TP 5700

Installation
Industrial Generator Sets
Models:
10-3250 kW
TP-5700 8/20aa
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. Record field-installed
kit numbers after installing the kits.
Generator Set Identification Numbers
Record the product identification numbers from the engine nameplate(s).
Model Designation _________________________________________________________
Specification Number _______________________________________________________
Serial Number: ____________________________________________________________
Controller Identification
Record the controller description from the generator set operation manual, spec sheet, or sales invoice.
Controller Description________________________________________________________
Engine Identification
Record the product identification information from the engine nameplate.
Manufacturer_________________________________________________________________
Model Designation___________________________________________________________
Serial Number_______________________________________________________________
Accessory Number Accessory Description Accessory Number Accessory Description
2 TP-5700 8/20
Table of Contents
Safety Precautions and Instructions ........................................................................................................................................ 7

Introduction .............................................................................................................................................................................. 15
Service Assistance................................................................................................................................................................... 16
Section 1. General.................................................................................................................................................... 17
Section 2. Loading and Transporting..................................................................................................................... 19
2.1Lifting...................................................................................................................................................................... 19
2.1.1 Weight and Center of Gravity ................................................................................................................... 20
2.1.2 Lifting the Generator Set .......................................................................................................................... 20
2.1.3 Lifting the Subbase Fuel Tank ................................................................................................................. 22
2.1.4 Lifting the Generator Set with Attached Enclosure ................................................................................... 23
2.1.5 Lifting the Generator Set, Enclosure, and Subbase Fuel Tank Assembly ................................................ 24
2.1.6 Lifting Single Point Lift Assemblies .......................................................................................................... 28
2.2 Generating Set Transporting .................................................................................................................................. 29
Section 3. Location .................................................................................................................................................. 31
3.1Location Factors ..................................................................................................................................................... 31
3.2Mounting Surface ................................................................................................................................................... 32
3.2.1 Single-Pad Mounting ................................................................................................................................ 32
3.2.2 Dual-Pad Mounting .................................................................................................................................. 33
3.2.3 Four-Pad Mounting .................................................................................................................................. 33
3.2.4 Mounting Pad Specifications .................................................................................................................... 34
3.3 IBC Seismic Installation.......................................................................................................................................... 34
3.4 Vibration Isolation ................................................................................................................................................... 35
3.5 Dual-Bearing Alternator Alignment ......................................................................................................................... 38
Section 4. Air and Cooling ...................................................................................................................................... 39
4.1General .................................................................................................................................................................. 39
4.2Air-Cooled Engines ................................................................................................................................................ 39
4.3Liquid-Cooled Engines ........................................................................................................................................... 39
4.3.1 System Features ...................................................................................................................................... 39
4.3.2 Installation Considerations ....................................................................................................................... 40
4.3.3 Recommended Coolant ........................................................................................................................... 41
4.4 Unit-Mounted Radiator Cooling .............................................................................................................................. 42
4.4.1 System Features ...................................................................................................................................... 42
4.5 Remote Radiator Cooling ....................................................................................................................................... 44
4.5.1 General .................................................................................................................................................... 44
4.5.2 Vent Lines ................................................................................................................................................ 47
4.5.3 Fill Lines (Balance or Static) .................................................................................................................... 48
4.5.4 Location Considerations .......................................................................................................................... 48
4.5.6 Surge (Expansion) Tank for Horizontal Discharge Radiator..................................................................... 50
4.5.7 Procedure to Fill with Deaeration ............................................................................................................. 51
4.5.8 Procedure to Fill without Deaeration ........................................................................................................ 51
4.5.9 Checks after Initial Startup ....................................................................................................................... 51
4.6 City Water Cooling ................................................................................................................................................. 52
4.6.1 System Features ...................................................................................................................................... 52
4.7 Cooling Tower ........................................................................................................................................................ 53
4.8 Block Heaters ......................................................................................................................................................... 53
Section 5. Exhaust System ..................................................................................................................................... 55
5.1 Flexible Exhaust Line ............................................................................................................................................. 55
TP-5700 8/20 3
5.2 Condensation Trap ................................................................................................................................................. 56
5.3 Piping ..................................................................................................................................................................... 56
5.4 Double-Sleeved Thimbles ...................................................................................................................................... 57
5.5 Exhaust Outlet ........................................................................................................................................................ 58
5.6 Exhaust System Backpressure .............................................................................................................................. 59
Section 6. Fuel System ............................................................................................................................................ 67
6.1 Diesel Fuel Systems............................................................................................................................................... 68
6.1.1 Main Tank ................................................................................................................................................ 69
6.1.2 Day Tanks ................................................................................................................................................ 74
6.1.3 Fuel Lines ................................................................................................................................................ 75
6.1.4 Auxiliary Fuel Pumps ............................................................................................................................... 76
6.2 Gas Fuel Systems, Common Components ............................................................................................................ 77
6.2.1 Gas Lines ................................................................................................................................................. 78
6.2.2 Gas Regulators ........................................................................................................................................ 79
6.3 LP Fuel Systems .................................................................................................................................................... 80
6.3.1 LP Gas Liquid-Withdrawal Systems ......................................................................................................... 82
6.3.2 LP Gas Vapor-Withdrawal Systems ......................................................................................................... 83
6.4 Natural Gas Systems ............................................................................................................................................. 84
6.5 Combination Systems ............................................................................................................................................ 85
6.5.1 Combination Natural Gas and LP Gas ..................................................................................................... 85
6.6 Pipe Size Requirements for Gas Fuel Systems ..................................................................................................... 87
Section 7. Electrical System ................................................................................................................................... 89
7.1 Generator Set Voltage Reconnection ..................................................................................................................... 90
7.2 Electrical Connections ............................................................................................................................................ 90
7.3 Load Lead Connections ......................................................................................................................................... 91
7.4 Grounding and Grounded Conductor (Neutral) Connections ................................................................................. 92
7.5 Terminal Connector Torque ................................................................................................................................... 93
7.6 Batteries ................................................................................................................................................................. 94
7.7 Battery Chargers .................................................................................................................................................... 95
7.8 Component and Accessory Power Source Requirements ...................................................................................... 96
7.9 Optional Accessories.............................................................................................................................................. 97
7.9.1 Bus Bar Kits/Bus Lugs ............................................................................................................................. 98
7.9.2 Gas Fuel Valve Kit ................................................................................................................................... 98
7.9.3 Line Circuit Breaker ................................................................................................................................. 99
7.9.4 Run Relay Kit ........................................................................................................................................... 99
7.9.5 Wireless Monitor .................................................................................................................................... 100
7.9.6 Wiring Connections ................................................................................................................................ 102
Section 8. APM402/Decision-Maker 3000 Controller Accessories .................................................................... 103
8.1 Accessories and Connections .............................................................................................................................. 103
8.1.1 Battery Charger Kit with Alarm Option ................................................................................................... 104
8.1.2 Common Fault/Failure (32A) Relay ........................................................................................................ 105
8.1.3 Four-Input/Fifteen-Output Module .......................................................................................................... 106
8.1.4 Gas Fuel Valve Kit ................................................................................................................................. 110
8.1.5 Two-Input/Five-Output Module............................................................................................................... 110
8.1.6 Low Fuel (Level/Pressure) Switch.......................................................................................................... 112
8.1.7 Prime Power Switch Kit .......................................................................................................................... 113
8.1.8 Remote Emergency Stop Kit .................................................................................................................. 114
8.1.9 Remote Reset Feature ........................................................................................................................... 115
8.1.10 Remote Serial Annunciator (RSA III) ..................................................................................................... 116
8.1.11 Shunt-Trip Line Circuit Breaker .............................................................................................................. 118
8.2 Accessory Connections ........................................................................................................................................ 119
4 TP-5700 8/20
Section 9. APM603 Controller Accessories and Connections ........................................................................... 123
9.1 APM603 Controller Optional Connections ............................................................................................................ 123
9.1.1 Run Relay .............................................................................................................................................. 123
9.1.2 Factory-Defined Inputs and Outputs ...................................................................................................... 123
9.2.1 6-Amp Battery Charger Kit ..................................................................................................................... 124
9.2.2 10-Amp Battery Charger Temperature Compensation Kit ..................................................................... 125
9.2.3 Common Fault/Failure Relay ................................................................................................................. 126
9.2.5 Fuel Level Sender and Fuel Leak Alarm ................................................................................................ 132
9.2.9 Power Distribution Switchboards ........................................................................................................... 136
9.3.1 Controller Connections .......................................................................................................................... 137
Section 10. APM603 and APM802 Controller Accessories, KD800–KD3250 ...................................................... 141
10.1 Input/Output Modules ........................................................................................................................................... 142
10.1.1 Analog Input/Output Module .................................................................................................................. 142
10.1.2 Digital Input/Output Module.................................................................................................................... 143
10.1.3 Thermocouple Input Module .................................................................................................................. 145
10.2 Remote Emergency Stop Kit ................................................................................................................................ 146
10.3 Remote Serial Annunciator (RSA III) .................................................................................................................... 147
Section 11. Decision-Maker 550 Controller Accessories ..................................................................................... 151
11.1.1 Audiovisual Alarm Kit ............................................................................................................................. 151
11.1.2 Common Failure Relay Kit ..................................................................................................................... 152
11.1.3 Controller (Customer) Connection Kit .................................................................................................... 153
11.1.4 Float/Equalize Battery Charger Kit with Alarm Option ............................................................................ 154
11.1.5 Ground Fault Annunciation .................................................................................................................... 154
11.1.6 Idle (Speed) Mode Feature .................................................................................................................... 157
11.1.7 Low Fuel (Level/Pressure) Switch.......................................................................................................... 158
11.1.13 Single-Relay Dry Contact Kit.................................................................................................................. 165
11.1.14 Ten-Relay Dry Contact Kit ..................................................................................................................... 166
11.1.15 Twenty-Relay Dry Contact Kit ................................................................................................................ 167
Section 12. Decision-Maker 3500 Controller Accessories ................................................................................... 171
12.1.1 Fifteen-Relay Dry Contact Kit................................................................................................................. 172
TP-5700 8/20 5
Section 13. Decision-Maker 6000 Controller Accessories ................................................................................... 179
13.1.1 Audiovisual Alarm Kit ............................................................................................................................. 179
13.1.2 Common Failure Relay Kit ..................................................................................................................... 180
13.1.3 Float/Equalize Battery Charger Kit with Alarm Option ............................................................................ 181
13.1.4 Ground Fault Annunciation .................................................................................................................... 181
13.1.5 Idle (Speed) Mode Feature .................................................................................................................... 184
13.1.6 Low Fuel (Level/Pressure) Switch .......................................................................................................... 185
13.1.11 Shunt Trip Line Circuit Breaker .............................................................................................................. 191
13.1.12 Single-Relay Dry Contact Kit.................................................................................................................. 192
13.1.13 Ten-Relay Dry Contact Kit ..................................................................................................................... 193
13.1.14 Twenty-Relay Dry Contact Kit ................................................................................................................ 194
Section 14. Remote Adjustment/Control Systems ................................................................................................ 199
14.1 Automatic Transfer Switches ................................................................................................................................ 200
14.2 APM402 and Decision-Maker 3000 Controller Voltage Regulator ........................................................................ 200
14.3 APM603 Controller Voltage Regulator ................................................................................................................. 200
14.4 APM802 Controller Voltage Regulator ................................................................................................................. 200
14.5 Decision-Maker 550 Controller, Voltage Regulator and Paralleling Applications ................................................. 200
14.6 Decision-Maker 3500 Controller Voltage Regulator ............................................................................................. 201
14.7 Decision-Maker 6000 Controller Voltage Regulator and Paralleling Applications ................................................ 201
14.8 Decision-Maker 8000 Controller Voltage Regulator and Paralleling Applications ................................................ 201
14.9 Remote Speed Adjustment .................................................................................................................................. 201
14.10 Remote Voltage Adjustment................................................................................................................................. 203
14.11 Remote Wiring ..................................................................................................................................................... 205
14.12 Voltage Regulator DVR 2000 / Remote Voltage Regulator Kit, 350 kW and Above ............................................. 205
Appendix A. Abbreviations ....................................................................................................................................... 207
Appendix B. Common Hardware Application Guidelines ...................................................................................... 211
Appendix C. Torque Specifications ......................................................................................................................... 213
Appendix D. Fuel Physical Properties ..................................................................................................................... 214
Appendix E. Gas Fuel Vapor Pressures .................................................................................................................. 215
Appendix F. Gas Fuel System Installation Planning .............................................................................................. 216
6 TP-5700 8/20
Safety Precautions and 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.
TP-5700 8/20 7
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) Move the generator set master switch to the OFF
position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (–) lead first. Reconnect the
negative (–) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an
automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
(Decision-Maker® 3+ and 550 Controllers)
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.
(APM402, APM603 and Decision-Maker® 3000, 3500, and 6000 Controllers)
equipment connected to the set, disable the generator set as follows: (1) If the controller is not already in the MAN (manual)
mode, press the Controller Mode button and then press the MAN mode button. (2) If the generator set is running, press and hold
the Manual-Stop button for at least 2 seconds to stop the generator set. (3) Press the Controller Mode button and then press
the controller Off mode 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.
(Decision-Maker® 8000 Controller)
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)
8 TP-5700 8/20
Battery
WARNING Sulfuric acid in batteries.

