.

Supports

Flexible section
Silencer Pitch line downward

Water trap
Drain
Solid section petcock

Manifold

Figure 70 Exhaust System, End Inlet Silencer

45° Y fitting

Silencer Exhaust wall thimble

45° elbow
Water trap
Drain petcock
Outer diameter adapter and clamp

Flexible section

Manifold

Figure 71 Exhaust System, Side Inlet Silencer

The flexible line limits stress on the engine exhaust manifold or turbocharger. Never allow the engine manifold or turbocharger
to support the silencer or exhausting piping.

Note:
Do not bend the flexible section or use it to compensate for misalignment between the engine exhaust and the exhaust piping.

TP-7153 5/24 85
7.2 Condensation Trap
Some silencers are equipped with a drain pipe plug for draining condensation; see Figure 72. Otherwise, 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 73. The
trap prevents condensed moisture in the engine exhaust from draining into the engine after shutdown. Periodically drain collected
moisture from the trap.

Pipe Plug

Figure 72 Silencer Condensation Drain Plug

Condensation Trap

Figure 73 Condensation Trap

7.3 Piping
Note:
Select piping with a diameter that is the same size as, or larger than, the manifold outlet’s inside diameter.

• Keep exhaust lines as short and straight as possible.

• Use schedule 40 black-iron pipe.

• Use sweep elbows with a radius of at least three times the pipe diameter wherever possible to minimize restriction.

• Use exhaust piping that conforms to applicable codes.

• Support the exhaust piping securely, allowing for thermal expansion. Assure the piping is not placing a high mount load
on the turbocharger, when applicable.

• Insulate the exhaust piping with high-temperature insulation to reduce the heat rejected by exhaust piping and
consequently the amount of ventilating air required and the temperature rise to radiator core.

In general, exhaust temperatures measured at the engine’s exhaust outlet are less than 538°C (1000°F), except for infrequent
brief periods; therefore, low-heat appliance standards apply. Each generator set specification sheet provides exhaust
temperatures.

For units with exhaust temperatures below 538°C (1000°F), route the exhaust piping a minimum of 457 mm (18 in.) from
combustible material, including building materials and natural surroundings. If exhaust temperatures exceed 538°C (1000°F),
the minimum distance is 914 mm (36 in.).
When planning exhaust silencer and piping placement, consider the location of combustible materials. Insulating the exhaust
system piping downstream of the turbocharger is acceptable, however it is not acceptable to apply an insulation wrap to the
turbocharger. 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

86 TP-7153 5/24
include building materials as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material
a safe distance from the exhaust system.

7.4 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 74 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.

Gradual U bend

Rain cap (or

gradual U bend) Rain shield

254 mm (10 in.) minimum Outer sleeve

Inner sleeve
Ventilation holes at both ends

Flashing Exhaust pipe

diameter Thimble outer
25 mm (1 in.) minimum diameter
25 mm (1 in.)
minimum outside
254 mm (10 in.)
minimum
254 mm (10 in.) 254 mm (10 in.)
minimum inside minimum outside
Ventilation holes at both ends Exhaust pipe

Figure 74 Double-Sleeved Thimbles and Rain Cap

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 the
following section on Exhaust Outlet for additional exhaust outlet location and protection considerations.

TP-7153 5/24 87
7.5 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
intake air filters and radiator adversely affects engine cooling and engine performance. Locate the exhaust outlet to prevent
exhaust fumes from entering a building or enclosure.

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. In a climate where freezing is
common, check the installation and see if there is a risk that the rain cap could freeze in a closed position. The recommended
option is to 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 or utilize a mitered horizontal pipe discharge. Keep the pipe outlet at least 457 mm (18 in.)
from the roof to prevent hot exhaust from igniting the roof material.

Generator set with enclosure

To avoid exceeding the engine manufacturer’s maximum allowable backpressure specification, enclosure tail pipe extensions
or attachments are not recommended.

88 TP-7153 5/24
7.6 Exhaust System Backpressure
Exhaust backpressure limits engine power and excessive backpressure causes serious engine damage. Excessive
backpressure usually results from one or more of the following reasons:

• The exhaust pipe diameter is too small.

• The exhaust pipe is too long.

• The exhaust system has too many sharp bends.

• The exhaust silencer is too small.

• The exhaust silencer is not the correct design for the application.

Use the following procedure to verify that the installed exhaust system does not exceed the engine’s maximum exhaust
backpressure limit as specified in the generator set specification sheet.

Exhaust System Backpressure Calculation Procedure

Determine the total backpressure by calculating the effects of the individual exhaust system components and adding the results.
Make calculations using either English or metric units. Exhaust pipe references are nominal pipe NPT (in.) sizes. The procedure
shows an example with italic text. Calculations relate to end inlet silencers.

Note:
When calculating backpressure drop for side inlet silencers, use the end inlet values shown and add 0.75 kPa (0.25 in. of mercury
or 3.4 in. of water) to backpressure calculations.

1. Select the exhaust silencer type for the application—hospital, critical, residential, or industrial. See the silencer
specification sheet for definitions for each exhaust silencer type. Confirm silencer type availability for your generator
set with your authorized distributor/dealer, as some generator sets do not use all four types.

Example: Determine the silencer backpressure for the recommended critical silencer on a 230 kW, 60 Hz diesel
generator set.

2. Refer to the generator set specification sheet for:

a. Engine exhaust flow at rated kW in m3/min. (cfm)

Example: 57.5 m3/min. (2030 cfm)

b. Maximum allowable backpressure in kPa (in. of Hg)

Example: 10.2 kPa (3.0 in. Hg)

3. Refer to the submittal catalog for:

a. The recommended critical silencer part number

Example: 343616

b. Silencer inlet diameter in mm (in.)

Example: 152 mm (6 in.)

c. Silencer inlet position (end or side)

Example: end inlet

d. The flexible exhaust adapter part number

Example: 343605

e. Flexible exhaust adapter, flexible section length

Example: 857 mm (33.75 in.)

TP-7153 5/24 89
 4. Determine the exhaust gas velocity through the silencer as follows:

a. Using the exhaust silencer inlet diameter determined in step 3, determine corresponding inlet area using Figure
75.

Example: 0.0187 m2 (0.201 sq. ft.)

b. Use this data to calculate the exhaust gas velocity. Divide the engine exhaust flow from step 2 in m3/min. (cfm) by
the silencer inlet area m2 (sq. ft.) to get flow velocity in m (ft.) per minute.

Example:
57.5 m3/min. / 0.0187 m2 = 3075 m/min. (2030 cfm / 0.201 sq. ft. = 10100 ft./min.)

Nominal Pipe Size, in. NPT Inlet Area, m2 Inlet Area, ft2
1 0.00056 0.0060
1¼ 0.00097 0.0104
1½ 0.00131 0.0141
2 0.00216 0.0233
2½ 0.00308 0.0332
3 0.00477 0.0513
4 0.00821 0.0884
5 0.0129 0.139
6 0.0187 0.201
8 0.0322 0.347
10 0.0509 0.548
12 0.0722 0.777
14 0.0872 0.939
16 0.1140 1.227
18 0.1442 1.553
Figure 75 Cross Sectional Area for Standard Silencer Sizes
5. Refer to Figure 76. Use the exhaust gas velocity determined in step 4 and find the exhaust gas velocity value in
thousands on the bottom scale. Move vertically up until this value intersects the curve of the corresponding silencer
type as determined in step 1. Move left on the horizontal axis and determine the backpressure drop value in kPa (in. of
Hg).

Example: Exhaust velocity, 3075 m/min. (10100 ft./ min.) intersects with critical silencer curve B and the corresponding
backpressure value is approximately 2.8 kPa (0.85 in. of mercury). Silencer type is end inlet from step 3 information
with no additional backpressure drop value per the following note.

Note:
When calculating backpressure drop for side inlet silencers, use the end inlet values shown and add 0.75 kPa (0.25 in.
of mercury or 3.4 in. of water) to backpressure calculations.
Note:
Refer to Figure 77 to calculate in inches of water and feet per minute.

90 TP-7153 5/24
 6. Total the number of elbows and flexible sections in the exhaust system between the engine and the exhaust system
outlet. Compare the radius of the bend (R) to the pipe diameter where (D) is the nominal pipe diameter in inches.
Determine the equivalent length in m (ft.) of straight pipe for the elbows and flexible sections from the following:

Bend Angle Type Bend Radius Conversion Factor

90° Close R=D 32 x D* / 12
90° Medium R = 2D 10 x D* / 12
90° Sweep R = 4D 8 x D* / 12
90° Close R=D 15 x D* / 12
90° Sweep R = 4D 9 x D* / 12
Flex Sections 2 x Length** / 12

* Use the diameter of the silencer inlet in inches from step 3 for the initial calculation. If
the results from step 9 indicate excessive backpressure drop, then recalculate using
the larger-diameter pipe size selected.

** Use the flexible exhaust adapter length from step 3 and add any additional flex sections
in the exhaust system expressed in inches

Convert the equivalent pipe length calculated in feet to meters using ft. x 0.305 = m, as needed.

Examples:

45° sweep elbows:

9 x 6.0 in. / 12 = 4.5 equiv. ft. or 1.4 equiv. m

90° close elbows:

32 x 6.0 in. / 12 = 16.0 equiv. ft. or 4.9 equiv. m

Flexible sections:

2 x 33.75 in. / 12 = 5.6 equiv. ft. or 1.7 equiv. m

Equivalent of straight pipe:

4.5 + 16.0 + 5.6 = 26.1 equiv. straight ft.

1.4 + 4.9 + 1.7 = 8.0 equiv. straight m

TP-7153 5/24 91
 kPa in. of Hg A B

Pressure
Drop A = Hospital Silencer
B = Critical Silencer
C = Residential Silencer
D = Industrial Silencer

Note:
When figuring the silencer
pressure drop for side inlet, add
0.75kPa (0.25 in. of mercury or 3.4
in. of water) to the backpressure.

(m/min)

(ft./min)

Exhaust Gas Velocity in Thousands

Figure 76 Silencer Backpressure Drop (in. of Hg)

mm of Water in. of Water
A B

A = Hospital Silencer
C B = Critical Silencer
C = Residential Silencer
D = Industrial Silencer
D

Note:
When figuring the silencer
pressure drop for side inlet, add
0.75kPa (86 mm of water or 3.4 in.
of water) to the backpressure.

(m/min)
(ft./min)

Exhaust Gas Velocity in Thousands

Figure 77 Silencer Backpressure Drop (in. of water)

92 TP-7153 5/24
 7. Determine the total length of straight pipe used in the exhaust system. Add this calculation to the equivalent length for
elbows and flexible sections obtained in step 6.

Example:

Straight pipe = 3.0 m (10 ft.).

Equivalent straight pipe from step 6: 8.0 m (26.1 ft.)

3.0 m + 8.0 m = 11.0 m or

10 ft. + 26.1 ft. = 36.1 ft. total

8. Refer to Figure 78 if the pipe size is 102 mm (4 in.) or less or Figure 79 if the pipe size is 127 mm (5 in.) or larger.

Place a straight edge across the chart with the edge in line with the pipe size in inches (D) on the right column from
step 3 and the engine exhaust flow (Q) from step 2 on the left column.

Read backpressure kPa/m or in. of Hg/ft. (ΔP) from the center column. Calculate the total piping system backpressure
by multiplying the total equivalent straight pipe in m (ft.) from step 7 by the kPa/m or in. of Hg/ft. of pipe from this step.

Example:

11.0 equiv. m x 0.04 kPa/m =

0.4 total system backpressure in kPa

36.1 equiv. ft. x 0.004 in. Hg/ft. =

0.14 total system backpressure in inches of Hg

9. Add the backpressure of the piping determined in step 8 to the backpressure of the silencer determined in step 5. The
total should not exceed the engine manufacturer’s maximum allowable system backpressure determined in step 2 or
on the generator set’s specification sheet. If the total exceeds the maximum, use a larger pipe size or silencer or both.
Repeat the calculation if new components are selected to verify that the system backpressure would not exceed the
limit using the larger component(s).

Example:

0.4 kPa (step 8) + 2.8 kPa (step 5) = 3.2 kPa Maximum allowable backpressure = 10.2 kPa 3.2<10.2 backpressure
drop is acceptable

0.14 in. Hg. (step 8) + 0.85 in. Hg. (step 5) =

0.99 in. Hg.

Maximum allowable backpressure = 3.0 in. of Hg. 0.99< 3.0 backpressure drop is acceptable

TP-7153 5/24 93
 Q Engine Exhaust Flow

m3/min cfm

D Pipe Diameter

mm inches

D P Backpressure

kPa per m In. Hg per foot

(Cfm x 0.02832 = m3/min.) (in. Hg x 3.387 = kPa) (in. x 25.4 = mm)

Figure 78 Backpressure using Pipe Size 4 in. (102 mm) or Less

94 TP-7153 5/24
 Q Engine Exhaust Flow D Pipe Diameter

mm inches
m3/min cfm

D P Backpressure

kPa per m In. Hg per foot

(Cfm x 0.02832 = m3/min.) (in. Hg x 3.387 = kPa) (in. x 25.4 = mm)

Figure 79 Backpressure using Pipe Size 5 in. (127 mm) or Larger

TP-7153 5/24 95
96 TP-7153 5/24
 Section 8. Fuel System

Comply with applicable state and local codes when installing any fuel system.

WARNING 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.

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 in a well-ventilated area away from 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-7153 5/24 97
The main components of a typical diesel fuel system are a main fuel storage tank, a day tank, fuel lines, and an auxiliary fuel
pump. See Figure 80.

Engine return line

Fuel supply line from day
tank to engine connection Day tank vent

Day tank

Auxiliary
fuel
Tank filling inlet pump

Fuel tank vent

Overflow line Tank

drain

Fuel supply line from main Electric fuel level

fuel tank to day tank control switch

Main fuel storage tank

Foot valve

Figure 80 Diesel Fuel System

98 TP-7153 5/24
8.1 Main Tank

Storage

Because it is less volatile than gas or gasoline, diesel fuel is safer to store and handle. Regulations for diesel storage tank
placement are less stringent than the regulations for gas or gasoline storage. In some locations, large main tanks are permitted
inside the building or enclosure.

Tank location

Locate fuel storage tanks above ground or bury them underground in accordance with applicable codes. Figure 81 shows a
commonly used above-ground subbase tank contained in the generator set mounting base.

Side View End View

Generator Set Skid Subbase Fuel Tank

Figure 81 Subbase Fuel Tank

Tank size

Codes requiring standby power often specify a minimum onsite fuel supply. Such requirements are included in NFPA70, National
Electrical Code, and NFPA99, Standard for Health Care Facilities. Diesel fuel deteriorates if stored for more than one year;
therefore, size the tank to ensure that regular generator set exercising will use the tank’s contents within one year. If there are
no applicable code requirements, the manufacturer recommends a tank sized for eight hours of operation at rated load. Refer
to the generator set specification sheet for fuel consumption data.

Tank venting

Vent the main fuel tanks to allow air and other gases to escape to the atmosphere without allowing dust, dirt and moisture to
enter the tank.

Fuel expansion

Never fill the tank more than 95% full to allow for fuel expansion. On overhead main tanks, use a fuel shutoff solenoid to prevent
hydraulic lock or tank overflow caused by excessive static head fuel pressures.

Fuel specifications

Refer to the engine operation manual for diesel fuel recommendations. Most diesel engines operate satisfactorily on No. 2 diesel
fuel available in most parts of the US. Ensure that the diesel fuel meets the minimum requirements for wax point, pour point,
sulfur content, and cetane number as these factors influence cold weather starting and generator set power output. When
supplying multiple applications from the same main fuel tank, provide each with a separate supply line.

TP-7153 5/24 99
8.1.1 Fuel Tank Monitoring Panel

DANGER Hazardous voltage. Moving parts.

Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.

Short circuits. Hazardous voltage/current will 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.

Screw caps Enclosure entrance

90%-full fuel
level switch

Fuel Monitoring
panel

Flexible conduit,
GM75504 Flexible conduit,
GM75505

Figure 82 Fuel Monitoring Panel, Overview

The fuel monitoring panel provides visual warning lights and audible alarms for low, 90%-full, and 95%-full tank fuel levels. To
monitor these tank fuel levels, the fuel monitoring panel connects to switches through wiring harnesses that are protected by
flexible conduit. If the fuel tank and the generator set enclosure are shipped separately, the wiring harness may need to be
connected during the installation process. Because the generator set batteries provide DC voltage to power the fuel monitoring
panel, an AC power supply is not needed for this accessory. The following procedure shows the connections for the wiring
harness from the monitoring panel to the connections on the tank and batteries. See the system overview, Figure 82, and the
wiring diagram, Figure 86.

Note:
The enclosure should be installed on the fuel tank before routing the wiring harness.

1. Use the following steps to remove the generator set from service.

a. Press the Emergency Stop (E-Stop) button on the generator set, if equipped.

b. Turn off the generator set by pressing the OFF/RESET button on the generator set controller or placing the
generator set master switch in the OFF position.

c. Disconnect the power to any generator set accessories such as a battery charger.

d. Disconnect the generator set engine starting battery, negative (-) lead first.

e. Disconnect the generator set from load by opening the line circuit breaker.

100 TP-7153 5/24

 Knockout

Enclosure entrance

Figure 83 Enclosure Entrance

2. Locate and remove the knockout in the enclosure base. See Figure 83.

3. To secure the conduit to the enclosure:

a. From the enclosure exterior, insert the threaded end of the flexible conduit through the enclosure wall.

b. On the enclosure interior, use the lock washer to secure the conduit to the enclosure.

4. From the enclosure interior, route wiring harness, GM75504, through the enclosure wall and the flexible conduit.

Screw

Panel Cover

Terminal block

GM75504 GM75505

Figure 84 Panel Cover Removed

5. To remove the cover of the fuel monitoring panel:

a. Remove the five screw caps.

b. Remove the five screws. See Figure 84.

6. To connect the wiring harnesses to the fuel monitoring panel:

a. Insert the wiring harnesses, GM75504 (low fuel, battery power, and 95%-full fuel level), through entry holes in the
bottom of the fuel monitoring panel.

b. Connect the wiring harness to the terminal block as shown in Figure 86.

Note:
The wiring harness, GM75505 (90%-full fuel level), is typically connected at the factory. If harness GM75505 is not
installed, refer to the wiring diagram to complete the connections to the 90%-full fuel level switch.

7. Reposition the cover and secure with the five screws. Replace the screw caps.

TP-7153 5/24 101

 Low fuel level switch

95%-full fuel level switch

Figure 85 Wiring Harness Connections, GM75504

8. Inside the enclosure, make the following connections for the switches.

a. Connect the quick connects 3 and 4 to the 95%-full fuel level switch. See Figure 86.

b. Connect quick connects 5 and 6 to the low fuel level switch.

9. Position the battery ring terminals on the battery studs as follows:

a. Place the red ring terminal over the battery positive (+) stud.

b. Place the black ring terminal over the battery negative (–) stud.

10. Return the generator set to service.

a. Check that the manual key switch, if equipped, is in the OFF position.

b. Check that the Emergency Stop button is activated

c. Reconnect the generator set engine starting battery, negative (–) lead last.

d. Reconnect the power to any generator set accessories such as a battery charger or block heater.

e. Reconnect the generator set to load by closing the line circuit breaker.

f. Reset the Emergency Stop button.

g. Clear the emergency stop fault on the controller.

h. Return the generator set to normal operation by pressing the generator set master control AUTO or RUN button
or by placing the generator set master switch in the AUTO or RUN position, as required.

102 TP-7153 5/24

Figure 86 Fuel Monitoring Panel Wiring Diagram, GM86940 Sheet 2

TP-7153 5/24 103

8.2 Day Tanks
The terms day tank and transfer tank are interchangeable. Having a day tank adjacent to the engine allows the engine fuel
transfer pump to easily draw fuel during startup and provides a convenient location to connect fuel return lines. See Figure 87.

Connect a float-switch-controlled solenoid antisiphon valve or a float valve to prevent siphoning fuel from the main storage tank
if the main tank fuel level is above the day tank inlet.

Tank size

Standard tanks are available in many sizes with or without integral electric fuel transfer pumps. Because engines are subject to
fuel supply temperature power deration above 70°C (158°F), a day tank providing at least four hours of fuel consumption should
be used to provide enough capacity to cool the fuel returning from the engine. If smaller day tanks are used, the generator set
manufacturer may recommend installing a fuel cooler or routing engine fuel return lines to the main storage tank. See Figure 87.

Optional equipment includes fuel level gauges, manual priming pumps, float switches for pump control, float valves, rupture
basins, and low level alarms. Remove the plastic shipping plugs and install metallic pipe plugs in all unused fuel tank ports to
provide a liquid-tight seal.

Vent (to outside)

Overhead main tank

Fuel shutoff solenoid

Return line from fuel pump

Maximum
7.6 m (25 ft.),
minimum
25 mm (1 in.)
Fuel supply line
from main fuel
tank to day tank
Fuel pump Filter
Fuel supply line
Flexible line from day tank to
engine connection

Day tank

Figure 87 Diesel Fuel System with Overhead Main Tank and Day Tank

104 TP-7153 5/24

8.3 Fuel Lines
The following items describe fuel line selection and application. Never use the fuel piping or fuel line clamps to ground any
electrical equipment.