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
WARNING Explosion.
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.
TP-5700 8/20 9
Engine Backfire/Flash Fire
WARNING Risk of fire.

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 mixer, fuel line, fuel filter, or other potential sources of fuel vapors. When removing the fuel line or fuel system be aware that
liquid propane can cause frostbite on contact.
(Gaseous-fueled Model)
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.
(Diesel-fueled Model)
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.
10 TP-5700 8/20
Fuel System
WARNING Explosive fuel vapors.

Use extreme care when handling, storing, and using fuels.
WARNING Avoid high pressure fluids.

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.
Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels:
Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.
Propane (LPG)—Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in
a room. Inspect the detectors per the manufacturer’s instructions.
Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect
the detectors per the manufacturer’s instructions.
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.
Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the
LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6–
8 ounces per square inch (10–14 inches water column). Do not use a soap solution containing either ammonia or chlorine
because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
LPG liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an
explosion. Check the LPG liquid withdrawal fuel system for leakage by using a soap and water solution with the fuel system test
pressurized to at least 90 psi (621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent
bubble formation. A successful test depends on the ability of the solution to bubble.
TP-5700 8/20 11
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.
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.

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).
12 TP-5700 8/20
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)
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 Unbalanced weight.

Improper lifting can cause severe injury or death and equipment damage.
Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting
holes on the skid.
WARNING Unbalanced and elevated weight.

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.
TP-5700 8/20 13
Hot Parts
WARNING Hot coolant and steam.

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.

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.
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.
14 TP-5700 8/20
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.
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.
Multiple Part Numbers
Generator Set/Controller Wiring Diagram Manual
Contact your Distributor/Dealer
Monitor III Converters, Connections, and Controller Setup TT-1405
Monitor III Software Spec Sheet G6-76
Monitor III Converter, Modbus®/Ethernet Spec Sheet G6-79
Monitor III Software Operation Manual TP-6347
Modbus® Communications Protocol Operation Manual TP-6113
Protocol Manual, APM603 Controller TP-7151
Program Loader Software Installation TT-1285
SiteTech™ Software Operation Manual TP-6701
Remote Serial Annunciator (RSA) TT-1625
Decision-Maker® Paralleling System (DPS) Spec Sheet G6-110
Decision-Maker® Paralleling System (DPS) Operation Manual TP-6747
Commissioning Manual. APM603 Controller TP-7131
Battery Charger, 10 amp float/equalize TP-7077
Battery Charger, 6 amp float/equalize TT-1702
Battery Charger, ESCR II TP-7025
APM802 Operation Manual TP-7070
KD800 – KD3250 Installation Manual TP-7153
25CCL – 36CCL Installation Manual TP-7119
Figure 1 Related Literature
TP-5700 8/20 15
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
16 TP-5700 8/20
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
Water trap with drain Silencer
Exhaust thimble
(for wall or ceiling)
Electrical conduit
Fresh air intake Flexible sections
Controller
Duct work for
cooling air outlet
Mounting base
Figure 2 Typical Stationary-Duty Generator Set Installation

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-5700 8/20 17
18 TP-5700 8/20
Section 2. 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.
2.1 Lifting
WARNING Unbalanced and elevated weight.

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.
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, alternator, or the top of the radiator as these
lifting eyes cannot support the total weight of the generator set.
 Always protect cables, chains, and straps from sharp edges.
Reinforcing plate
Figure 3 Improper Lifting Hook Placement (above 1000 kW)

 Generator sets typically above 1000 kW may have reinforcing plates on the skid. Do not attach lifting hooks to the
reinforcing plate. See Figure 3.
 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.
TP-5700 8/20 19
2.1.1 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)
2.1.2 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. Remove cover plates as needed to access the generator set skid lifting
eyes.
 See Figure 4 for the spreader bar and hook methods.
 See Figure 5 for the spreader bar and skid lifting bar 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 4 Single and Double Spreader Bar and Hook Method
20 TP-5700 8/20
Single Spreader Bar and Skid Lifting Bar Method Double Spreader Bar and Skid Lifting Bar Method
Spreader bar Spreader bar
20° 20° max.

max. 20° max. 20° max.
Lifting bar Lifting bar
Figure 5 Single and Double Spreader Bar and Skid Lifting Bar Method
TP-5700 8/20 21
2.1.3 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 6 Fuel Tank with Single and Double Spreader Bar Method
22 TP-5700 8/20
2.1.4 Lifting the Generator Set with Attached Enclosure
Enclosure Attached Directly to the Generator Set Skid
Refer to Figure 7. Lift the assembly by lifting on the skid as shown in the previous section on Lifting the Generator Set.
Do not attach hoisting equipment to the enclosure.
Generator Set Skid Skid Lifting Eyes
Figure 7 Typical Enclosure Attached Directly to the Generator Set Skid
Enclosure Attached Directly to the Subbase Fuel Tank
Refer to Figure 8. Lift the assembly by lifting on the subbase fuel tank lifting eyes. Lift using all of 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.
Enclosure Attached to the Enclosure Base and Assembled to the Subbase Fuel Tank
Refer to Figure 9.
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 from the following illustrations
based on the matching number of available enclosure base lifting eyes.
Subbase Fuel Tank Lifting Eyes
Figure 8 Typical Enclosure Attached Directly to the Subbase Fuel Tank
TP-5700 8/20 23
Lift the entire enclosure, generator set, and subbase fuel tank assembly by lifting on the subbase fuel tank lifting eyes. Lift using
all of 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.
Enclosure Base Lifting Eyes
Figure 9 Typical Enclosure Attached to the Enclosure Base and Assembled to the Subbase Fuel Tank
2.1.5 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.
2.1.5.1 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.
24 TP-5700 8/20
2.1.5.2 Six Eye Lifting Method
Hoisting using Six Eye Lifting Method
Apply one spreader bar and two chain falls or three spreader bars and two chain falls for six eyes lifting.
 Install a pair of outer slings to the maximum angle as shown in Figure 10.
 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.
Single Spreader Bar and Two Chain Falls
Three Spreader Bars and Two Chain Falls
Spreader bar
Spreader bar
20° max.
20° max. 20°
max. 20°max.
Chain fall Lifting eyes Chain fall Lifting eyes
Figure 10 Six Eye Lifting Methods
TP-5700 8/20 25
2.1.5.3 Eight Eye Lifting Method
Hoisting using Eight Eye Lifting Method
 Apply two spreader bars and four chain falls (Figure 11) for eight eye lifting.
 Install a pair of outer slings up to the maximum angle as shown in Figure 11.
the slack.
carrying load.
Spreader bar
20°
max.
20°
max.
Chain fall Lifting eyes
Figure 11 Eight Eyes, Two Spreader Bars, and Four Chain Falls Lifting Method
26 TP-5700 8/20
2.1.5.4 Ten Eye Lifting Method
Hoisting using Ten Eye Lifting Method
Apply three spreader bars and six chain falls for ten eye lifting.
the slack.
carrying load.
Spreader bar
20°
max.
20° max.
Chain fall Chain fall Lifting eyes
Figure 12 Ten Eyes, Three Spreader Bars, and Six Chain Falls Lifting Method
TP-5700 8/20 27
2.1.5.5 Twelve Eye Lifting Method
Hoisting using Twelve Eye Lifting Method
Apply three spreader bars and eight chain falls for twelve eye lifting.
the slack.
carrying load.
Spreader bar
20°
max. 20°
max.
Chain fall Chain fall Lifting eyes
Figure 13 Twelve Eyes, Three Spreader Bars, and Eight Chain Falls Lifting Method
2.1.6 Lifting Single Point Lift Assemblies
Some units have an enclosure integral to the skid and attach a single point lifting eye located at the top and center of the
enclosure. The entire assembly may be lifted with this eye.
28 TP-5700 8/20
2.2 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-5700 8/20 29
30 TP-5700 8/20
Section 3. Location
3.1 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.
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
TP-5700 8/20 31
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.
3.2 Mounting Surface
Figure 14 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.
Extend the concrete

Battery rack
Generator set skid surface a minimum of
Allow at least 457 mm (18 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 14 Mounting Surface Detail (top view)
3.2.1 Single-Pad Mounting
The manufacturer recommends a single, level concrete mounting pad as shown in Figure 15. 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 15 Single-Pad Mounting
32 TP-5700 8/20
3.2.2 Dual-Pad Mounting
The two-pad arrangement shown in Figure 16 provides easy access to conveniently drain the oil. Follow the oil draining
considerations outlined in the previous section, Single-Pad Mounting.
Figure 16 Dual-Pad Mounting
3.2.3 Four-Pad Mounting
The four-pad arrangement shown in Figure 17 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 17 Four-Pad Mounting
TP-5700 8/20 33
3.2.4 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 roughins and stubups including model specific clearances.
3.3 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.
34 TP-5700 8/20
3.4 Vibration Isolation
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.
Isolator types
The two primary types of isolators are neoprene and spring-type. Figure 18 shows neoprene isolators 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% vibration isolation efficiency and are often sufficient for
installations at or below grade.
To engine-generator
Neoprene
Neoprene To engine-generator vibration
vibration isolator
isolator
Skid crossmember Skid crossmember
Figure 18 Neoprene-Type Integral Vibration Isolators

Figure 19 through Figure 23 shows the spring-type isolator kit 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.
Generator sets with integral vibration isolation (neoprene isolators)
Skids for generator sets 20 kW and larger use I or C section-fabricated steel with a width of 52-76 mm (2-3 in.) per channel. The
length varies with the size of the unit, resulting in a static load on the generator set skid of 69-72 kPa (10-25 psi) if the total
bottom surface of the channel is in contact with the mounting pad.
Generator sets with direct mounting (spring-type isolators)

Larger generator sets typically mount directly to a structural steel base. For these units, install the recommended 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).
Note:
Refer to the instructions supplied with the vibration isolator kits for more details.
TP-5700 8/20 35
Note: Dimensions shown are mm (inches)
51 (2)
11 (0.44)
191 (7.5)
Ø 11 (0.44) 4 holes
203 (8)
Ø 16 (0.62)
127 (5) ref.
Figure 19 Vibration Isolators GM39515 and GM41122

4 x Ø 19.05 (0.75) for attachment to concrete
158.8 (6.25) 57.2 (2.25)
2 x Ø 19.05 (0.75) for attachment to steel

184.2 (7.25)
5/8” removable adjustment bolt
156 (6.1) free &

operating height
228.6 (9)
Figure 20 Vibration Isolators GM66019, GM66304 and GM76149
Note: Dimensions shown are in mm and inches. 4 x Ø 20.64 (0.8125) for attachment to concrete
57.2 158.8
(2.25) (6.25)
101.6 (4)
22.2
285.8 (11.25) (0.875)
5/8” removable adjustment bolt
4 x Ø 19.05 (0.75) for attachment to steel
158.8
(6.125)
Figure 21 Vibration Isolators GM66020, GM66022, GM66023, GM66024, and GM66313
36 TP-5700 8/20
6 x Ø 20.63 (0.8125) for mounting to concrete
177.8
(7)
241.5 (9.5) Typical
7/8 clamp down stud washer and nut
228.6 (9) free &

operating height
Figure 22 Vibration Isolator GM66025
Note: Dimensions shown are in mm (inches). 4 X (base plate) Ø 19 (0.75) hole

for attachment to steel
Ø 6 x 21 (0.81) hole for (View cut away for clarity)
attachment to concrete
29 (1.13) 305 (12)
159
(6.25)
57
(2.25)
73
(2.88)
181 (7.13)
22 38 286 (11.25)
(0.88) (1.5)
19 (0.75) removable
adjusting bolt
156 (6.13)
free &
operating
height
Figure 23 Vibration Isolator GM84038, GM84954, 11808000100, 11808000200, and 11808000300
TP-5700 8/20 37
Generator sets mounted on subbase fuel tanks
Do not install vibration spring isolators under the subbase fuel tank.
Dual isolation. For applications involving integral vibration isolators and where the factory does not offer spring-type isolators
as a standard accessory, spring-type isolators may be installed under the skid provided they equal the number of neoprene
isolators, are inline front-to-back with the existing neoprene isolators, and additional support plates are installed, as required.
See Figure 24.
Generator set neoprene

integral vibration isolators
Skid rail gussets

Generator set skid rail
Axial Direction
Locate accessory spring-type vibration Support plate, 13 mm (1/2in.) thick steel, of sufficient
isolators axially aligned with neoprene length to distribute loads directly to skid rail gussets.
isolators
Concrete mounting pad
Figure 24 Accessory Vibration Mount Location
3.5 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.
38 TP-5700 8/20
Section 4. Air and Cooling
4.1 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 70% 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.
4.2 Air-Cooled Engines
Refer to the generator set specification sheet for air requirements. Generally, airflow requirements do not present a problem
since air-cooled models are designed for outside installation.
When planning outside installation, consider how buildings and landscaping affect airflow. Also consider seasonal changes such
as snow or foliage accumulation and potential flooding conditions. Follow a regular maintenance routine to remove snow and
foliage accumulations.
4.3 Liquid-Cooled Engines

4.3.1 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-5700 8/20 39
4.3.2 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 25. 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 25 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 26. 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 26 Stationary Air Inlet Louvers and Moveable Air Inlet Louvers
40 TP-5700 8/20
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.
4.3.3 Recommended Coolant
All applications require antifreeze/coolant protection. Add antifreeze/coolant before starting the generator set or energizing the
block heater(s). Most diesel engine manufacturers require the use of an inhibitor additive to the antifreeze/coolant.
Use a proper mixture of glycol (ethylene, propylene, or extended life organic acid), water, and supplemental coolant additive
(SCA) based on the engine manufacturer’s recommendations. The antifreeze/ coolant and additive mixture reduces corrosion,
sludge formation, and cavitation erosion and provides boil and freeze protection.
Refer to the engine manufacturer’s operation manual for engine antifreeze/coolant specifications, concentration levels, and
inhibitor selection recommendations.
TP-5700 8/20 41
4.4 Unit-Mounted Radiator Cooling
The unit-mounted radiator is the most common cooling system for engine-driven generator sets.
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.
Figure 27 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
Pusher fan Flexible section with radiator duct flange
Figure 27 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.
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 1.5 times the radiator duct flange area or larger and
the inlet air opening to 2.0 times the radiator duct flange area or larger.
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.
42 TP-5700 8/20
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 28 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 28 Air Control Louvers
TP-5700 8/20 43
4.5 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 specification sheet, obtain the:
 Engine jacket water flow, Lpm (gpm)
 Cooling air required for generator set based on 14°C (25°F) rise and an ambient temperature of 29°C (85°F),
m3/min. (cfm)
 Maximum static (vertical) head allowable above engine, kPa (ft. H2O)
 Heat rejection to coolant
From the engine and/or radiator data sheet, obtain the:
 Maximum water pump inlet restriction kPa (psi)
 Maximum allowable coolant pressure differential external to engine kPa (psi)
 Maximum top tank temperature
4.5.1 General
System limitations.
Cooling systems are limited by radiator cap ratings. The maximum radiator operating pressure is 138 kPa (20 psi) and the
maximum operating temperature is 121°C (250°F). Radiators are available for vertical or horizontal discharge. See Figure 29
and Figure 30.
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 29°C (85°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, if necessary, 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.
44 TP-5700 8/20
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 29 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 30 Remote Horizontal Radiator (Vertical Discharge) System
TP-5700 8/20 45
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. The allowable static head ranges from
5.2 m-15.2 m (17 ft.-50 ft.) and is listed on the generator set specification sheet. 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 water 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.
46 TP-5700 8/20
4.5.2 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 circuits including the radiator core. Refer to the
installation drawings for vent points.
Size the vent line the same as the connection point on the engine. The vent lines may be slightly larger; however, vent lines
sized too large will increase fill line flow and possibly reduce head pressure applied to the engine water pump inlets.
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 31 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 32 Compound Remote Radiator/Heat Exchanger Cooling System
TP-5700 8/20 47
4.5.3 Fill Lines (Balance or Static)
Connect the fill line(s) to the bottom of the expansion tank. 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.
The minimum fill line sizes cannot be smaller than the connection point on the engine. Do not allow fittings on the fill lines to
reduce the effective size. If other cooling system components vent too much coolant to the expansion tank, larger diameter fill
lines may be needed.
4.5.4 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.
48 TP-5700 8/20
When installing the remote radiator:
 Use a remote radiator setup kit, if available, to aid installation. See Figure 33.
 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.
Drain valve
Belt guard bracket
Upper radiator hose outlet
Top belt guard
Top mounting bracket
Right-hand
belt guard
Left-hand belt guard
Lower radiator
hose inlet
Front belt guard
Bottom belt guard
Figure 33 Remote Radiator Setup Kit, Typical
TP-5700 8/20 49
4.5.6 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 34.
Drawdown Volume Typical 5-8%

Deaeration Volume Typical >10%
Expansion Volume Typical 8-10% fluid
Total Tank Approximately 25% total system volume
Figure 34 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.
50 TP-5700 8/20
4.5.7 Procedure to Fill with Deaeration
For radiators designed for full deaeration, fill the radiator according to the following procedure.
1. Fill the cooling system from the bottom when possible. Otherwise, fill the radiator at the filler neck.
2. Next, fill the radiator through one of the top tank or expansion/surge tank inlets located before the final hose connection.
3. Continue filling the system to cover the filler neck bottom until coolant appears in the sight glass located in the radiator
top tank.
4. Check and correct any leaks in the system.
5. After initial startup, check coolant levels and add coolant as necessary.
4.5.8 Procedure to Fill without Deaeration
For radiators designed without deaeration, fill the radiator according to the following procedure.
1. Initially, fill the radiator through one of the top tank inlets located before the final hose connection for faster and more
complete fillup.
2. 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. Check for and correct any leaks in the system.
4. After initial startup, check coolant levels and add coolant as necessary.
4.5.9 Checks after Initial Startup
If any problems arise during startup, immediately shut down the generator set. See Figure 35, 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 35 Cooling System Checklist
TP-5700 8/20 51
4.6 City Water Cooling
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 36 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 36 City-Water Cooling System with Heat Exchanger
Vibration isolation requirements
Water inlet and outlet connections are mounted on the generator set skid and isolated from engine vibration by flexible sections.
If the generator set is vibration-mounted to the skid and the skid is bolted directly to the mounting base, no additional flexible
sections are needed between connection points on the skid and city water lines. If the generator set skid is mounted to the base
with vibration isolators, use flexible sections between the connection points on the skid and city water lines.
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.
52 TP-5700 8/20
4.7 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 37.
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 37 Cooling Tower System
4.8 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.
TP-5700 8/20 53
54 TP-5700 8/20
Section 5. Exhaust System
Satisfactory generator set performance requires proper exhaust system installation. The following sections detail arrangements
of typical exhaust systems and exhaust system components.
5.1 Flexible Exhaust Line
Install a section of seamless stainless steel flexible exhaust line at least 305 mm (12 in.) long within 610 mm (2 ft.) of the engine
exhaust outlet. See Figure 38 and Figure 39.
Supports
Flexible section
Silencer Pitch line downward
Water trap
Solid section Drain
152-203mm (6-8 in.) petcock
Manifold
Figure 38 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 39 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.
When using threaded flexible exhaust connectors, place a 152–203 mm (6–8 in.) length of pipe between the flexible exhaust
connectors and the exhaust manifold. See Figure 38. The pipe reduces the temperature of the flexible connection, simplifies
flexible section removal, and reduces strain on the engine exhaust manifold.
TP-5700 8/20 55
5.2 Condensation Trap
Some silencers are equipped with a drain pipe plug for draining condensation; see Figure 40. 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 41. 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 40 Silencer Condensation Drain Plug
Condensation Trap
Figure 41 Condensation Trap
5.3 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. If the proximity of the
exhaust system to the combustible materials cannot be avoided, follow a regular maintenance schedule to ensure that
combustible materials are kept away from the exhaust pipes after installation. Combustible materials include building materials
as well as natural surroundings. Keep dry field grass, foliage, and combustible landscaping material a safe distance from the
exhaust system.
56 TP-5700 8/20
5.4 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 42 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 42 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-5700 8/20 57
5.5 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, do not use a rain cap. Instead, extend the exhaust piping at least 610 mm (24 in.) beyond the roof line and create a
gradual U bend at the end to direct the exhaust outlet downward 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.
Note:
Do not use a rain cap in areas subject to freezing temperatures.
Generator set with enclosure
To avoid exceeding the engine manufacturer’s maximum allowable backpressure specification, enclosure tail pipe extensions
or attachments are not recommended.
58 TP-5700 8/20
5.6 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-5700 8/20 59
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
43.
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 43 Cross Sectional Area for Standard Silencer Sizes
5. Refer to Figure 44. 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 45 to calculate in inches of water and feet per minute.
60 TP-5700 8/20
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:
Flexible sections:
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-5700 8/20 61
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 44 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 45 Silencer Backpressure Drop (in. of water)
62 TP-5700 8/20
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 46 if the pipe size is 102 mm (4 in.) or less or Figure 47 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-5700 8/20 63
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 46 Backpressure using Pipe Size 4 in. (102 mm) or Less
64 TP-5700 8/20
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 47 Backpressure using Pipe Size 5 in. (127 mm) or Larger
TP-5700 8/20 65
66 TP-5700 8/20
Section 6. Fuel System
Comply with applicable state and local codes when installing any fuel system.


Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.
TP-5700 8/20 67
6.1 Diesel Fuel Systems


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 48.
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 48 Diesel Fuel System
68 TP-5700 8/20
6.1.1 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 49 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 49 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 alternatives
Most diesel engines operate satisfactorily on No. 2 domestic burner oil available in most parts of the US. If the site heating
system is oil-fired, consider supplying the engine with fuel from the same tank used for heating oil to reduce costs and to ensure
a continually fresh fuel supply for the engine. This practice necessitates that the fuel oil meets the engine manufacturer’s
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-5700 8/20 69
6.1.1.1 Fuel Tank Monitoring Panel

Screw caps Enclosure entrance
90%-full fuel
level switch
Fuel Monitoring
panel
Flexible conduit,
GM75504 Flexible conduit,
GM75505
Figure 50 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 50, and the
wiring diagram, Figure 54.
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.
70 TP-5700 8/20
Knockout
Enclosure entrance
Figure 51 Enclosure Entrance

2. Locate and remove the knockout in the enclosure base. See Figure 51.
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 52 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 52.
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 54.
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-5700 8/20 71
Low fuel level switch
95%-full fuel level switch
Figure 53 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 54.
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.
72 TP-5700 8/20
Figure 54 Fuel Monitoring Panel Wiring Diagram, GM86940 Sheet 2
TP-5700 8/20 73
6.1.2 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 55.
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 sizes from 38-3952 L (10-1044 gal.) with or without integral electric fuel transfer pumps. Because
engines are subject to fuel temperature deration above 38°C (100°F) and are subject to damage if operated with fuel
temperatures above 60°C (140°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 55.
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
Return line from fuel injectors/fuel rack

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
Flexible line
Fuel supply line from day

tank to engine connection Day tank
Figure 55 Diesel Fuel System with Overhead Main Tank and Day Tank
74 TP-5700 8/20
6.1.3 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 KD and KDI TCR 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 injectors. Size the fuel return lines no smaller than the fuel supply lines.
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.
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-5700 8/20 75
6.1.4 Auxiliary Fuel Pumps
Primary, engine-driven fuel pumps typically develop a maximum of 48 kPa (7 psi) pressure and draw fuel to approximately
1.2-1.4 m (4-5 ft.) vertically or 6 m (20 ft.) horizontally. When the main tank is located a greater distance from the engine or for
a more reliable fuel system, use an auxiliary pump alone or in combination with a day tank. Limit auxiliary fuel pump pressure to
approximately 35 kPa (5 psi).
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.
On engines using less than 38 L (10 gal.) of fuel per hour (approximately 100 kW or less), connect an engine starting battery-
powered electric fuel transfer pump in series with the engine-driven transfer pump. Locate the electric pump nearer to the fuel
tank than to the engine. An auxiliary pump located at the fuel tank approximately doubles the horizontal and vertical distance
limits of a single engine-driven pump.
On engines using more than 38 L (10 gal.) of fuel per hour or when drawing fuel more than 1.8 m (6 ft.) vertically or 12 m (40 ft.)
horizontally, 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 5.5 m (18 ft.) or draw it
horizontally up to 61 m (200 ft.).
Where vertical runs exceed 5.5 m (18 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.
76 TP-5700 8/20
6.2 Gas Fuel Systems, Common Components
Gas fuel systems operate on either LP (liquefied petroleum) or natural gas.
Note:
Design and install gas fuel systems in accordance with NFPA 54, National Fuel Gas Code, and applicable local codes.
All gas systems include a carburetor, secondary gas regulator, electric gas fuel solenoid shutoff valve, and flexible fuel connector.

TP-5700 8/20 77
6.2.1 Gas Lines
Never use fuel piping to ground electrical equipment. The gas supplier is responsible for installation, repair, and alteration to gas
piping.
Line type
Use Schedule 40 black-iron pipe for gas piping. Copper tubing may be used if the fuel does not contain hydrogen sulfide or other
ingredients that react chemically with copper.
Line size
Size piping according to the requirements of the equipment. Refer to the generator set specification sheet or the dimension
drawing for detailed information on your system. In addition to the actual fuel consumption, consider the following pressure loss
factors:
 Pipe length
 Other appliances on the same fuel supply
 Number of fittings
Flexible connections
Rigid-mount the piping but protect it from vibration. Use flexible connections spanning a minimum of 152 mm (6 in.) between the
stationary piping and the engine fuel inlet connection.
78 TP-5700 8/20
6.2.2 Gas Regulators
Gas regulators reduce high incoming fuel pressures to lower levels acceptable for engines. Refer to the generator set spec sheet
for fuel supply pressures. Install a solenoid valve upstream from the gas regulator and the flexible fuel connector to prevent the
accumulation of an explosive mixture of gas and air caused by leaks in the flexible connection or the gas regulator. The generator
set installer normally wires the engine battery-powered solenoid valve to the engine starting controls to open the valve when the
engine cranks or runs.
For UL compliance, the fuel solenoid valves are needed per UL 2200, Section 35.3.2.2.1.
The typical gas system uses two gas regulators:
 Primary gas regulator. Provides initial control of gas from the fuel supply. The primary gas regulator reduces the high
pressure from a tank or transmission line to the low pressure required by the secondary gas regulator(s). Typically, the
primary gas regulator is set at the higher pressure value when a range is given. The gas supplier typically provides the
primary gas regulator, as conditions that dictate the type of gas regulator used vary depending on the method of
supplying fuel. The supplier is also responsible for providing sufficient gas pressure to operate the primary gas
regulator. Primary gas regulator must be vented to the outside if installed within any building.
 Secondary gas regulator. This low-pressure gas regulator is mounted on the engine and limits the maximum inlet
pressure to the engine. The engine operates satisfactorily at the lower pressure value when a range is given, but these
lower pressures may result in poor response to load changes or a lack of power if the primary gas regulator is not near
the engine.
Modification for fuel type
Many gas regulators are compatible with both natural gas and LP gas. Typically, the user installs the spring and retainer in the
gas regulator when connecting to natural gas and removes it from the gas regulator when connecting to LP vapor gas. Refer to
the appropriate generator set’s operation manual and/or the decal attached to the generator set for information regarding
spring/adjustment screw usage for specific models. Some models may require new diaphragm kits and/or inverting the gas
regulator when changing fuel type.
Rating change
Converting the fuel will change the generator set rating. See the generator set specification sheet for ratings with natural gas
and LP. Order a new nameplate with the updated rating and fuel information from an authorized distributor/dealer, if necessary.
Provide the following information from the original nameplate:
 Model number
 Spec number
 Serial number
 Fuel (original and new)
 kW
 kVA
 Amps
 Volts
 Hz
Attach the new nameplate over the old one. Do NOT cover the UL listing information on the old nameplate.
Installation position for fuel type
The gas regulator functions normally pointing downward for both natural gas and LP gas. If only natural gas fuel is used, the gas
regulator should be installed pointing upward.
Pressure testing
Some gas regulators provide for installation of a pressure gauge to test inlet and outlet pressures. If no such provision is
available, install pipe tees in the fuel line to test pressure and use pipe plugs to plug unused openings.
TP-5700 8/20 79
6.3 LP Fuel Systems

80 TP-5700 8/20
Fuel characteristics
LP fuel exists as a vapor and a liquid in pressurized tanks. Since LP fuel does not deteriorate in storage, a large supply of fuel
can be kept onsite indefinitely for operation during emergency conditions. This makes LP gas ideal for applications with
uninterrupted (onsite) fuel supply requirements.
Fuel mixture
LP gas is propane, butane, or a mixture of the two gases. The ratio of butane to propane is especially important when the fuel
flows from a large outdoor tank. A fuel supplier may fill the tank in the warm summer months with a mixture composed mainly of
butane; however, this mixture may not provide sufficient vaporized pressure at cold temperatures to start and operate the engine.
A local fuel supplier is likely to be the best source of information on what size tank is necessary to provide adequate fuel vapor.
The fuel mixture and vaporization pressure at the anticipated temperatures influence the selection of gas regulator equipment.
Pure butane gas has little or no vaporization pressure in temperatures below 4°C (40°F). Even at 21°C (70°F), the pressure is
approximately 124 kPa (18 psi). Some primary gas regulators do not operate at tank pressures below 207 kPa (30 psi) while
others operate at incoming pressures as low as 20.7-34.5 kPa (3-5 psi).
Fuel consumption and tank size
Since LP fuel is supplied in pressurized tanks in liquid form, it must be converted to a vapor state before being introduced into
the carburetor. The amount of vapor contained in 3.8 L (1.0 gal.) of liquid (LP) fuel is:
Butane Gas 0.88 m3 (31.26 cu. ft.)
Propane Gas 1.03 m3 (36.39 cu. ft.)
See the generator set specification sheets for fuel consumption at different loads, and contact your fuel supplier for information
regarding tank sizes.
System types
Single-source gas fuel systems include LP gas vapor-withdrawal and LP gas liquid-withdrawal.
TP-5700 8/20 81
6.3.1 LP Gas Liquid-Withdrawal Systems
LP liquid-withdrawal fuel systems are available for generator sets but are not recommended for automatic standby service. With
liquid-withdrawal systems, liquid LP at 1034-1379 kPa (150-200 psi) flows to the engine. A combination of converters
(vaporizers) and gas regulators then reduces the pressure to a usable level.
In Figure 56, a converter (a combination of a vaporizer and primary and secondary gas regulators) changes the liquid to vapor
using heat from the engine’s cooling system. For a period following startup, a liquid-withdrawal system may be unable to vaporize
enough fuel for an engine running under load until the engine reaches operating temperature. The engine needs time to warm
sufficiently to provide adequate heat to vaporize the fuel.
Solenoid valve (quantity of two in series

may be required for UL applications)
Converter (vaporizer)
LP gas filter (supplied by

gas supplier or installer)
Carburetor
Figure 56 LP Gas Liquid Withdrawal System

Some codes prohibit gas fuel pressurization greater than 34.5 kPa (5 psi) inside buildings. This might preclude the use of a
liquid-withdrawal system. To ensure code compliance, converters are sometimes located outside the building housing the
generator set. However, the great length of pipe between the converter and the carburetor does not allow sufficient heat buildup
and heat retention to maintain the fuel in its vapor state, which can cause startup problems.
82 TP-5700 8/20
6.3.2 LP Gas Vapor-Withdrawal Systems
A vapor-withdrawal system draws on the fuel vapor that collects in the space above the liquid fuel. Consider the following during
installation:
 Generally, allow 10%-20% of tank capacity for fuel expansion from a liquid to a vapor state. The liquid level in LP gas
tanks must never exceed 90% of the tank capacity.
 Maintain air temperature surrounding the tank high enough to vaporize the liquid fuel.
Applications in colder climates may require an independent heat source to increase natural vaporization within the tank.
Withdraw liquid fuel and vaporize it in an electrically heated, engine water jacket-heated, or LP gas-heated vaporizer. Figure 57
shows the components of the vapor-withdrawal system used in a typical stationary application. The LP gas regulator is typically
installed in the inverted position (pointing downward).
Solenoid valve (quantity of

Carburetor two in series may be required
for UL applications) Pressure
Secondary gas gauge
regulator
Primary gas regulator (supplied by

gas supplier or installer)
Figure 57 Typical LP Gas Vapor-Withdrawal System
TP-5700 8/20 83
6.4 Natural Gas Systems

The utility supplies natural gas in a vapor state. A natural gas fuel system consists of the same basic components and operates
with the same general sequence as LP gas vapor-withdrawal systems. See Figure 58 and Figure 59. Note that when the heat
content of the fuel falls below 1000 Btu, as it does with sewage-derived and some other natural gas fuels, the generator set will
not produce its rated power. The natural gas regulator is typically installed in the upright position (pointing upward).
Solenoid valve (quantity of two

in series may be required for UL Secondary regulator
applications)
Pressure gauge
Primary gas regulator Carburetor

(Supplied by gas
supplier or installer)
Note: Install a gauge to test fuel pressure during

setup and replace with a pipe plug when setup is
complete, if required
Figure 58 Natural Gas Fuel System with Pressure Gauge
84 TP-5700 8/20
may be required for UL applications) Secondary gas regulator
Carburetor
Primary gas regulator

(Supplied by gas
Manual shutoff valve
Figure 59 Natural Gas Fuel System without Pressure Gauge and with Manual Shutoff Valve
6.5 Combination Systems
Combination fuel source systems include:
 Natural gas and LP gas
6.5.1 Combination Natural Gas and LP Gas
Some applications use natural gas as the main fuel and LP gas as the emergency fuel when natural gas is not available.
The natural gas and LP gas, liquid withdrawal system uses a converter (vaporizer) to change the LP liquid to gas vapor. A
pressure switch on the primary fuel source closes when fuel pressure drops, which energizes a relay that closes the primary fuel
solenoid and opens the secondary or emergency fuel solenoid. A separate LP gas load adjustment valve ensures the right fuel-
to-air mixture in the carburetor. The load adjustment valve is located in-line between the converter (vaporizer) and the carburetor.
See Figure 60.