Use Schedule 40 black-iron pipe or other materials which do not contain the below listed elements.

• Barium (Ba) D

• Calcium (Ca)

• Copper (Cu)

• Lead (Pb)

• Magnesium (Mg)

• Phosphorous (P)

• Potassium (K)

• Sodium (Na)

• Zinc (Zn)
These metals react adversely with diesel fuel to form deposits on the fuel system causing a gradual decrease in fuel system
efficiency and eventually can cause fuel system failure. Use of such materials may affect fuel system warranty.

Note:
The KD700 – KD4000 engines require that the above elements are not present in the fuel system components.

Line size

Use the smallest diameter fuel line that still delivers enough fuel to the engine with an acceptable pressure drop of 6.9 kPa (1.0
psi). Using oversize piping increases the chance of air introduction into the fuel system during engine priming, which increases
the potential for fuel pump damage and hard starting.

Flexible connectors

Use flexible connections spanning a minimum of 152 mm (6 in.) between the stationary piping and the engine fuel inlet
connection.

Return lines

A diesel system delivers more fuel to the injectors than the engine uses; therefore, a system has one supply line from the fuel
tank and at least one return line from the fuel pump injectors. See the generator set specification sheet for the recommended
fuel return line size.

Route the return fuel line to either the day tank or the main storage tank. Place the return lines as far away from the pickup or
fuel dip tube as possible to prevent air entry and to keep warm fuel from being reintroduced to the engine. If fuel lines are routed
to the day tank, note the day tank size requirements in the previous section, Day Tanks. Use a baffle between the return lines
and the supply lines, if possible.

A properly designed fuel return line is unrestricted and as short as possible, and it allows gravity return of fuel to the storage
tanks. In installations where gravity return is not possible, obtain approval of the design from the generator set supplier based
upon the engine’s specifications before installing a fuel system with static head pressure on the return lines. Fuel return line
restriction can cause engine hydraulic lock or uncontrollable overspeed on some systems.

TP-7153 5/24 105

8.4 Auxiliary Fuel Pumps
When the installation exceeds the maximum fuel supply restriction, use an auxiliary pump alone or in combination with a day
tank. Limit auxiliary fuel pump pressure to the maximum pump head and pump lift calculated for the installation.

Use a shutoff solenoid valve wired into the engine run circuit or a check valve to help keep the fuel line primed. Install the check
valve on the outlet side of the auxiliary fuel pump to minimize inlet restriction.

Auxiliary fuel pump options.

Use an electric motor-driven positive displacement pump with a day tank and float switch. Electrically connect the fuel pump to
the transfer switch load side for maximum reliability. This type of pump can typically lift fuel 5.2 m (17 ft.) or draw it horizontally
up to 61 m (200 ft.).

Where vertical runs exceed 5.2 m (17 ft.) or horizontal runs exceed 61 m (200 ft.), remote-mount the pump adjacent to the fuel
storage tank. This type of installation allows these pumps to push fuel over 305 m (1000 ft.) horizontally or more than 31 m
(100 ft.) vertically and deliver adequate fuel for generator sets up to 2000 kW. Always connect a positive-displacement pump
directly to a day tank and float switch to protect the engine fuel system from excessive fuel pressures.

106 TP-7153 5/24

 Section 9. Electrical System

WARNING 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.

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 generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.

(APM603 Controller)

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 generator set as follows: (1) Shut down the generator set. (2) Place the controller
in Out of Service mode. (3) Press the emergency stop button. (4) Disconnect the power to the battery charger, if equipped. (5)
Remove the battery cables, negative (–) lead first. Reconnect the negative (–) lead last when reconnecting the battery. Follow
these precautions to prevent the starting of the generator set by the remote start/stop switch.

(APM802 Controller)

DANGER Hazardous voltage. Moving parts.

Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.

Short circuits. Hazardous voltage/current will 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.

TP-7153 5/24 107

9.1 Electrical Stub-up Areas
Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories
for the generator set. Carefully install the selected generator set accessories. Route wiring to the generator set through flexible
connections. Regarding the application of bushings and grommets for the entry of wiring, use Class 1 wiring methods for field
wiring connections to a Class 2 circuit. Comply with applicable national and local codes when installing a wiring system.

AC circuit protection

All AC circuits must include circuit breaker or fuse protection. Select a circuit breaker for up to 125% of the rated generator set
output current. The circuit breaker must open all ungrounded conductors. The circuit breaker or fuse must be mounted within
7.6 m (25 ft.) of the alternator output terminals.

Figure 88 provides a typical example of stub-up locations for electrical connections and various available accessories. Stub-up
locations and dimensions vary depending on the generator set model, voltage rating, and available accessories. Refer to the
generator set drawing for specific locations and dimensions.

Load lead conduit (only when breakers Battery rack, optional

or load bus are on the left side) Controller
conduit Fuel return
Redundant battery Fuel supply
charger conduit

Redundant battery
charger conduit

Typical generator load lead conduit

Battery rack Block heater conduit
Battery charger conduit

Figure 88 Typical Stub Up Locations (KD1250A and KD1350 Shown)

108 TP-7153 5/24

9.2 Generator Set Voltage Reconnection
For KD700 – KD4000 generator sets, the alternators for each voltage configuration are unique and cannot be reconnected.

9.3 Electrical Connections

Several electrical connections must be made between the generator set and other components of the system for proper
operation. Because of the large number of accessories and possible combinations, this manual does not address specific
applications. Refer to the submittal catalog accessory drawings and wiring diagrams for connection and location. Most
field-installed accessory kits include installation instructions.

For customer-supplied wiring, select the wire temperature rating in Figure 89 based upon the following criteria:

• Select row 1, 2, 3, or 4 if the circuit rating is 110 amperes or less or requires #1 AWG (42.4 mm2) or smaller conductors.

• Select row 3 or 4 if the circuit rating is greater than 110 amperes or requires #1 AWG (42.4 mm2) or larger conductors.

Comply with applicable national and local codes when installing a wiring system.

Row Temp. Rating Copper (Cu) Only Cu/Aluminum (Al) Combinations Al Only
60°C (140°F) Use No. * AWG, 60°C wire or Use 60°C wire, either No. * AWG Cu, or No. * Use 60°C wire, No. * AWG
1 or use No. * AWG, 75°C wire AWG Al or use 75°C wire, either No. * AWG Cu or
75°C (167°F) or No. * AWG Al use 75°C wire, No. * AWG
60°C (140°F) Use No. * AWG, 60°C wire Use 60°C wire, either No. * AWG Cu or No. *
2 Use 60°C wire, No. * AWG
AWG Al
75°C (167°F) Use No. *+ AWG, 75°C wire Use 75°C wire, either No. *+ AWG Cu or No.
3 Use 75°C wire, No.*+ AWG
*+ AWG Al
90°C (194°F) Use No. *+ AWG, 90°C wire Use 90°C wire, either No. *+ AWG Cu or No.
4 Use 90°C wire, No.*+ AWG
*+ AWG Al
* The wire size for 60°C (140°F) wire is not required to be included in the marking. If included, the wire size is based on ampacities for the
wire given in Table 310-16 of the National Electrical Coder, in ANSI/NFPA 70, and on 115% of the maximum current that the circuit
carries under rated conditions. The National Electrical Coder is a registered trademark of the National Fire Protection Association, Inc.
+ Use the larger of the following conductors: the same size conductor as that used for the temperature test or one selected using the
guidelines in the preceding footnote.
Figure 89 Terminal Markings for Various Temperature Ratings and Conductors

TP-7153 5/24 109

9.4 Load Lead Connections
Load leads feed into either a circuit breaker box or, if a circuit breaker box is not present, a junction box. Load leads typically
feed through the bottom entry panel on both the circuit breaker box and the junction box. See Figure 90.

Use a minimum of 13 mm (0.5 in.) spacing between the conduit bushing and any uninsulated live parts in the junction box. All
conduit openings in the junction box must be made such that no metal particles including drill chips contaminate the components
in the junction box.

Refer to the generator set dimension drawing, the electrical contractor prints, and/or the circuit breaker drawing (ADV-8877) for
detailed information including stub-up area recommendations.

Circuit Breaker Box Junction Box

Conduit from ceiling

Conduit stubbed up from below

Conduit stubbed up from below

Figure 90 Typical Load Lead Connection

110 TP-7153 5/24

9.5 Grounding and Grounded Conductor (Neutral) Connections
Connect the electrical system grounding conductor to the equipment grounding connector. The equipment grounding connector
will be located either in a circuit breaker box or a junction box. See the examples in Figure 91 and refer to the generator set
wiring diagram for specific details. Depending upon code requirements, the grounded conductor (neutral) connection is typically
grounded.

Circuit Breaker Box Examples Junction Box Examples

Neutral bus bar

Neutral bus bar

Equipment Ground

Neutral bond Neutral bus bar

Neutral bus bar

Equipment Ground
Neutral bus bar
Equipment
Ground

Neutral bus bar

Neutral bond

Figure 91 Generator Set Equipment Grounding Connections, Typical

TP-7153 5/24 111

Generator sets are typically shipped from the factory with the neutral attached to the alternator in the junction box for safety
reasons per NFPA 70. At installation, the neutral can remain grounded at the alternator or be isolated if the installation requires
an ungrounded neutral connection at the generator set. The generator set will operate properly in either configuration.

Various regulations and site configurations including the National Electrical Coder (NEC), local codes, and the type of transfer
switch used in the application determine the grounding of the neutral at the generator set.

Allowable Ampacity, Min. Size of Equipment Copper

Amps Grounding Conductor, AWG or Kcmil
20 12
60 10
90 8
100 8
150 6
200 6
300 4
400 3
500 1
600 1
800 1/0
1000 2/0
1200 3/0
1600 4/0
2000 250
2500 350
3000 400
4000 500
5000 700
6000 800
Figure 92 Grounding Conductor (Lug) Selection
Important:
When using a ground fault relay and bonding at the generator set, the grounding cables provided must be used to bond neutral
to ground.

If bonding at the ATS:

1. Remove the cable(s) and discard.

2. Make neutral to ground bonding conductor per NEC 250.102(D) and 250.122 with a length and effective gauge required
for a 2 milliohm resistance.
3. Remove the jumper between terminals 11 and 12 on ground fault relay.

112 TP-7153 5/24

9.6 Terminal Connector Torque
Use torque values shown in Figure 93 or Figure 94 for terminal connectors. Refer to UL 486A-486B and UL 486E for information
on terminal connectors for aluminum and/or copper conductors. See the previous section, “Electrical Connections,” for
information on temperature rating of the customer-supplied wire. Comply with applicable national and local codes when installing
a wiring system.