Converter (vaporizer)
LP gas filter (supplied by gas

Pressure LP gas supply

Load adjustment valve gauge
Carburetor Solenoid valve (quantity of two in series

Secondary natural
gas regulator Natural gas supply
Note: Install a gauge to test fuel
pressure during setup and replace
with a pipe plug when setup is
Primary gas regulator (supplied
complete, if required.
by gas supplier or installer)
Figure 60 Natural Gas and LP Gas System, Liquid Withdrawal
TP-5700 8/20 85
The natural gas and LP gas, vapor withdrawal system contains a separate secondary gas regulator and solenoid valve for each
fuel. The LP gas regulator typically mounts in the inverted position. A pressure switch on the primary fuel source closes when
fuel pressure drops, which energizes a relay that closes the primary fuel solenoid and opens the secondary or emergency fuel
solenoid. A separate LP gas load adjustment valve ensures the right fuel-to-air mixture in the carburetor.
The load adjustment valve is located in-line between the secondary gas regulator and the carburetor. See Figure 61.

Secondary LP gas regulator

LP gas supply
Load adjustment valve Solenoid valve (quantity of two in series

Carburetor
Natural gas supply
Secondary natural gas regulator

Low pressure switch
Figure 61 Natural Gas and LP Gas System, Vapor Withdrawal
86 TP-5700 8/20
6.6 Pipe Size Requirements for Gas Fuel Systems
The type of fuel, the distance it must travel from gas meter/tank to fuel shutoff solenoid, and the amount consumed by the engine
must be considered when determining fuel line pipe size.
To find the correction necessary for the different specific gravity of the particular fuel used, refer to Figure 62.
Fuel Specific Gravity Correction Factor
Sewage Gas 0.55 1.040
Natural Gas 0.65 0.962
Air 1.00 0.775
Propane (LP) 1.50 0.633
Butane 2.10 0.535
Figure 62 Fuel Correction Factors
Figure 63 is based on gas pressures of 3.4 kPa (0.5 psi, 13.8 in. water column) or less and a pressure drop of 0.12 kPa (0.018 psi,
0.5 in. water column) with a 1.60 specific gravity and with a normal amount of restriction from fittings. To calculate the correct
pipe size for a specific installation, refer to the chart and follow the procedure outlined below.
Nominal Length of Pipe, m (ft.)
Internal IPS
Iron Pipe
Diameter, 3.0 (10) 6.1 (20) 9.1 (30) 12.2 (40) 15.2 (50) 18.3 (60) 21.3 (70)
Size
mm (in.) Fuel Consumption Value, m3/hr. (ft3/hr.)
(IPS), In.
1/4 9.25 (0.364) 1.2 (43) 0.82 (29) 0.68 (24) 0.57 (20) 0.51 (18) 0.45 (16) 0.42 (15)
3/8 12.52 (0.493) 2.7 (95) 1.8 (65) 1.5 (52) 1.3 (45) 1.1 (40) 1.0 (36) 0.93 (33)
1/2 15.80 (0.622) 5.0 (175) 3.4 (120) 2.7 (97) 2.3 (82) 2.1 (73) 1.9 (66) 1.7 (61)
3/4 20.93 (0.824) 10.2 (360) 7.1 (250) 5.7 (200) 4.8 (170) 4.3 (151) 3.9 (138) 3.5 (125)
1 26.64 (1.049) 19.3 (680) 13.2 (465) 10.6 (375) 9.1 (320) 8.1 (285) 7.4 (260) 6.8 (240)
1 1/4 35.05 (1.380) 39.6 (1400) 26.9 (950) 21.8 (770) 18.7 (660) 16.4 (580) 13.9 (490) 13.0 (460)
1 1/2 40.89 (1.610) 59.5 (2100 41.3 (1460) 33.4 (1180) 28.0 (990) 25.5 (900) 22.9 (810) 21.2 (750)
52.50 (2.469 111.9 (3950) 77.9 (2750) 62.3 (2200) 53.8 (1900) 47.6 43.0 (1520) 39.6
2
(1680) (1400)
62.71 (2.469) 178.4 (6300) 123.2 (4350) 99.7 (3520) 85.0 (3000) 75.0 68.0 (2400) 63.7
2 1/2
(2650) (2250)
77.93 (3.068) 311.5 218.0 (7700) 177.0 (6250) 150.0 (5300) 134.6 121.8 (430) 110.4(390
3
(11000) (4750) 0)
102.26 (4.026) 651.2 447.4 362.5 308.7 274.7 249.1 (8800) 229.4
4
(23000) (15800) (12800) (10900) (9700) (8100)
Nominal Length of Pipe, m (ft.)

Internal IPS
Iron Pipe
Diameter, 24.4 (80) 27.4 (90) 30.5 (100) 38.1 (125) 45.7 (150) 53.3 (175) 61.0 (200)
Size
mm (in.) Fuel Consumption Value, m3/hr. (ft3/hr.)
(IPS), In.
1/4 9.25 (0.364) 0.39 (14) 0.37 (13) 0.34 (12) 0.31 (11) 0.28 (10) 0.25 (9) 0.23 (8)
3/8 12.52 (0.493) 0.88 (31) 0.82 (29) 0.76 (27) 0.68 (24) 0.62 (22) 0.57 (20) 0.54 (19)
1/2 15.80 (0.622) 1.6 (57) 1.5 (53) 1.4 (50 ) 1.2 (44) 1.1 (40) 1.0 (37) 0.99 (35)
3/4 20.93 (0.824) 3.3 (118) 3.1 (110) 2.9 (103) 2.6 (93) 2.4 (84) 2.2 (77) 2.0 (72)
1 26.64 (1.049) 6.2 (220) 5.8 (205) 5.5 (195) 5.0 (175) 4.5 (160) 4.1 (145) 3.8 (135)
1 1/4 35.05 (1.380) 13.0 (460) 12.2 (430) 11.3 (400) 10.2 (360) 9.2 (325) 8.5 (300) 7.9 (280)
1 1/2 40.89 (1.610) 19.5 (690) 18.4 (650) 17.6 (620) 15.6 (550) 14.2 (500) 13.0 (460) 12.2 (430)
2 52.50 (2.067) 36.8 (1300) 34.5 (1220) 32.6 (1150) 28.9 (1020) 26.9 (950) 24.1 (850) 22.7 (800)
62.71 (2.469) 58.1 (2050) 55.2 (1950) 52.4 (1850) 46.7 (1650) 42.5 38.8 (1370) 36.2
2 1/2
(1500) (1280)
77.93 (3.068) 104.8 (3700) 97.7 (3450) 92.0 (3250) 83.5 (2950) 75.0 69.4 (2450) 64.6
3
(2650) (2280)
102.26 (4.026) 212.4 (7500) 203.9 (7200) 189.7 (6700) 169.9 (6000) 155.7 141.6 (5000) 130.3
4
(5500) (4600)
Note: When the fuel has a specific gravity of 0.7 or less no correction factor is necessary – use this table without a correction factor.
Figure 63 Maximum Flow Capacity of Pipe in Cubic Meters (Cubic Feet) of Gas per Hour
TP-5700 8/20 87
1. Refer to the fuel consumption on the generator set specification sheet. Note type of fuel used, generator set application
rating, and the m3/hr. (ft3/hr.) consumption at 100% load.
Example:
80 kW, propane gas, 60 Hz standby rating = 12.0 m3/hr. (425 ft3/hr.).
2. Refer to the Fuel Correction Factors in Figure 62. Locate the correction factor for specific gravity of the selected fuel.
When the fuel has a specific gravity of 0.7 or less no correction factor is necessary – use Figure 63 without a correction
factor.
Example:
propane gas specific gravity = 1.50 fuel correction factor = 0.633.
3. Divide the consumption value from step 1 by the correction factor from step 2.
Example:
12.0 m3/hr. (425 ft3/hr.) divided by 0.633 = 19.0 m3/hr. (671 ft3/hr.).
4. Determine the length of pipe between the gas meter/tank and the fuel shutoff solenoid at the generator set.
Example: 34.7 m (114 ft.).
5. Find the value closest to pipe length in the Length of Pipe column in.
Example: 38.1 m (125 ft.).
Example:
At 28.9 m3/hr. (1020 ft3/hr.) the pipe size = 2 in. IPS.
6. Move vertically down the table in Figure 63 from the determined value in Length of Pipe column.
Example: 38.1 m (125 ft.)
Stop at the value that is equal to or greater than corrected consumption value from step 3.
Example:
28.9m3/hr. (1020 ft.3/hr.).
7. Move to the left column from the value in step 6 to determine the correct pipe size.
88 TP-5700 8/20
Section 7. Electrical System
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.

(APM802 Controller)
TP-5700 8/20 89
7.1 Generator Set Voltage Reconnection
To change the voltage of 10- or 12-lead generator sets, use the procedure shown in the operation manual containing the
respective controller setup. Adjust the governor and voltage regulator for frequency changes. Consult the generator set service
manual for frequency adjustment information.
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.
Equipment damage
Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the selected line voltage.
Reconnect the generator set stator leads to change the output phase or voltage. Reference the appropriate voltage reconnection
drawing in the respective Wiring Diagram Manual.
Follow the safety precautions at the front of this manual and in the text and observe National Electrical Code (NEC) guidelines.
7.2 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 64 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 64 Terminal Markings for Various Temperature Ratings and Conductors
90 TP-5700 8/20
7.3 Load Lead Connections
Feed load leads to the generator junction box from one of several different areas. Generator sets rated 300 kW and below
commonly use the bottom entry where conduit is stubbed up into the junction box from the concrete slab. Other methods include
flexible conduit roughed into the sides or top of the junction box. When using flexible conduit, do not block the front or rear of
the controller. See Figure 65
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.
Generator sets larger than 300 kW have the junction box mounted on the rear of the generator set. Larger sets may have
oversized junction boxes supplied as an option or to accommodate bus bar connections. Refer to the generator set dimension
drawing and/or the electrical contractor prints for detailed information including stub-up area recommendations.
The four bus bars contained in the optional bus bar kits simplify the connection process by offering a neutral bus bar in addition
to the three load bars. Optional bus lugs offer an array of terminal and wire connections.
Conduit from ceiling
Conduit stubbed up
from below
Figure 65 Typical Load Lead Connection
TP-5700 8/20 91
7.4 Grounding and Grounded Conductor (Neutral) Connections
Connect the electrical system grounding conductor to the equipment grounding connector on the alternator. See Figure 66.
Depending upon code requirements, the grounded conductor (neutral) connection is typically grounded.
Equipment Ground
Viewed from Engine End
Figure 66 Generator Set Equipment Grounding Connection

Ungrounded neutral connections use an insulated standoff (not supplied) to isolate the neutral connection from the grounding
connection. For grounding lug selection, see Figure 67.
The four bus bars contained in the optional bus bar kits simplify the connection process by offering a neutral bus bar in addition
to the three load bars. Optional bus lugs offer an array of terminal and wire connections.
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 lifted from the grounding stud and
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 67 Grounding Lug Selection
92 TP-5700 8/20
7.5 Terminal Connector Torque
Use torque values shown in Figure 68 or Figure 69 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 68 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 69.
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 69 Tightening Torque for Screw-Type Pressure Wire Connectors
TP-5700 8/20 93
7.6 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 when choosing a battery rack. Figure 70 shows a typical battery system.
Battery cables
Battery secured
in mounting rack
Generator set skid