Socket Size Across Flats, mm (in.) Tightening Torque, Nm (in.lb.)

3.2 (1/8) 5.1 (45)

4.0 (5/32) 11.4 (100)
4.8 (3/16) 13.8 (120)
5.6 (7/32) 17.0 (150)
6.4 (1/4) 22.6 (200)
7.9 (5/16) 31.1 (275)
9.5 (3/8) 42.4 (375)
12.7 (1/2) 56.5 (500)
14.3 (9/16) 67.8 (600)
Note: For values of slot width or length not corresponding to those specified, select the largest torque value
associated with the conductor size. Slot width is the nominal design value. Slot length is to be measured at the
bottom of the slot.
Figure 93 Tightening Torque for Pressure Wire Connectors with Internal-Drive Socket-Head Screws
If a connector has a clamp screw such as a slotted, hexagonal head screw with more than one means of tightening, test the
connector using both applicable torque values provided in Figure 94.

Tightening Torque, Nm (in. lb.)

Wire Size for Unit
Connection Hexagonal Head – External Drive
Slot Head 4.7 mm (No. 10) or Larger*
Socket Wrench

Slot Width <1.2 mm (0.047 in.) Slot Width > 1.2 mm (0.047 in.) Split-Bolt Other
AWG, kcmil (mm2)
Slot Length <6.4 mm (0.25 in.) Slot Length >6.4 mm (0.25 in.) Connectors Connections
18-10 (0.82-5.3) 2.3 (20) 4.0 (35) 9.0 (80) 8.5 (75)
8 (8.4) 2.8 (25) 4.5 (40) 9.0 (80) 8.5 (75)
6-4 (13.3-21.2) 4.0 (35) 5.1 (45) 18.6 (165) 12.4 (110)
3 (26.7) 4.0 (35) 5.6 (50) 31.1 (275) 16.9 (150)
2 (33.6) 4.5 (40) 5.6 (50) 31.1 (275) 16.9 (150)
1 (42.4) - 5.6 (50) 31.1 (275) 16.9 (150)
1/0-2/0 (53.5-67.4) - 5.6 (50) 43.5 (385) 20.3 (180)
3/0-4/0 (85.0-107.2) - 5.6 (50) 56.5 (500) 28.2 (250)
250-350 (127-177) - 5.6 (50) 73.4 (650) 36.7 (325)
400 (203) - 5.6 (50) 93.2 (825) 36.7 (325)
500 (253) - 5.6 (50) 93.2 (825) 42.4 (375)
600-750 (304-380) - 5.6 (50) 113.0 (1000) 42.4 (375)
800-1000 (406-508) - 5.6 (50) 124.3 (1100) 56.5 (500)
1250-2000 (635-1016) - - 124.3 (1100) 67.8 (600)
* For values of slot width or length not corresponding to those specified, select the largest torque value associated with the conductor size.
Slot width is the nominal design value. Slot length is to be measured at the bottom of the slot.

Note: If a connector has a clamp screw such as a slotted, hexagonal head screw with more than one means of tightening, test the
connector using both applicable torque values.

Figure 94 Tightening Torque for Screw-Type Pressure Wire Connectors

TP-7153 5/24 113

9.7 Batteries

Battery location

When determining the battery placement, ensure that the location:

• Is clean, dry, and not exposed to extreme temperatures

• Provides easy access to battery caps for checking the electrolyte level (when using maintenance type batteries)

• Is close to the generator set to keep cables short, ensuring maximum output

Refer to the submittal drawings for the generator set to locate the position of the battery rack. Figure 95 shows a typical battery
system.

End View

Generator set skid

Battery secured
in mounting rack

Battery secured
in mounting rack
Generator set skid

Figure 95 Typical Battery System

Battery type

Standard starting batteries for the KD series are Absorbed Glass Mat (AGM) type and are sized according to the engine
manufacturer’s recommendation for a particular ambient temperature and required cranking time. NFPA 110 recommends three
15-second crank cycles separated by 15-second rests. Refer to the respective generator set specification sheet for the required
battery cold-cranking ampere (CCA) rating.

Nickel-cadmium batteries are sometimes used for standby generator sets because of their long life (20 years). However, initial
high cost, larger space requirements, and special charging requirements can offset this benefit. Therefore, conventional lead-
acid batteries have proven satisfactory for the majority of generator set applications.

Battery cables

A UL 2200 listed generator set requires battery cables with positive (+) lead boots. Factory-supplied and optional battery cables
include positive (+) lead boots. When battery cables are not factory-supplied, source battery cables with positive (+) lead boots
for UL 2200 compliance.

Note:
Some units are equipped with an insulating and reflective heat shield sleeve on the battery cables and other wires that are
fastened to the starter solenoid. This sleeve is a conductive material and must be secured approximately 25 mm (1 in.) away
from the exposed cable terminal.

114 TP-7153 5/24

9.8 Battery Chargers
The KD series generator sets use an engine-driven, battery-charging alternator to charge the batteries whenever the generator
set operates. Engine-driven systems can quickly restore the charge used in a normal cranking cycle. When the engine is not
operating, a very low charge rate from an AC-powered battery charger is usually sufficient to maintain a full charge on the
batteries.

KD series generator sets typically use either one or two 20-amp battery chargers depending upon the generator set model.
Redundant engine starters require a second bank of battery chargers and can increase the total number of chargers to four.
Refer to the product label and the battery charger operation manual for specific details.

9.9 Component and Accessory Power Source Requirements

Several components require a power source other than the engine starting batteries. The utility power supply outlet or electrical
box should be in close proximity to the generator set. Load centers are available with electrical hook-up connections. Most
accessories require a dedicated circuit with separate circuit breaker. Comply with applicable national and local codes when
providing an electrical power source connection. These items include but are not limited to the following items:

• Alternator Heater (generator heater) varies depending upon the alternator used with the generator set.

One alternator strip heater requires 208-480 V (see below for W).
KH02970TO4D KH03450TO4D KH03544TO4D KH03546TO4D
Alternator Models
KH04070TO4D KH04830TO4D KH05520TO4D
Volts 208 230 255 277
Watts 189 231 284 335
Two alternator strip heaters require 208-480 V
(See below for single-heater watts. Wattage requirements double with two heaters).
KH03850TO4D KH04590TO4D KH04920TO4D KH05740TO4D
Alternator Models
KH06400TO4D KH06810TO4D KH08200TO4D
Volts 208 230 255 277
Watts 189 231 284 335
Two alternator strip heaters require 120 V, 500 W (1000 W total).
Alternator Models KH04401TO4D KH04970TO4D KH05790TO4D KH06930TO4D
Two alternator strip heaters require 120 V, 600 W (1200 W total).
KH05641TO4D KH06220TO4D KH06721TO4D KH07001TO4D
Alternator Models KH07000TO4D KH07770TO4D KH07771TO4D KH07801TO4D
KH08430TO4D KH08431TO4D
Two alternator strip heaters require 220-277 V, 1000 W (2000 W total).
KH06270TO4D KH06670TO4D KH07080TO4D KH07630TO4D
KH07631TO4D KH07632TO4D KH07640TO4D KH08100TO4D
Alternator Models
KH08590TO4D KH09270TO4D KH09370TO4D KH09390TO4D
KH10171TO4D

• Battery Charger typically requires a 105–264 V, 45–65 Hz, 2.45–5.00 A power source. Some generator set models
include multiple battery chargers and require additional chargers with redundant engine starters. Check the component
for specific information. See the battery charger operation manual and specification sheet for additional information.

o KD700–KD750, include one charger with a single starter.

o KD800–KD1350, include one charger with a single starter and two chargers with a redundant starter.

o KD1500–KD4000 include two chargers with a single starter and four chargers with a redundant starter.

TP-7153 5/24 115

 • Battery Heater requires a 120 V, 60 Hz power supply. Check the component for specific information.

o KD700–KD750, requires 100 W per heater includes one heater with a standard starter setup.

o KD800–KD1000, requires 100 W per heater includes one heater with a standard starter setup and two heaters
with a redundant starter setup.

o KD1250A–KD4000 requires 100 W per heater and includes two heaters with a standard starter setup and four
heaters with a redundant starter setup.

• Controller Heater (APM802 Controller only) requires a 208-240 V, 60 Hz, 188-250 W or 230 V, 50 Hz, 250 W power
source. Check the component for specific information.

• Engine Block Heaters are available with a 208, 240, 480 V, 60 Hz power source or 380 V, 50 Hz power source. Watts
range from 6000–12000. Check the component for specific information.

Note:
For additional electrical requirements related to the exhaust aftertreatment system in tier 4 generator sets, refer to the exhaust
aftertreatment system installation and application manual.

9.10 Optional Accessories

The generator set manufacturer offers optional accessories that require connection to other components in the system. These
accessories enable the generator set to meet standards for local and national codes, make operation and service more
convenient, or satisfy specific customer installation requirements.

Accessory kits generally include installation instructions. See the wiring diagrams manual for electrical connections not shown
in this section. See the installation instructions and drawings supplied with the kit for information on the kit mounting location.

The instructions provided with the accessory kit supersede these instructions, if different. In general, run AC and DC wiring in
separate conduit. Use shielded cable for all analog inputs. Observe all applicable national and local electrical codes during
accessory installation.

Accessory wiring

To determine the appropriate size for the customer-supplied wiring of the engine battery-powered accessories, use the
guidelines in Figure 96. Use 18-20 gauge wire for signal wires up to 305 m (1000 ft.).

Length, m (ft.) Wire Gauge

30.5 (100) 18-20
152.4 (500) 14
304.8 (1000) 10
Figure 96 Wire Length and Size, Lead N and 42B
Match the wire terminals to the terminal strip conductor screw size. Use a maximum of two wire terminals per terminal strip
screw unless otherwise noted on the respective accessory drawing or installation instruction.

Accessory connections

Do not direct-connect accessories to the controller terminal strip. Connect accessories to a dry contact kit. Connect the dry
contact kit(s) to the controller (customer) connection kit. Connect all accessories except the emergency stop kit to the connection
kit terminal strip(s).

Terminal strips and available connections vary by controller. Refer to the respective controller operation manual and the
accessory wiring diagrams in the wiring diagram manual for connection of kits. Field-installed accessories include installation
instructions and/or wiring diagrams.

116 TP-7153 5/24

9.10.1 Bus Bar Kits/Bus Lugs

The four bus bars contained in the optional bus bar (load bus) kits simplify the connection process by offering bus connections
for load and neutral when the generator set mounted breaker is not selected. Optional bus lugs offer an array of terminal and
wire connections. See Figure 97.