End view
Figure 70 Typical Battery System, Side View
Battery type
Starting batteries are usually the lead-acid type and are sized according to the engine manufacturer’s recommendation for a
particular ambient temperature and required cranking time. NFPA 110 recommends cranking periods, including a single 45-
second cycle for generator sets below 15 kW and three 15-second crank cycles separated by 15-second rests for larger models.
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.
94 TP-5700 8/20
7.7 Battery Chargers
Most industrial generator sets use an engine-driven, battery-charging alternator to charge the batteries whenever the generator
set operates. Engine-driven systems are normally capable of charge rates of 30 amps or more and 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.
Some industrial generator sets have no battery-charging alternator and, therefore, require a separate AC-powered battery
charger.
Select an automatic or manual battery charger with a high charge rate of 2 amps and a trickle charge rate up to 300 milliamps.
The low maximum charge rate makes the charger ill-suited to restore fully discharged batteries. For full recovery capability
independent of the engine-driven charging system, use an automatic float battery charger with a high charge rate of at least 10
amps.
Use separate, self-contained battery chargers or units built into the automatic transfer switch. Run leads from a transfer switch-
mounted battery charger in conduit separate from the conduit that holds the generator load cables or remote engine-start circuits.
Note:
Digital controllers with microprocessor circuitry and vacuum fluorescent displays typically draw more than 300 milliamps, making
trickle charge battery chargers inappropriate for systems with these controllers. Select only automatic float/ equalize battery
chargers with a 3 amp or greater rating for units with digital controllers.
Battery failure is the most common reason for emergency generator set start failure. Two common battery failure causes are a
manual charge rate set too low to maintain the battery and a manual charge rate set too high, resulting in loss of battery
electrolyte. To avoid battery failure, use an automatic float charger, which varies the charge rate in response to battery condition.
For large engines with two starters, use either one bank of batteries and chargers for both starters or use separate battery
systems. The latter system is preferable because it reduces the chance of a single component failure rendering the entire system
inoperative.
TP-5700 8/20 95
7.8 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. Some factory-supplied enclosures 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 Strip Heater requires a 110-120 volt or 190-240 volt, 50/60 Hz, 15-amp power source. Check the
component and instructions for specific information.
 Battery Charger typically requires a 110-120 volt or 190-240 volt, 50/60 Hz power source. Some generator set models
require multiple battery chargers. Check the component for specific information as some battery chargers are only 110-
120 volt, 50/60 Hz. See the previous section about Battery Chargers for additional information.
 Battery Heater requires a 110-120 volt, 50/60 Hz, 15-amp power source. Some kits require multiple outlets for the
plate and wrap connections. Check the component and instructions for specific information.
 Controller Heater (APM802 Controller only) requires a 208-240 volt, 60 Hz or 230 volt, 50 Hz power source. Check
the component and instructions for specific information.
 Crankcase Ventilation Heater (Some 125/150 kW Gas Models only) require a 110-120 volt, 50/60 Hz, 37.5 watt power
source. Check the component and instructions for specific information.
 Engine Block Heater typically requires a 110-120 or 190-240 volt, 50/60 Hz, 15- or 20-amp power source. Some kits
require multiple outlet circuits. Check the component and instructions for specific information. See the subsection in
this manual about Block Heaters for additional information.
96 TP-5700 8/20
7.9 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 71. 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 71 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.
TP-5700 8/20 97
7.9.1 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 72
A B C Optional lugs
Figure 72 Bus Bar Kits/Bus Lugs
7.9.2 Gas Fuel Valve Kit
This section provides the wiring information for an additional gas fuel valve kit required for UL Approval. See the figure below.
Refer to the respective generator set wiring diagrams for additional information and for LP liquid applications.
Typical for PSI, GM, and Doosan Engines KG80–KG125, KG80R–KG125R

(KG6208TA Engine) Connections
Note: UL fuel valve is standard on KG40-KG60 (KG6208).
Figure 73 Gas Fuel Valve Kit Connections
98 TP-5700 8/20
7.9.3 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 74.
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 74 Line Circuit Breaker
7.9.4 Run Relay Kit
The run relay kit energizes only during generator set operation. The three sets of contacts typically control air intake and/or
radiator louvers. However, alarms and other signaling devices can also connect to the contacts. See Figure 75.
Figure 75 Run Relay Kit
TP-5700 8/20 99
7.9.5 Wireless Monitor
The wireless monitor system has two components: a wireless monitor unit and a website. The monitor unit transmits messages
in response to signals received from the equipment controller and notifies designated recipients of selected operating conditions.
The website monitors these messages.
There are three monitor models: GM23409-KP1 for use with hardwire inputs; GM23409-KP2 for use with a 550 controller using
Modbus® communication; and GM23409-KP3 for use with a 550 controller using hardwire inputs that require a customer
interface board.
Note:
The 550 controller supports only one connection for Modbus® communication. If the controller’s RS-485 connection is already
used for Modbus® communication with other equipment, use wireless monitor model GM23409-KP1 or -KP3 with hardwire
inputs through a customer connection board for monitoring.
Typical messages might include:
 Overcrank
 Low oil pressure
 Overspeed
 Common fault
At the website, the user configures which individuals will receive messages regarding selected operating conditions and the
message delivery method. Delivery methods include pagers (alphanumeric, numeric), fax, XML, e-mail, PCS, or telephone (voice
delivery). Each message sent will contain the condition that generated the transmission and also the make, model, and location
of the equipment. Up to 40 messages each day can be delivered. Single or multiple messages can be sent to selected recipients
via multiple delivery methods. More than one delivery method can be used for each recipient.
The wireless monitor is powered by the equipment power source or by the generator set and constantly monitors the inputs.
When an input is triggered, the wireless monitor sends the condition over the North American AMPS (advanced mobile phone
system). An operations center server receives the transmission and forwards the message to the selected recipients according
to the configured delivery method.
Every 24 hours, the wireless monitor also sends information about itself and the system it is monitoring. This heartbeat
transmission tells the Kohler center that the wireless monitor is properly functioning, powered, and able to generate messages.
If a device fails to report a nightly heartbeat for more than a day, the system sends a Unit Failed to Report Heartbeat alarm
message to the website.
Generator set run times and the number of cycles are reported. Models GM23409-KP1 and -KP3 accumulate run times over a
24-hour period and report the run times with the heartbeat message. Model GM23409-KP2 (for the 550 controller only) reports
the total accumulated run time and the total number of starts. Run times for model GM23409-KP2 are also totaled using the
Control Panel function and can be updated upon request.
Upon power loss, a rechargeable battery powers the wireless monitor. The monitor continues to transmit messages for 15
minutes, then transmits a loss of power signal and enters the sleep mode. The sleep mode can last up to 18 hours, until the
battery completely discharges or power is restored. The wireless monitor continues to send scheduled heartbeat messages
during the sleep mode until the battery discharges completely.
100 TP-5700 8/20

86
(3.4)
275
244 (10.8)
(9.6)
181
(7.1) 95
211 (3.75)
(8.3)
Dimensions are in mm (in.).

All dimensions are approximate.
51 51 27
(2) (2) (1.06)
Figure 76 Wireless Monitor
TP-5700 8/20 101

7.9.6 Wiring Connections
Although equipment and connections vary, Figure 77 shows examples of the options and wire connections necessary to make
an industrial system operational. Always refer to the wiring diagram for details of wire size, location, and number.
Remote
Audiovisual Generator Set
Emergency
Alarm Kit Controller
Stop Kit
2 Wires 18-20 Ga.
3 Wires 18-20 Ga.
Must be mounted at generator

Safeguard Circuit
4-Input/15- Battery Heater Generator
Breaker Terminal Strip
Output Dry Customer Kit Heater Kit
(in Junction Box)
Contact Connection
Kit
Customer Accessories
3 Wires Max. 18-20 Ga. Common Block Heater
Fault Relay Kit
Kit Run Relay
14 Wires 18-20 Ga. Kit AC Connection
2 Wires: Box (Installer
30 m (100 Ft.) 18-20 Ga. Supplied)
152 m (500 Ft.) 14 Ga.
305 m (1000 Ft.) 10 Ga. Generator Junction Box
3 Wires 18-20 Ga.

Must be mounted 61 m (200 ft.) Max.
at generator 1 Wire 18-20 Ga.
Single Relay
Dry Contact
Kit 2 Wires 18-20 Ga.
Customer Engine Start Terminals
Accessories 2 Wires 18-22 Ga.
3 Wires Max.
18-20 Ga.
Remote Start Battery
Switch Charger Kit
(installer
Supplied) AC Power, Independent
of Generator
3 Wires 18-20 Ga. Low Fuel

Switch Kit
Transfer
Remote
Switch
Annunciator
(Optional)
10-Relay Dry
Contact Kit
Note 1:
Generator Battery Hard wired to generator battery
Positive Connection negative engine connection.
Generator Battery Negative
and Positive Connection Customer Accessories Note 2:
2 Wires 14 Ga. 30 Wires Max. 18 Ga. For remote annunciator: “C” terminals
of the remote annunciator dry
contacts must be hard wired to the
generator battery negative engine
See note 2
connection. “P” terminal of the remote
annunciator dry contact must be hard
See note 1 wired to the generator battery positive
Generator Battery Negative Connection
engine connection.
Figure 77 Generator Set Connections, Typical
102 TP-5700 8/20

Section 8. APM402/Decision-Maker 3000 Controller Accessories
8.1 Accessories and Connections
Note:
In 2018, Kohler adopted a global controller naming convention. To support this, the name of the Decision-Maker® 3000 controller
transitioned to APM402. The APM402 has the same form, fit and function as the Decision-Maker® 3000 and supports the same
accessories.
Several accessories help finalize installation, add convenience to operation and service, and establish state and local code
compliance.
Accessories vary with each generator set model and controller. Select factory-installed and/or shipped-loose accessories. See
the figure below for a list of available kits. Obtain the most current accessory information from your local authorized service
distributor/dealer.
This section illustrates several accessories available at print time of this publication. Accessory kits generally include installation
instructions. See wiring diagrams manual for electrical connections not shown in this section. See the installation instructions
and drawings supplied with 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 the following subsection, “Accessory Connections,” for terminal identification.

Kit Description
Common Fault/Failure (32A) Connections
Fifteen-Relay Dry Contact Kit
Float/Equalize Battery Charger (with alarms)
Gas Fuel Valve Kit
Input/Output Module Board
Low Fuel (Level) Switch
Low Fuel (Pressure) Switch
Prime Power Switch
Remote Emergency Stop
Remote Reset Feature
Remote Serial Annunciator (RSA III)
Shunt-Trip Line Circuit Breaker
Figure 78 Optional Accessories
TP-5700 8/20 103

8.1.1 Battery Charger Kit with Alarm Option
The battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects to the controller
for fault detection. Battery chargers for 12- or 24-volt models are available as a generator set accessory. See Figure 79 and
Figure 80 for battery connections.
Note:
On charger GM87448, the Battery Charger Fault is communicated through CAN communication and the connection on TB1 is
not used.
Battery Charger Connections

(Optional)
Battery Ground
Connect to TB1
Charger Malfunction
Battery Charger Alarm

LV HV CM Terminal Strip
Figure 79 Battery Charger Connections
DEC 3000 Controller
Figure 80 Battery Charger to Controller Connections
104 TP-5700 8/20

8.1.2 Common Fault/Failure (32A) Relay
The common fault relay is standard on the controller circuit board and located at the TB2 terminal strip connections. Contacts
are rated at 2 amps at 32 VDC or 0.5 amps at 120 VAC max. See Figure 81 and Figure 82.
The optional common fault relay shown in Figure 82 as DCB2 has contacts rated at 10 amps at 28 VDC or 120 VAC and can be
connected to user-supplied accessories.
The optional common fault relay shown in Figure 82 as DCB1 has contacts rated at 10 amps at 28 VDC or 120 VAC and is used
to trigger the shunt-trip line circuit breaker kit (mentioned later in this section).
APM402 / DEC 3000 Controller
Figure 81 Common Fault Relay Wiring (Standard)
Figure 82 Common Fault Relay Kit and Shunt-Trip Relay Kit Wiring
TP-5700 8/20 105