A B C Optional lugs

Figure 97 Bus Bar Kits/Bus Lugs

9.10.2 Line Circuit Breaker

The line circuit breaker interrupts generator output if an overload or short circuit occurs. Use the line circuit breaker to manually
disconnect the generator set from the load during generator set service. See Figure 98.

The circuit breaker must open all ungrounded connectors. Refer to the circuit breaker drawing (ADV-8877) and circuit breaker
spec sheet (G6-88) for all trip unit adjustments and settings.

Figure 98 Line Circuit Breaker

TP-7153 5/24 117

118 TP-7153 5/24
 Section 10. APM603 and APM802 Controller Accessories

Optional accessories help finalize installation, add convenience to operation and service, and establish state and local code
compliance. This section covers accessories and connections for both the APM603 and the APM802 controllers on the KD series
generator sets.

Select factory-installed and/or shipped-loose accessories. Factory installed kits are not covered in this Installation manual. Refer
to the generator set operation manual or the documentation provided with the accessory for operation instructions.

Connect external optional accessories including alarms, battery chargers, thermocouples, and remote switches to the terminal
block or modules in the customer connection box. See Figure 99. Do not attempt to connect directly to the controller.

For specific information on accessory connections, refer to the accessory wiring diagrams in the wiring diagram manual and the
instruction sheet accompanying the kit. See the generator set wiring diagram for terminal block customer connections.

This section illustrates selected loose accessories available at print time of this publication. Accessory kits generally include
installation instructions.

• See the wiring diagram manual for electrical connections not shown in this section.

• See the installation instructions and drawings supplied with the kit for information on kit mounting location.

The instructions provided with the accessory kit supersede these instructions where there are differences. In general, run AC
and DC wiring in separate conduit. Use shielded cable for all analog inputs. Observe all applicable national, state, and local
electrical codes during accessory installation.

See subsection Accessory Connections, for terminal identification.

APM603 APM802
USB port (under
hinged panel)

Terminal block TB10 for

accessory connections
240 VAC/60 Hz power
supply connection

Terminal Block TX1,

Terminal block
Remote breakers,
TB10 for accessory
Paralleling, and RS-485
connections

Optional module Optional module

locations locations

Figure 99 APM603 and APM802 Controller and Customer Connection Box

TP-7153 5/24 119

 DANGER Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.

Short circuits. Hazardous voltage/current will 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.

10.1 Input/Output Modules

The following factory-installed modules are available as optional accessories.

• Analog Input/Output and Thermocouple Module (AIOTM)*

• Digital I/O Module

 Combined module replaces the separate Analog I/O Module and Thermocouple Module.

The modules are factory-installed in the customer connection box. Module power and CAN Bus communications with the
controller are factory connected. The communication speed and module CAN addresses are factory set. Do not change the
speed or CAN address DIP switch settings.

The modules are equipped with diagnostic LEDs that can be used for troubleshooting. See the Module Diagnostic LEDs figure.
10.1.1 Analog Input/Output and Thermocouple Module

A single module replaces the original Analog I/O Module and the Thermocouple Module. The analog inputs/outputs and the
temperature inputs are now located on one module. See Figure 100 to compare the original and updated modules. The module
is factory-installed and used on selected generator sets equipped with Kohler APM802 or APM603 controllers.

Combined Analog I/O and

Original Analog I/O Module Original Thermocouple Module Thermocouple Input Module (AIOTM)

Images are not to scale. 31613391201/301/401 11609000100

Figure 100 Module Comparison

Inputs and Outputs

Each AIOTM provides the following input and output connections for factory use. See the generator set wiring diagram for
connections.
• 2 isolated analog inputs
• 2 isolated analog outputs

120 TP-7153 5/24

 • 6 thermal sensor/resistive inputs
o 1 PT1000 (RTD)/thermocouple/resistive input
o 5 PT100 (RTD)/thermocouple/resistive inputs (factory connected)
• 1 mag pick up input
• 1 PWM output
Note:
See the generator set wiring diagrams for connections.
Environmental Specifications

Operating temperature - 40 to + 70ºC (-40 to + 158ºF)

Storage temperature - 45 to + 85ºC (- 49 to + 185ºF)
Relative humidity 98% at 40ºC (104ºF)
Altitude 3000 meters (9843 ft.)

For additional specifications, see the Kohler specification sheet for the Analog I/O and Thermocouple Module.

Switches and Indicators

The module is equipped with the following switches and indicators.

• CAN and RS-485 switches activate termination resistance. Turn on for only the last module in the communication
network.
• Two LEDs indicate RS-485 and CAN communication.
• Five factory-set CAN address switches. Each analog l I/O module in the system must have a different CAN address.
See Figure 101 for indicator and switch locations.

CAN bus connections (factory connected)

CAN and RS-485 switches for termination resistance

CAN and RS-485 communication indicators
DC power connection (factory connected)

Factory-set CAN address switches

Note:
Each analog I/O module in the system must
have a different CAN address.

Note:
See the generator set wiring diagram for input and output connections. GM119135

Figure 101 Analog Input/Output/Thermocouple Module (AIOTM)

TP-7153 5/24 121

10.1.2 Digital Input/Output Module

The Digital 8 Input/Output Module Kit is available as an optional accessory. The modules are factory-installed in the customer
connection box. Module power and CAN communication with the controller are factory-connected. The module CAN address is
factory-set. Do not change the CAN address DIP switch settings.

The original DIOM provides 8 digital inputs and 4 digital (relay) outputs. The updated D8IOM adds more outputs, providing 8
digital inputs and 8 digital (relay) outputs. See Figure 102 to compare the original and updated designs. Full support of the new
D8IOM requires firmware version 3.6 or later for the APM603 controller and version 1.11 or later for the APM802 controller.

Original DIOM Updated D8IOM

CAN communication indicator

Factory connections
and settings.
DO NOT CHANGE.
Factory connections
and settings.
DO NOT CHANGE

Digital (relay) output

Digital input connections 0 - 7
connections 0 - 7

Digital (relay) output

connections 0 - 3
Digital input
connections 0 – 7
(See detail)

DIGITAL INPUT CONNECTION DETAIL

DI0 DIR0
DI1 DIR1
DI2 DIR2
DI3 DIR3
DI4 DIR4
DI5 DIR5
DI6 DIR6
Note: DI7 DIR7
The locations of the input and output connections on the updated module are
different from the original.
11609000401

Figure 102 Digital Input/Output Modules, Original and Updated

122 TP-7153 5/24

See the table below for contact specifications. Refer to the D8IOM specification sheets, UL and CE versions, for additional
specifications.

Inputs

Number of inputs 8 configurable inputs

Input voltage 12 VDC/24VDC

Contacts Normally open (NO). Activates on ground connection

Connection 0.75 to 1.5 mm2 (20AWG-16AWG)

Inputs isolated Yes

Outputs

Number of outputs Binary outputs for power: 8

Form C, rated 3 A @ 250 VAC (UL version)
Contacts
Form C, rated 3 A @ 30 VDC (CE version)
Connections 0.75 to 1.5 mm2 (20AWG-16AWG)
250 VAC maximum (UL version)
Voltage
30 VDC (CE version)
Current 3 Amps maximum
375 VA maximum (UL version)
Power
90 W (CE version)
Number of operation cycles at full load 100 000

Minimum current: 10 mAmps

Figure 103 Input and Output Specifications (updated D8IOM)

The updated module is equipped with one diagnostic LED to show the status of CAN communication between the module and
the generator controller. See Figure 104.

LED Description LED Operation

CANbus 1 Communication LED Flashing green: CAN communication is consistent.
Steady green: No CAN communication.
Off: No CAN communication.
Figure 104 CAN Communication Indicator
The DIOM kit includes two digital input/output modules, referred to as DIOM 1 and DIOM 2. The digital inputs and outputs on
DIOM 1 and DIOM 2 can be configured by an authorized service technician. Contact your Kohler distributor with your
requirements for digital inputs and outputs.

TP-7153 5/24 123

Digital Input/Output Module with the APM603

On KD Series Generators equipped with the APM603 controller, one base D8IOM is supplied as standard equipment. It is
factory-installed and factory-configured. The base D8IOM connections and settings are not available to the customer.

Factory Settings
Digital Inputs/Outputs Module 0 (not configurable) Optional Module 1 Optional Module 2
Input DI0 Power Supply 1 Fault Warning Configurable Configurable
Input DI1 Power Supply 2 Fault Warning Configurable Configurable
Input DI2 Remote Reset Configurable Configurable
Input DI3 Auxiliary Shutdown Configurable Configurable
Input DI4 High Fuel Level Switch Warning Configurable Configurable
Input DI5 Auxiliary Warning Configurable Configurable
Input DI6 Low Oil Level Switch Warning Configurable Configurable
Input DI7 Reserved Factory Use Configurable Configurable
Output DO0 System Ready Configurable Configurable
Output DO1 Low Coolant Temp Configurable Configurable
Output DO2 Not In Auto Configurable Configurable
Output DO3 EPS Supplying Load Configurable Configurable
Output DO4 NA Configurable Configurable
Output DO5 NA Configurable Configurable
Output DO6 NA Configurable Configurable
Output DO7 NA Configurable Configurable
Figure 105 Digital 8 I/O Module Default Settings (Tier 2 and Tier 4 Generator Sets)

124 TP-7153 5/24

Digital Input/Output Module with the APM802

On KD Series generator sets with the APM802 controller, the Module #0 position is reserved for the Manual Key Switch/Load
Shed module. Inputs and outputs are factory-set to the default settings shown in Figure 106.

The I/O settings for optional I/O module 1 are not defined at the factory. The digital inputs and outputs can be configured by an
authorized service technician. Contact your Kohler distributor with your requirements for digital inputs and outputs.

Factory Settings

Module 0
Digital Inputs/Outputs (Key Switch/Load Shed Only) Optional Module 1
Input DI0 Key switch AUTO Undefined
Input DI1 Key switch Manual Undefined
Input DI2 Key switch OFF Undefined
Input DI3 Start/Stop Button Undefined
Input DI4 Reserved Undefined
Input DI5 Reserved Undefined
Input DI6 Reserved Undefined
Input DI7 Reserved Undefined
Output DO0 Load 1 Undefined
Output DO1 Load 2 Undefined
Output DO2 Load 3 Undefined
Output DO3 Load 4 Undefined
Output DO4 Reserved Undefined
Output DO5 Reserved Undefined
Output DO6 Reserved Undefined
Output DO7 Reserved Undefined

Figure 106 Digital 8 I/O Module Default Settings

TP-7153 5/24 125

10.2 Remote Emergency Stop Kit
The emergency stop kit allows immediate shutdown of the generator set from a remote location. See the following figures for
connection details. Install the emergency stop switch in a location that is easily accessible by operating personnel. Connect as
many emergency stop switches as required; however, connect multiple switches in series so the system functions correctly.