8.1.3 Four-Input/Fifteen-Output Module
The optional 4-input/15-output module is available for selected models. The 4-input/15-output module is not available with the
2-input/5-output module.
15-Relay Dry Contact Kit

Controller Location
GM75749
Figure 83 Optional 15-Relay Dry Contact Kit

The optional 4-input/15-output module (see Figure 83 and Figure 84) provides normally open and normally closed contacts to
activate warning devices and other user-provided accessories allowing remote monitoring of the generator set. Connect any
controller fault output to the module. Typically, lamps, audible alarms, or other devices signal the fault conditions.
The 4-input/15-output module is factory-installed and connected to the controller.
A personal computer with Kohler® SiteTech™ software is required to assign the inputs and outputs. SiteTech™ is available only
to Kohler-authorized distributors and dealers.
The module has four digital inputs and two analog inputs. There are fourteen programmable relay outputs (K1 – K14) and one
common fault relay output (K15).
When a generator fault condition occurs, the contact kit relay is energized. The relay energization corresponds to the controller
output being activated.
Check the electrical requirements of the user-supplied accessories prior to installation of the relay dry contact kit. User-supplied
accessories require their own electrical source and must not exceed the relay contact ratings.
Connect to the normally open (NO) or normally closed (NC) terminals as required for each accessory. The relay contacts (K1 to
K14) are rated:
 10 amp @ 120 VAC
 10 amp @ 28 VDC (max.)
 0.01 amp @ 28 VDC (min.)
The common fault relay contact (K15) is rated:
 500 mA @ 125 VAC
 2 amp @ 30 VDC
106 TP-5700 8/20

Battery negative (-) connections (TB5-2)
P35 4-position jack connects to controller
CAN connections (TB5-CAN (+)/-CAN (-) (factory-connected)
TB5 output connections C and NO for the common TB6 8-position terminal block,
fault relay K15 (other TB5 terminals are factory digital inputs/digital returns
connections only) (D11, D12, D13 and D14)
Battery positive (+) connections (TB5-42A)
P36 8-position pin,
analog inputs
TB7 through TB13, connections for relays K1 through K14 with

Normally Open (NO) and Normally Closed (NC) contacts GM97144
Figure 84 4-Input/15-Output Module Customer Connections
Connections
Leads 42A and 2 provide power to the relays. Do not use terminals 42A (+) or 2 (GND) on the controller connection kit terminal
strip to supply voltage to user-supplied accessories. User-supplied DC accessories require separate leads connected directly to
the battery for the voltage supply. Attach user-supplied 12/24-volt DC accessories to the battery positive (+) connection at the
starter solenoid and to the battery negative (-) connection at the engine ground. The 120 VAC accessories require a user-
supplied voltage source.
Note:
A maximum of three inputs may be connected to a single relay driver output. Inputs include dry contacts, remote annunciator,
common failure alarm, A/V alarm, and shunt trip line circuit breaker.
Note:
Only one 4-input/15-output module can be connected to the controller.

Electrical Connection Procedure
TP-5700 8/20 107

1. Press the generator set master control OFF/RESET button.
2. Disconnect the power to the battery charger, if equipped.
3. Disconnect the generator set engine starting battery(ies), negative (-) lead first.
4. Remove the top panel of the controller connection box.
a. 80 – 300 kW models: Remove the top panel of the controller connection box.
b. 350 – 500 kW models: Remove the front panel from the junction box below the controller.
5. See Figure 85 for connections of analog inputs.
6. Select the normally open (NO) contacts of the relay, Form A dry contact, depending upon the application. Use a two-
wire harness for the NO connections.
7. Supply two lengths of stranded wire to make leads long enough to connect the user-supplied device to the dry contact
terminals and power supply. Use color-coded wire for easy identification. Make leads long enough to allow for walls,
ductwork, and other obstructions. Use separate conduit for the dry contact wiring.
8. 12/24-Volt DC Devices.
Attach the user-supplied 12/24-volt DC accessories to the starting battery positive (+) connection at the starter solenoid
and to the battery negative (-) connection at the engine ground. Otherwise, use a separate 12/24-volt DC supply. Do
not use terminals 42A and 2 on the controller connection kit terminal strip to supply the voltage to the relay contacts.
Supply separate leads connected directly to the battery for the supply voltage. The circuit must include fuse or circuit
breaker protection.
9. 120-Volt AC Devices.
Connect the user-supplied accessories to a separate 120-volt AC power supply. The circuit must include fuse or circuit
breaker protection.
10. Connect the user-supplied device per the Instructions and/or schematic supplied with the device to a power source and
to the dry contact terminals. Cut the user-supplied leads to length, strip lead ends, crimp on spade terminals (not
supplied), and connect the leads to the relay contact screw terminals. Route the wiring for the relay dry contacts away
from the generator set output leads.
11. Repeat Step 6 for the remaining dry contact relays.
12. Replace the cover on the controller connection box.
13. Check that the generator set is in the OFF mode.
14. Reconnect the generator set engine starting battery, negative (-) lead last.
15. Reconnect power to the battery charger, if equipped.
P36 Optional 5 V Power P36 Optional 5 V Power P36

(50 mA max.) (50 mA max.)
+5 +5 +5
VPx VPx + VPx

Analog Output Analog
VNx Device VNx Device - VNx
GND GND GND
GND
100 ohm min. or GND TP-6694-6
50 mA max. current
0-5 Volt Ratiometric Sensor 0-5 Volt Analog Device +/- 3 Volt Analog Device
Figure 85 Dry Contact Kit Analog Input Connections P36
108 TP-5700 8/20

Program the inputs and outputs using SiteTech™
Use a computer with Kohler SiteTech™ software to assign functions to digital and analog inputs and outputs. Each input and
output corresponds to a controller connection. Verify that the settings are appropriate for the connected sensor, switch, or
equipment. Do not change factory-set inputs and outputs without verifying the input and output connections.
Refer to Introduction-List of Related Materials for the SiteTech™ Software Operation Manual part no.
SiteTech™ input and output parameters C1 through C14 are designated for use on the optional 15-relay dry contact board. See
Figure 86.
Test Dry Contact Relays
Verify the dry contact relay function by using the following procedure when troubleshooting.
1. Remove the user-supplied device wiring from the relay dry contact terminals.
2. Test the relay operation by connecting an ohmmeter across the NO and C terminals on the relay terminal strip.
3. Use a jumper wire to ground the selected fault terminal on the controller connection terminal strip. The relay contacts
should close and the ohmmeter should display a low resistance reading (continuity).
4. Install the user-supplied device wiring on the relay dry contact output terminals
Optional Dry Contact Board
SiteTech I/O Name
Connection
Analog Input C1 P36 Analog Input VN1/VP1
Analog Input C2 P36 Analog Input VN2/VP2
Digital Input C1 TB6 DI1
Digital Output C1 TB7 K1
Figure 86 Optional Inputs and Outputs with Dry Contact Kit
TP-5700 8/20 109

8.1.4 Gas Fuel Valve Kit
This section provides the wiring information for an additional gas fuel valve kit required for UL Approval. See the figure below.
Refer to the respective generator set wiring diagrams for additional information and for LP liquid applications.
Typical for PSI, GM, and Doosan Engines KG80–KG125, KG80R–KG125R

(KG6208TA Engine) Connections
Note: UL fuel valve is standard on KG40-KG60 (KG6208).
Figure 87 Gas Fuel Valve Kit Connections
8.1.5 Two-Input/Five-Output Module
The two-input/five-output module provides a generator set mounted panel with two analog or digital inputs and five digital outputs.
See Figure 89 for circuit board components and electrical connections to the controller.
 See Figure 90 for connections of analog inputs.
 See the following subsection, Accessory Connections, for terminal identification.
Use a computer with Kohler SiteTech™ software to assign functions to digital outputs. Each input and output corresponds to a
controller connection. Verify that the settings are appropriate for the connected sensor, switch, or equipment.
 Refer to Introduction—List of Related Materials for the SiteTech™ Software Operation Manual part no.
SiteTech™ analog inputs B1 and B2 and digital outputs B1 through B5 are designated for use on the optional two-input/five-
output module. See Figure 88.
SiteTech I/O Name Optional I/O Module Connection

Analog Input B1 P28 Analog Input VN1/VP1
Analog Input B2 P28 Analog Input VN2/VP2
Digital Output B1 P29 (K1)
Figure 88 Input/Output Assignments
110 TP-5700 8/20

P29/P30/P31 K1/K2/K3 2-amp relay outputs P32 K4/K5 10-amp relay outputs
P27 CAN
terminator
P26 RJ45 Out

SW1 switch
P25 RJ45 In
(APM402/DEC
3000 P23)
P28 In1/In2 analog or digital inputs
Figure 89 Two-Input/Five-Output Module Board

+5 +5 +5
VPx VPx + VPx

GND GND GND
GND
50 mA max. current
Figure 90 Analog Input Connections P28
TP-5700 8/20 111

8.1.6 Low Fuel (Level/Pressure) Switch
Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the same controller
terminal as the low fuel level switch on diesel-fueled models. See Figure 91, Figure 92, and Figure 93.
Note:
The main tank or the transfer/day tank includes the low fuel level switch. The fuel tank supplier typically provides the low fuel
level switch.
Low Fuel Switch (Optional)

Located in Main Tank as
Provided by Fuel Tank Supplier
Connect to TB1 (for

warning) or TB3
(for shutdown)
Battery Ground
Figure 91 Low Fuel Switch (Level or Pressure)
Aux Shutdown Switch

(Customer Provided)
Aux Warning Switch

(Customer Provided)
Figure 92 Low Fuel Switch Connection to Controller Connection

Switch Rating 12 volts DC minimum, 0.5 amp minimum
Wiring Recommendation
Gauge mm (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 93 Switch Rating & Wiring Recommendation
112 TP-5700 8/20

8.1.7 Prime Power Switch Kit
The prime power switch kit prevents battery drain during generator set no -operation periods and when the generator set battery
cannot be maintained by an AC battery charger. See Figure 94 for an illustration of the kit and Figure 95 for the electrical
connections.
Stop the generator set using the stopping procedures in respective operation manual before placing the generator set in the
prime power mode. Move the prime power switch located on the junction box to the DOWN position. The controller including the
digital display, LEDs, and alarm horn does not function when the generator set is in the prime power mode.
Move the prime power switch located on the junction box to the UP position. The generator set is now ready for starting.
Prime Power Decal (293668)

Prime Power
Switch Toggle Switch (354464)
Figure 94 Prime Power Switch
To Engine Harness
Prime
Power
Toggle switch shown in the Switch
prime power mode off
position (contacts open)
Figure 95 Prime Power Switch Connections
TP-5700 8/20 113

8.1.8 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 96 Emergency Stop Kits
See Figure 97 for typical connections. Refer to the generator set wiring diagram for your model. See the following subsection,
Accessory Connections, for terminal identifications.
Local Emergency
Stop Switch
(Standard)
Local Remote
Emergency Emergency
Stop Switch Stop Switch
(Standard) (Optional)

Switch Connections
Figure 97 Remote Emergency Stop Kit Connections
114 TP-5700 8/20

8.1.9 Remote Reset Feature
The remote reset switch provides generator set controller resetting after a fault shutdown at a remote location. See Figure 98
and Figure 99 for user-supplied switch connection.
Press and hold the switch for 2-3 seconds and release to reset the generator set controller.
Remote Reset Switch

Contacts Normally Open
Momentary Closed to Activate
Battery Ground
Connect to TB1 as a Digital Input
Figure 98 Remote Reset Switch Connections

Switch Rating 12 volts DC minimum, 1 amp minimum
Gauge m (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 99 Switch Rating & Wiring Recommendations
TP-5700 8/20 115