Two emergency stop kits are available. See the image below.

• For the emergency stop switch, use the single glass piece located inside the switch for replacement and order additional
glass pieces as service parts. See the respective operation manual for the Emergency Stop Switch Reset Procedure.
See the following subsection, “Accessory Connections,” for terminal identifications.

• The lockable emergency stop kit allows the installation of a lockout/tagout device to lock the switch in the STOP position.
Insert a locking device through the openings in the shroud to prevent resetting the switch.

Refer to the instructions provided with the kit for installation instructions.

A-222654 GM103743
TP-5352-1 TT-1736

Emergency Stop Switch Lockable Emergency Stop Switch

Figure 107 Emergency Stop Kits

See the figure below for typical connections. Refer to the generator set wiring diagram for your model. Remove the jumper
across the E-stop connections when installing the switch.

Also see subsection Accessory Connections.

Emergency Stop Kit Connection Customer Connection Terminal Block Detail

(with multiple switches)

Optional remote e-stop

Terminal block**

JP1 **

Emergency Stop Kit Connection

(with single switch)
Terminal block**

GM105223

** Remove JP1 jumper, if remote emergency stop is connected.

Figure 108 Remote Emergency Stop Kit Connections

126 TP-7153 5/24

10.3 Remote Serial Annunciator (RSA III)
Refer to the RSA III installation instructions, TT-1625.

RSA III is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA III is a remote
serial annunciator that monitors the condition of the generator set and/or ATS from a remote location. The RSA III alerts the
operator through visual and audible signals using LED indication and a horn. An alarm silence and lamp test switch are included.

The RSA III meets NFPA 110, Level 1 (2005) applications that require remote controls and alarms to be powered by a storage
battery such as the engine starting battery. AC adaptor kit GM62466-KP1 is available when NFPA is not required.

A personal computer (PC) with Kohler SiteTech™ software is required to make the RSA III functional. SiteTech™ is available to
Kohler authorized distributors and dealers.

An RSA III annunciator can be used for a single generator set or with a combination of a generator set and automatic transfer
switch(es). In systems using more than a single RSA III, one must be designated as the master device to broadcast to additional
RSA III annunciators, designated as slave devices. Up to five RSA III slave devices can be used with an RSA III master device.
All RSA III annunciators are factory set as the master device, but can be changed to a slave device using a personal computer
(PC) and SiteTech™ software that connects to the RSA III front panel via a universal serial bus (USB) connection.

For long distances and to reduce electrical noise, a lower baud rate, such as 19200, is recommended. See TT-1625 for more
details.

Use SiteTech™ software to select that either the generator set controller or the transfer switch activates the EPS Supplying
Load LED.

See the subsection, Accessory Connections, for terminal identifications.

RSA III with Single Generator Set RSA III with Single ATS Control RSA III with Four ATS Controls

Figure 109 Remote Serial Annunciator (RSA III)

Wiring

• For communication between the controller and RSA III master, see the figure below, P27 Connector on Master RSA
III.

• For communication between RSA III Master and RSA III Slave, see the figure below, P27 Connection on RSA III Slave.

• Refer to the generator set wiring diagram for the RSA connections to the controller.

• If five or more devices are connected, place a terminating resistor on the last RSA III slave in the daisy chain connection.

Note:
When using RS-485 communication cable, connect the “shield” wire at either end but not at both ends.

TP-7153 5/24 127

 P27 RS-485 Connections (from Controller to Master )
P27-1 (-) Black (from controller)
P27-2 (+) White (from controller)
P27-3 Shield (from controller)
P27-4 (-) Black (to slave or terminating resistor)
P27-5 (+) White (to slave or terminating resistor)
P27-6 Shield (to slave or open)
Note: When using RS-485 communication cable, connect the “shield” wire at either end but not at
both ends.
Figure 110 P27 Connector on Master RSA III
Communication between RSA III Master and RSA III Slave. Select and connect the RS-485 wiring from the RSA III master
to the RSA III slave(s) in a daisy chain wiring configuration. The figure below, “P27 Connection on RSA III Slave,” shows the
master/slave RS-485 connections and “RSA III Circuit Board GM86125 Connectors” shows the RSA III with P27 location.

• For communication connections, use #12-24 AWG shielded, twisted-pair communication cable. For indoor, non-plenum
installations, Belden #9841 or equivalent cable is recommended.

• For outdoor or plenum installations, including those with buried cables and/or conduit, use outdoor-rated cable, Belden
#89841 or equivalent.

All wiring must comply with applicable national and local codes.

P27 RS-485 Connections (from Master to Slave )

P27-1 (-) Black (from master or previous slave)
P27-2 (+) White (from master or previous slave)
P27-3 Shield (from master or previous slave)
P27-4 (-) Black (to next slave or terminating resistor)
P27-5 (+) White (to next slave or terminating resistor)
P27-6 Shield (to next slave or open)
Note: When using RS-485 communication cable, connect the “shield” wire at either end but not at
both ends.
Figure 111 P27 Connection on RSA III Slave

Top View Bottom View

P39, 3-pin Isolated/non-isolated jumper

P27, 6-pin RS-485 connections

P34, 3-pin RS-485 termination

resistor for last device

P41, 8-pin input (EPS/User)

connections

P42, 4-pin Input user 4 & 5 connections

P40, 6-pin Common fault and horn dry contacts

P37, 3-pin Power/CAN connections

Figure 112 RSA III Circuit Board GM86125 Connectors

128 TP-7153 5/24

10.4 Accessory Connections
Factory-defined inputs and outputs are shown in subsection “Controller Connections”. Connect to these inputs and outputs at
customer connection terminal block. See Figures for terminal block connections and contact ratings. Also see the generator set
wiring diagram.

These factory-defined user inputs and outputs are not adjustable.

Controller Connections

All customer connections to the controller are made to terminal strips or terminal blocks. Do not attempt to connect customer
equipment directly to the controller.

Connectors inside the controller box provide connections for optional accessories. See Figure 110.

Terminal block TB10 provides customer connection points for emergency stop, remote start/stop, Modbus devices including the
RSA III, and standard inputs and outputs. See Figure 113.

Note:
Do not apply voltage to any dry contact inputs. Provide proper circuit protection to relay connections.

For specific information on accessory connections, refer to the accessory wiring diagrams in the wiring diagram manual and the
instruction sheet accompanying the kit.
TB10 Terminal Strip
APM603 APM802
Position Function Signal Description Position Function Signal Description
TB10–1 Remote emergency Use dry contact. Remove TB10–1 Remote emergency Remove jumper if using E-
TB10–2 stop jumper if using E-stop TB10–2 stop stop
TB10–3 TB10–3
Remote start Use dry contact Remote start Remote start signal
TB10–4 TB10–4
TB10–5 TB10–5
Idle switch Use dry contact Idle switch Idle switch
TB10–6 TB10–6
TB10–7 Non-isolated RS-485 TB10–7 RS485 positive
RSA RSA
TB10–8 remote serial annunciator TB10–8 RS485 return
TB10–9 TB10–9
Overspeed test Use dry contact Overspeed test Overspeed test
TB10–10 TB10–10
TB10–11 Low fuel level TB10–11 Low fuel level Low fuel level
TB10–12 TB10–12 Breaker open Breaker open
Dry contact to digital input
TB10–13 Remote reset TB10–13 Remote reset Remote reset
return
Dry contact to digital input
TB10–14 Auxiliary shutdown TB10–14 Auxiliary shutdown Auxiliary shutdown
return
Dry contact to digital input
TB10–15 High fuel TB10–15 High fuel High fuel
return
Dry contact to digital input
TB10–16 Auxiliary warning TB10–16 Auxiliary warning Auxiliary warning
return
Dry contact to digital input
TB10–17 Low oil level TB10–17 Low oil level Low oil level
return
TB10–18 Digital input return TB10–18
TB10–19 Digital input return TB10–19 GFCI tripped GFCI tripped
Remote speed Remote speed adjust
TB10–20 Digital input return TB10–20
adjust enable
Dry contact to digital input
TB10–21 Key switch TB10–21 Key switch Key switch enable
return
TB10–22 Common fault NC Dry Contact TB10–22 Common fault NC
TB10–23 Common fault NO 10 A @ 28 VDC max TB10–23 NO
10 A @ 120 VAC max
TB10–24 Common 10 mA @ 28 VDC min TB10–24 Common
10 mA @ 120 VAC min
TB10–25 System ready NC Dry Contact TB10–25 System ready NC
TB10–26 System ready NCO 8 A @ 240 VAC TB10–26 NO
8 A @ 30 VDC
TB10–27 Common TB10–27 Common
0.5 A @ 48 VDC
Common warning Dry Contact
TB10–28 TB10–28 Common warning NC
NC 10 A @ 28 VDC max
Common warning 10 A @ 120 VAC max
TB10–29 TB10–29 NO
NO 10 mA @ 28 VDC min
TB10–30 Common 10 mA @ 120 VAC min TB10–30 Common
TB10–31 Horn NO Dry Contact TB10–31 Horn Horn positive

TP-7153 5/24 129

 TB10 Terminal Strip
APM603 APM802
Position Function Signal Description Position Function Signal Description
10 A @ 28 VDC max
10 A @ 120 VAC max
TB10–32 Common TB10–32 Horn negative
10 mA @ 28 VDC min
10 mA @ 120 VAC min
Dry Contact Low coolant temp
Low coolant temp
TB10–33 8 A @ 240 VAC TB10–33 warning NO
warning NO
8 A @ 30 VDC No Connection
TB10–34 Common 0.5 A @ 48 VDC TB10–34 Common
TB10–35 No connection TB10–35 Shunt trip positive
Shunt Trip
TB10–36 No connection TB10–36 Shunt trip negative
TB10–37 Not in auto NO Dry Contact TB10–37 Not in auto NO
8 A @ 240 VAC
TB10–38 Common 8 A @ 30 VDC TB10–38 Common
0.5 A @ 48 VDC
Generator running Dry Contact
TB10–39 TB10–39 Generator running Battery positive
Common 10 A @ 28 VDC max
10 A @ 120 VAC max
Generator running
TB10–40 10 mA @ 28 VDC min TB10–40 Return
NO
10 mA @ 120 VAC min
EPS supply load Dry Contact
TB10–41 TB10–41 EPS supply load NO
NO 8 A @ 240 VAC
EPS supply load 8 A @ 30 VDC
TB10–42 TB10–42 Common
Common 0.5 A @ 48 VDC
TB10–43 Low fuel level TB10–43 NO
Use dry contact Low oil pressure
TB10–44 switch TB10–44 Common
TB10–45 Speed bias (+) TB10–45 High coolant NO
+30 VDC/-15 VDC Max
TB10–46 Speed bias (-) TB10–46 temperature Common
Requires controller range
TB10–47 Voltage bias (+) TB10–47 NO
setup Low coolant level
TB10–48 Voltage bias (-) TB10–48 Common
TB10–49 RM1 positive TB10–49 NO
Low fuel level
TB10–50 Ratiometric inputs RM1 TB10–50 Common
TB10–51 RM1 negative TB10–51 Speed bias Speed bias return
TB10–52 All shield wires Shield TB10–52 Speed bias positive
TB10–53 Return TB10–53 Ambient air return
Ambient air Ambient air
TB10–54 Signal TB10–54 Ambient air positive
TB10–55 Battery positive TB10–55 DC Positive
15 A fused @ 24 VDC
output (powered at 24 VDC
TB10–56 nominal TB10–56 DC Negative
all times)
TB10–57 Battery negative
0 VDC
TB10–58 output (ground)
Figure 113 Terminal Strip TB10 Customer Connections (APM603, KD700–KD4000)

130 TP-7153 5/24

 Section 11. Remote Adjustment/Control Systems

This section provides information about changes and adjustments when the system involves remote starting/control systems,
voltage regulation, and paralleling generator set applications. Use the respective switchgear literature as supplied with the unit.
Some of the items mentioned are available generator set accessories.

Before installing the generator set, provide for electrical connections through conduit to the transfer switch and other accessories
for the generator set. Carefully install the selected generator set accessories. Route wiring to the generator set through flexible
connections. Comply with all applicable codes when installing a wiring system.

See the previous section, Electrical System, for additional wiring information.

WARNING 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.

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 generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.

(APM603 Controller)

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 generator set as follows: (1) Shut down the generator set. (2) Place the controller
in Out of Service mode. (3) Press the emergency stop button. (4) Disconnect the power to the battery charger, if equipped. (5)
Remove the battery cables, negative (–) lead first. Reconnect the negative (–) lead last when reconnecting the battery. Follow
these precautions to prevent the starting of the generator set by the remote start/stop switch.

(APM802 Controller)

DANGER Hazardous voltage. Moving parts.

Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.

Short circuits. Hazardous voltage/current will 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.

TP-7153 5/24 131

11.1 Automatic Transfer Switches
A typical standby system has at least one automatic transfer switch connected to the generator set output to automatically
transfer the electrical load to the generator set if the normal source fails. When normal power returns, the switch transfers the
load back to the normal power source and then signals the generator set to stop.

The transfer switch uses a set of contacts to signal the engine/generator to start. When the normal source fails and the generator
set master switch is in the AUTO position, the transfer switch contacts close to start the generator set.

The engine start terminals are usually located near the transfer switch contactor with an engine start decal identifying the
terminals. Refer to the transfer switch decal, operation/installation manual, or wiring diagram manual to identify the engine start
terminals prior to making connections.

Make connections to the transfer switch engine-start terminals and remote manual engine-start switch using wire run through
conduit. Use separate conduits for engine-start leads, generator set load cables, battery charger leads, and remote annunciator
wiring.

Use a minimum of 13 mm (0.5 in.) spacing between the conduit bushing and any uninsulated live parts in the ATS enclosure.
All conduit openings in the ATS enclosure must be made such that no metal particles including drill chips contaminate the
components in the ATS enclosure.

11.2 APM603 Controller Voltage Regulator

The controller has a voltage regulation function that is internal to the processor.

See the APM603 Controller and SiteTech™ Operation Manuals for further details regarding voltage adjustment setup.

11.3 APM802 Controller Voltage Regulator

The generator set uses either a DER2 or D510C voltage regulator depending on the alternator.

See the APM802 Controller Operation Manual and Alternator Service and Maintenance Manual for further details regarding
voltage adjustment.

132 TP-7153 5/24

 Appendix A. Abbreviations

A, amp ampere blk. htr. block heater DAC digital to analog converter
ABDC after bottom dead center BMEP brake mean effective pressure dB decibel
AC alternating current bps bits per second dB(A) decibel (A weighted)
A/D analog to digital br. Brass DC direct current
ADC advanced digital control; BTDC before top dead center DCR direct current resistance
analog to digital converter
adj. adjust, adjustment Btu British thermal unit DEF diesel exhaust fluid
ADV advertising dimensional drawing Btu/min. British thermal units per minute deg., ° degree
AGM absorbent glass mat C Celsius, centigrade dept. department
Ah amp-hour cal. Calorie dia. Diameter
AHWT anticipatory high water CAN controller area network DI/EO dual inlet/end outlet
temperature
AISI American Iron and Steel Institute CARB California Air Resources Board DIN Deutsches Institut fur Normung e.
V. (also Deutsche Industrie
Normenausschuss)
ALOP anticipatory low oil pressure CAT5 Category 5 (network cable) DIP dual inline package
alt. alternator CB circuit breaker DPDT double-pole, double-throw
Al aluminum CC crank cycle DPST double-pole, single-throw
ANSI American National Standards cc cubic centimeter DS disconnect switch
Institute (formerly American
Standards Association, ASA)
AO anticipatory only CCA cold cranking amps DVR digital voltage regulator
APDC Air Pollution Control District ccw. Counterclockwise E2PROM, electrically-erasable
EEPROM programmable read-only memory
API American Petroleum Institute CEC Canadian Electrical Code E, emer. emergency (power source)
approx. approximate, approximately cert. certificate, certification, certified EATS Exhaust Aftertreatment System
APU Auxiliary Power Unit cfh cubic feet per hour ECM electronic control module, engine
control module
AQMD Air Quality Management District cfm cubic feet per minute EDI electronic data interchange
AR as required, as requested CG center of gravity EFR emergency frequency relay
AS as supplied, as stated, as CID cubic inch displacement e.g. for example (exempli gratia)
suggested
ASE American Society of Engineers CL centerline EG electronic governor
ASME American Society of Mechanical cm centimeter EGSA Electrical Generating Systems
Engineers Association
assy. Assembly CMOS complementary metal oxide EIA Electronic Industries Association
substrate (semiconductor)
ASTM American Society for Testing com communications (port) EI/EO end inlet/end outlet
Materials
ATDC after top dead center coml commercial EMI electromagnetic interference
ATS automatic transfer switch Coml/Rec Commercial/Recreational emiss. Emission
auto. Automatic conn. Connection eng. Engine
aux. auxiliary cont. continued EPA Environmental Protection Agency
avg. average CPVC chlorinated polyvinyl chloride EPS emergency power system
AVR automatic voltage regulator crit. Critical ER emergency relay
AWG American Wire Gauge CRM Common Rail Manifold ES engineering special, engineered
special
AWM appliance wiring material CSA Canadian Standards Association
bat. Battery CT current transformer ESD electrostatic discharge
BBDC before bottom dead center Cu copper est. estimated
BC battery charger, battery charging cUL Canadian Underwriter’s E-Stop emergency stop
Laboratories
BCA battery charging alternator cu. in. cubic inch etc. et cetera (and so forth)
BCI Battery Council International cw. Clockwise exh. exhaust
BDC before dead center CWC city water-cooled ext. external
BHP brake horsepower cyl. Cylinder F Fahrenheit, female
blk. black (paint color), block (engine) D/A digital to analog FDS Fluid Dosing System

TP-7153 5/24 133

 FHM flat head machine (screw) in. inch Lpm liters per minute
fl. oz. fluid ounce in. H2O inches of water LOP low oil pressure
flex. flexible in. Hg inches of mercury LP liquefied petroleum
freq. frequency in. Lb. inch pounds LPG liquefied petroleum gas
FS full scale Inc. incorporated LS left side
ft. foot, feet ind. Industrial Lwa sound power level, A weighted
ft. lb. foot pounds (torque) int. internal LWL low water level
ft./min. feet per minute int./ext. internal/external LWT low water temperature
ftp file transfer protocol I/O input/output m meter, milli (1/1000)
g gram IP internet protocol M mega (106 when used with SI
units), male
ga. gauge (meters, wire size) ISO International Organization for m3 cubic meter
Standardization
gal. gallon J joule m3/hr. cubic meters per hour
gen. generator JIS Japanese Industry Standard m3/min. cubic meters per minute
genset generator set k kilo (1000) mA milliampere
GFI ground fault interrupter K kelvin man. manual
GND, ground kA kiloampere max. maximum

gov. governor KB kilobyte (210 bytes) MB megabyte (220 bytes)

gph gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker
gpm gallons per minute kg kilogram MCM one thousand circular mils
gr. grade, gross kg/cm2 kilograms per square meggar megohmmeter
centimeter
GRD equipment ground kgm kilogram-meter MHz megahertz
gr. wt. gross weight kg/m3 kilograms per cubic meter mi. mile
HxWx height by width by depth kHz kilohertz mil one one-thousandth of an inch
D
HC hex cap kJ kilojoule min. minimum, minute
HCHT high cylinder head temperature km kilometer misc. miscellaneous
HD heavy duty kOhm, kilo-ohm MJ megajoule
kΩ
HET high exhaust temp., high kPa kilopascal mJ millijoule
engine temp.
hex hexagon kph kilometers per hour mm millimeter
Hg mercury (element) kV kilovolt mOhm, milliohm
mΩ
HH hex head kVA kilovolt ampere MOhm, megohm
MΩ
HHC hex head cap kVAR kilovolt ampere reactive MOV metal oxide varistor
HP horsepower kW kilowatt MPa megapascal
hr. hour kWh kilowatt-hour mpg miles per gallon
HS heat shrink kWm kilowatt mechanical mph miles per hour
hsg. Housing kWth kilowatt-thermal MS military standard
HVAC heating, ventilation, and air L liter ms millisecond
conditioning
HWT high water temperature LAN local area network m/sec. meters per second
Hz hertz (cycles per second) LxWx length by width by height mtg. mounting
H
IBC International Building Code lb. pound, pounds MTU Motoren-und Turbinen-Union
IC integrated circuit lbm/ft3 pounds mass per cubic feet MW megawatt
ID inside diameter, identification LCB line circuit breaker mW milliwatt
IEC International Electrotechnical LCD liquid crystal display µF microfarad
Commission
IEEE Institute of Electrical and LED light emitting diode µF microfarad
Electronics Engineers
IMS improved motor starting Lph liters per hour

134 TP-7153 5/24

 N, norm. normal (power source) PMG permanent magnet generator SCR silicon controlled rectifier
(electrical), selective catalytic
reduction (exhaust emissions)
NA not available, not applicable pot potentiometer, potential s, sec. second
nat. gas natural gas ppm parts per million SI Systeme international d’unites,
International System of Units
NBS National Bureau of Standards PROM programmable read-only SI/EO side in/end out
memory
NC normally closed psi pounds per square inch sil. Silencer
NEC National Electrical Code psig pounds per square inch gauge SMTP simple mail transfer protocol
NEMA National Electrical pt. pint SN serial number
Manufacturers Association
NiCd nickel cadmium PTC positive temperature coefficient SNMP simple network management
protocol
NFPA National Fire Protection PTO power takeoff SPDT single-pole, double-throw
Association
Nm newton meter PVC polyvinyl chloride SPST single-pole, single-throw
NO normally open PVC polyvinyl chloride spec specification
no., nos. number, numbers PWM pulse width modulated, pulse specs specification(s)
width modulation
NPS National Pipe, Straight qt. quart, quarts sq. square
NPSC National Pipe, Straight-coupling qty. quantity sq. cm square centimeter
NPT National Standard taper pipe R replacement (emergency) sq. in. square inch
thread per general use power source
NPTF National Pipe, Taper-Fine rad. radiator, radius SMS short message service
NR not required, normal relay RAM random access memory SS stainless steel
Ns nanosecond RDO relay driver output std. standard
OC overcrank ref. reference stl. Steel
OD outside diameter rem. Remote tach. Tachometer
OEM original equipment Res/Co Residential/Commercial TB terminal block
manufacturer ml
OF overfrequency RFI radio frequency interference TCP transmission control protocol
opt. option, optional RH round head TD time delay
OS oversize, overspeed RHM round head machine (screw) TDC top dead center
OSHA Occupational Safety and Health rly. Relay TDEC time delay engine cooldown
Administration
OSHPD Office of Statewide Health rms root mean square TDEN time delay emergency to
Planning and Development normal
(California)
OV overvoltage rnd. Round TDES time delay engine start
oz. ounce RO read only TDNE time delay normal to
emergency
p., pp. page, pages ROM read only memory TDOE time delay off to emergency
PC personal computer rot. rotate, rotating TDON time delay off to normal
PCB printed circuit board rpm revolutions per minute temp. temperature
pF picofarad RS right side term. Terminal
PF power factor RTDs resistance temperature THD total harmonic distortion
detectors
ph., ø phase RTU remote terminal unit TIF telephone influence factor
PHC Phillips® head Crimptiter RTV room temperature vulcanization tol. Tolerance
(screw)
PHH Phillips® hex head (screw) RW read/write turbo. Turbocharger
PHM pan head machine (screw) SAE Society of Automotive typ. typical (same in multiple
Engineers locations)
PLC programmable logic control scfm standard cubic feet per minute UF underfrequency

TP-7153 5/24 135

 UHF ultrahigh frequency
UIF user interface
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
URL uniform resource locator (web
address)
US undersize, underspeed
UV ultraviolet, undervoltage
V volt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
W watt
WCR withstand and closing rating
w/ with
WO write only
w/o without
wt. weight
xfmr transformer

136 TP-7153 5/24

 Appendix B. Common Hardware Application Guidelines

Use the information below and on the following pages to identify proper fastening techniques when no specific reference for
reassembly is made.

Bolt/Screw Length: When bolt/screw length is not given, use Figure 114 as a guide. As a general rule, a minimum length of one
thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method.

Washers and Nuts: Use split lock washers as a bolt locking device where specified. Use SAE flat washers with whiz nuts,
spiralock nuts, or standard nuts and preloading (torque) of the bolt in all other applications.

See the Torque Specifications in the appendix and other torque specifications in the service literature.

Preferred Nut/Bolt Clearance Unacceptable Nut/Bolt Clearance

1/2 of bolt Min. 1 full thread Below top of nut
diameter beyond top of nut

G-585

Figure 114 Acceptable Bolt Lengths

Steps for common hardware application:

1. Determine entry hole type: round or slotted.

2. Determine exit hole type: fixed female thread (weld nut), round, or slotted.

3. For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter, or 1/2 inch in diameter or
less. Hardware that is greater than 1/2 inch in diameter takes a standard nut and SAE washer. Hardware1/2 inch or
less in diameter can take a properly torqued whiz nut or spiralock nut. See Figure 115.

4. Follow these SAE washer rules after determining exit hole type:

a. Always use a washer between hardware and a slot.

b. Always use a washer under a nut (see step 2 above for exception).

c. Use a washer under a bolt when the female thread is fixed (weld nut).

5. Refer to Figure 115, which depicts the preceding hardware configuration possibilities.

TP-7153 5/24 137

 Entry hole types

Cap screw

Standard nut and

SAE washer

G-585

Exit hole types Weld nuts: above 1/2 in. dia.

Hardware Whiz nut or spiralock: up to 1/2
in. dia. Hardware

Figure 115 Acceptable Hardware Combinations

138 TP-7153 5/24

 Appendix C. Torque Specifications

American Standard Fasteners Torque Specifications

Assembled into Cast Iron or Steel Assembled
Size
into Aluminum
Grade 2 Grade 5 Grade 8
8-32 2.0 Nm (18 in. lb.) 3.1 Nm (27 in. lb.) -
10-24 3.2 Nm (28 in. lb.) 4.9 Nm (43 in. lb.) -
10-32 3.6 Nm (32 in. lb.) 5.5 Nm (49 in. lb.) -
12-24 5.0 Nm (44 in. lb.) 7.7 Nm (68 in. lb.) -
1/4-20 7.6 Nm (67 in. lb.) 11.6 Nm (103 in. lb.) 16.5 Nm (146 in. lb.)
1/4-28 8.6 Nm (76 in. lb.) 13.2 Nm (117 in. lb.) 18.8 Nm (166 in. lb.)
5/16-18 15.5 Nm (137 in. lb.) 24.0 Nm (212 in. lb.) 33.9 Nm (300 in. lb.)
5/16-24 17.1 Nm (151 in. lb.) 26.4 Nm (234 in. lb.) 40 Nm (28 ft. lb.)
3/8-16 27 Nm (243 in. lb.) 42 Nm (31 ft. lb.) 60 Nm (44 ft. lb.)
3/8-24 31 Nm (274 in. lb.) 47 Nm (35 ft. lb.) 68 Nm (50 ft. lb.)
7/16-14 43 Nm (32 ft. lb.) 68 Nm (50 ft. lb.) 96 Nm (71 ft. lb.) See Note 3
7/16-20 49 Nm (36 ft. lb.) 76 Nm (56 ft. lb.) 107 Nm (79 ft. lb.)
1/2-13 66 Nm (49 ft. lb.) 103 Nm (76 ft. lb.) 146 Nm (108 ft. lb.)
1/2-20 75 Nm (55 ft. lb.) 117 Nm (86 ft. lb.) 164 Nm (121 ft. lb.)
9/16-12 96 Nm (71 ft. lb.) 149 Nm (110 ft. lb.) 210 Nm (155 ft. lb.)
9/16-18 107 Nm (79 ft. lb.) 165 Nm (122 ft. lb.) 235 Nm (173 ft. lb.)
5/8-11 133 Nm (98 ft. lb.) 206 Nm (152 ft. lb.) 290 Nm (214 ft. lb.)
5/8-18 150 Nm (111 ft. lb.) 232 Nm (171 ft. lb.) 328 Nm (242 ft. lb.)
3/4-10 - 365 Nm (269 ft. lb.) 515 Nm (380 ft. lb.)
3/4-16 - 405 Nm (299 ft. lb.) 572 Nm (422 ft. lb.)
1-8 - 881 Nm (650 ft. lb.) 1245 Nm (918 ft. lb.)
1-12 - 961 Nm (709 ft. lb.) 1357 Nm (1001 ft. lb.)
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)
Assemblies into Cast Iron or Steel Assembled into
Size (mm)
Grade 5.8 Grade 8.8 Grade 10.9 Grade 12.9 Aluminum
Mxxx-04xxx-xx 1.9 (1.4) 2.9 (2.1) 4.3 (3.2) 4.3 (3.2)
Mxxx-05xxx-xx 3.8 (2.8) 5.8 (4.3) 8.5 (6.3) 8.5 (6.3)
Mxxx-06xxx-xx 6.5 (4.8) 10.4 (7.7) 14.7 (11) 17.6 (13)
Mxxx-08xxx-xx 16 (12) 25 (17) 36 (26) 43 (31)
Mxxx-08xxx-xxF 17 (13) 27 (20) 38 (28) 46 (34)
Mxxx-10xxx-xx 31 (23) 50 (37) 70 (52) 85 (62)
Mxxx-10xxx-xxF 33 (24) 53 (39) 74 (55) 89 (66)
Mxxx-12xxx-xx 55 (40) 87 (64) 123 (91) 147 (109)
Mxxx-12xxx-xxF 60 (44) 95 (70) 134 (99) 161 (119)
Mxxx-14xxx-xx 87 (64) 135 (103) 196 (145) 236 (174)
Mxxx-14xxx-xxF 94 (69) 151 (111) 212 (156) 254 (188)
Mxxx-16xxx-xx 135 (100) 217 (160) 305 (225) 365 (270)
See Note 3
Mxxx-16xxx-xxF 145 (107) 231 (171) 325 (240) 390 (288)
Mxxx-18xxx-xx 187 (138) 299 (221) 421 (310) 505 (373)
Mxxx-18xxx-xxF 210 (155) 336 (248) 473 (349) 567 (419)
Mxxx-20xxx-xx 264 (195) 423 (312) 595 (439) 714 (526)
Mxxx-20xxx-xxF 293 (216) 469 (346) 660 (487) 792 (584)
Mxxx-22xxx-xx 360 (266) 576 (425) 811 (598) 973 (718)
Mxxx-22xxx-xxF 396 (292) 633 (467) 890 (657) 1068 (788)
Mxxx-24xxx-xx 457 (337) 731 (539) 1028 (758) 1233 (910)
Mxxx-24xxx-xxF 498 (367) 797 (588) 1121 (827) 1345 (992)
Mxxx-27xxx-xx - 1072 (790) 1507 (1112) 1809 (1334)
Mxxx-27xxx-xxF - 1156 (853) 1626 (1199) 1952 (1439)
Mxxx-30xxx-xx - 1453 (1072) 2043 (1507) 2452 (1809)
Notes:

1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or
assembly drawings when they differ from the above torque values.

2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are
used.

3. At minimum, hardware threaded into aluminum must have two diameters of thread engagement. Hardware threaded
into steel and cast iron must have 1.25 diameters of thread.

4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 75%
of proof strength and a friction coefficient of 0.2.

TP-7153 5/24 139

140 TP-7153 5/24
TP-7153 5/24 141
TP-7153 5/24i KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
Original Instructions (English) For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
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