8.1.10 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 100 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.
116 TP-5700 8/20

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 101 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)
both ends.
Figure 102 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 103 RSA III Circuit Board GM86125 Connectors
TP-5700 8/20 117

8.1.11 Shunt-Trip Line Circuit Breaker
A shunt-trip line circuit breaker provides a 12- or 24-DC volt solenoid within the line circuit breaker case that can energize the
trip mechanism. This feature allows the circuit breaker to be tripped by the common fault (32A). Connection requires a shunt-
trip wiring kit and a dry contact kit. See Figure 104 and Figure 105.
The optional common fault relay shown in Figure 105 as DCB1 has contacts rated at 10 amps at 28 VDC or 120 VAC and is
used to trigger the shunt-trip line circuit breaker kit.
Figure 104 Shunt-Trip Wiring (Standard)
Figure 105 Shunt-Trip Relay Kit and Line Circuit Breaker Wiring (Shown with Common Fault/Failure Relay Kit)
118 TP-5700 8/20

8.2 Accessory Connections
The controller contains a circuit board equipped with terminal strip(s) for use in connecting external optional accessories
including alarms, battery chargers, and remote switches. The optional I/O board provides an additional two analog or digital
inputs and five digital outputs.
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 Figure 106, Figure 107, and Figure 108 for controller circuit board connections.
(4) Push-on terminal connectors
P21 6-pin connector
TB2 4-position terminal block
P23 8-pin connector (RJ45) TB3 6-position terminal block
TB1 6-position P1 24-pin connector

P22 3-pin connector
terminal block
Figure 106 Controller Circuit Board Connections
TP-5700 8/20 119

TB1 Terminal Strip
Analog and Digital Input Connections
Terminal Description Connection
TB1-DI 1 DCH1 No Function
TB1-DI 2 DCH2 Aux. Warning Switch
TB1-DI 3 DCH3 Battery Charger Fault
TB1-AI 1 ACH1 No Function
TB1-AI 2 ACH2 No Function
TB1-GND Ground Common A/D Ground
TB2 Terminal Strip
KI Relay Outputs
TB2-COM Common User-Defined
TB2-COM Common Common Fault (2)
TB2-NO Normally Open Common Fault (32A)
TB2-NC Normally Closed User-Defined
TB3 Terminal Strip
Accessory Power Output Connections
TB3-1 E-Stop E-Stop Ground
TB3-1A E-Stop E-Stop
TB3-3 Remote Start Remote Start
TB3-4 Remote Start Remote Start
TB3-AUX Auxiliary Aux. Shutdown Sw.
TB3-AUXR Auxiliary-R Aux. Shutdown Sw.
P1 24-Pin Connector
Engine Wiring Harness
P1-12 14P + 12VDC Prime Power Switch
P21 6-Pin Connector
RS-485 (RSA II)
P21-1 GND Shield
P21-2 (+) Red
P21-3 (-) Black
P21-4 GND Shield
P21-5 (+) Red
P21-6 (-) Black
TB1 Terminal Strip Designations
Analog and Digital Input Connections
Terminals on Board Controller Designation SiteTech Designation
TB1-DI 1 Dln A1 A1
TB1-DI 2 Dln A2 A2
TB1-DI 3 Dln A3 A3
TB1-AI 1 Aln A1 -
TB1-AI 2 Aln A2 A1
TB1-GND - -
Figure 107 Controller Connections
120 TP-5700 8/20

P25 Connector
RJ45 Remote I/O In
Connects to APM402/DEC 3000 P23
P26 Connector
RJ45 I/O Out
Open
P27 Connector
CAN Terminator
Place the P27 jumper on the IN pins
P28 Connector
Single-Ended (0-5 V) Analog Input Connections
Terminal Description
P28-GND AGND Analog return
P28-VN1 NO Connection
P28-VP1 ACH1 Signal
P28-+5V Supply (0.05 amp max.)
P28-GND AGND Analog Return
P28-VN2 NO Connection
P28-VP2 ACH2 Signal
P28 Connector
Differential (+/-3 V) Analog Input Connections
P28-GND AGND Analog Reference
P28-VN1 ACH1 Negative Differential Signal
P28-VP1 ACH1 Positive Differential Signal
P29 Connector
2 Amp. K1 Relay Output (2.1) Connections
P29-NC Normally Closed
P29-COM Common
P29-NO Normally Open
P30 Connector
P30-COM Common
P31 Connector
P31-COM Common
P32 Connector
P32-COM Common
P32-COM Common
P28 Connector Designations
Terminals on Board Controller Designation SiteTech Designation
P28-GND
P28-VN1
Dln B1 B1
P28-VP1
P28-+5V
P28-GND
P28-VN2
Din B2 B2
P28-VP2
P28-+5V
Figure 108 Input/Output Module Board Connections
TP-5700 8/20 121

122 TP-5700 8/20
Section 9. APM603 Controller Accessories and Connections
This section covers typical APM603 accessories when used with most generator sets. For connecting accessories to the
APM603 with generator sets KD800-KD3250, see the following section.
9.1 APM603 Controller Optional Connections
The APM603 provides a number of standard on-board inputs and outputs. Connect to these inputs and outputs at terminal strip
TB12. See subsection “Controller Connections” for a list of TB12 connections and contact ratings. Also see the generator set
wiring diagram.
Run AC and DC wiring in separate conduit. Use shielded cable for all analog inputs. Observe all applicable national, state, and
local electrical codes when making connections.
Customer connection Controller location

terminal strip TB12 (reference)
Controller location
GM105002 (reference) GM105183
80-300 kW Models 350-500 kW Models
Figure 109 Terminal Strip TB12 Location
9.1.1 Run Relay
The APM603 controller is supplied with a run relay that is energized when the generator set engine is running. The run relay
provides normally open (NO) and normally closed (NC) contacts for connection to customer-supplied equipment. Connect
customer equipment to the run relay (RR) connections on terminal strip TB12. Section for TB12 connections and contact ratings.
Also see the generator set wiring diagram.
9.1.2 Factory-Defined Inputs and Outputs
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.
TP-5700 8/20 123

Optional accessories help finalize installation, add convenience to operation and service, and establish state and local code
compliance.
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.
See Figure 110 for a list of available loose kits. Obtain the most current accessory information from your local authorized service
distributor/dealer.
Kit Description
Battery Charger, 6 Amps
Battery Charger, 10 Amps w/Alarms
Common Fault/Failure Relay
Four Input/ Fifteen-Output Module
Lockable Emergency Stop Switch
Manual Key Switch (factory installed only)
Remote Emergency Stop Switch
Shunt-Trip Line Circuit Breaker
Switchboards
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.
See subsection Accessory Connections, for terminal identification.
9.2.1 6-Amp Battery Charger Kit
The 6-Amp battery charger kit is available either factory installed or as a loose kit for installation in the field. For 24-volt systems,
two chargers are included in the kit. The recommended location for the battery charger(s) varies for different generator set sizes.
Follow the instructions provided with the kit for installation and connection.
Note: For 24-volt systems, two

chargers are included in the kit.
GM96383
Figure 111 6-Amp Battery Charger (typical)
124 TP-5700 8/20

9.2.2 10-Amp Battery Charger Temperature Compensation Kit
The 10-amp battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects to the
controller for fault detection. Battery chargers for 12- or 24-volt models are available as a generator set accessory. The 10-amp
battery charger is only available as a factory-installed kit.
A temperature compensation kit is available for the 10-amp battery charger. See Figure 112. The temperature compensation
harness connects to the negative (-) battery terminal. Refer to the installation instructions provided with the temperature
compensation kit for more information
Temperature compensation
kit connection
Connect to battery negative (-) terminal

GM87448
GM102246
Figure 112 Battery Charger Temperature Compensation Kit
TP-5700 8/20 125

9.2.3 Common Fault/Failure Relay
The optional common fault relay shown in Figure 114 has contacts rated 10 amps at 28 VDC or 120 VAC. Connect user-supplied
accessories to the normally open (NO) or normally closed (NC) contacts on TB2 of the relay board. See Figure 115 for customer
connection terminals.
Event Common Warning Common Fault
Alternator Thermal Protection ●
Battery Charger Fault * ▲
CAN Option Board Comm Loss ▲
Critically Low Fuel Level * ▲
ECM Diagnostic Event ▲
ECM Mismatch Shutdown ●
Fuel Leak Alarm * ▲
Gen Over Power Shutdown ●
Gen Over Power Warning ▲
High Battery Voltage Warning ▲
High Coolant Temperature Shutdown ●
High Coolant Temperature Shutdown ECM DTC ●
High Coolant Temperature Warning ▲
High Coolant Temperature Warning ECM DTC ▲
High Fuel Level Warning * ▲
High Oil Temperature Shutdown ●
High Oil Temperature Warning ▲
Local Emergency Stop Shutdown ●
Loss ECM Comms Shutdown ●
Loss Of Signal Low Coolant Level Voltage ▲
Low Battery Voltage Warning ▲
Low Coolant Level Shutdown ●
Low Coolant Temperature Warning ▲
Low Fuel Level Shutdown * ●
Low Fuel Level Warning * ▲
Low Oil Pressure Shutdown ●
Low Oil Pressure Shutdown ECM DTC ●
Low Oil Pressure Warning ▲
Low Oil Pressure Warning ECM DTC ▲
Low RTC Battery Voltage ▲
Maintenance Reminder1 ▲
Not In Auto Alarm ▲
Over Crank Shutdown ●
Over Current Shutdown (L1, L2, L3) ●
Over Current Warning (L1, L2, L3) ▲
Over Frequency Shutdown ●
Over Frequency Warning ▲
Over Power Shutdown ●
Over Power Warning ▲
Over Speed Shutdown ●
Over Voltage Shutdown (L–L, L–N, each phase) ●
Over Voltage Warning (L–L, L–N, each phase) ▲
Protective Relay Shutdown Over Current ●
Protective Relay Shutdown Over Power ●
Protective Relay Shutdown Reverse Power ●
Protective Relay Shutdown Reverse VAR ●
Protective Relay Trip Over Current ▲
Protective Relay Trip Over Frequency ▲
Protective Relay Trip Over Power ▲
Protective Relay Trip Over Voltage ▲
Protective Relay Trip Reverse Power ▲
Protective Relay Trip Reverse VAR ▲
Protective Relay Trip Under Frequency ▲
Protective Relay Trip Under Voltage ▲
Remote Emergency Stop Shutdown ●
Under Frequency Shutdown ●
Under Frequency Warning ▲
Under Voltage Shutdown (L–L, L–N, each phase) ●
Under Voltage Warning (L–L, L–N, each phase) ▲
Weak Cranking Battery ▲
* Function requires optional input sensors or kits
Figure 113 Common Warnings and Faults (factory-set)
126 TP-5700 8/20

80–300 kW Models, Controller Area 350–500 kW Models, Junction Box
APM603 controller location
Junction
GM105002 Box
GM105680
Common fault relay
Figure 114 Optional Common Fault Relay Locations
GM105223C-7
Figure 115 Common Fault Relay Wiring
TP-5700 8/20 127

The optional 4-input/15-output module (see Figure 116 and Figure 117) provides normally open and normally closed contacts
to activate warning devices and other user-provided accessories allowing remote monitoring of the generator set. Connect any
controller fault output to the module. Typically, lamps, audible alarms, or other devices signal the fault conditions.
The I/O module is factory-installed and connected to the controller.
A personal computer with Kohler® SiteTech™ software is required to assign the inputs and outputs. SiteTech™ is available only
to Kohler-authorized distributors and dealers.
The module has four digital inputs and two analog inputs. There are fourteen programmable relay outputs (K1 – K14) and one
common fault relay output (K15).
When a generator fault condition occurs, the contact kit relay is energized. The relay energization corresponds to the controller
output being activated.
Check the electrical requirements of the user-supplied accessories prior to installation of the relay dry contact kit. User-supplied
accessories require their own electrical source and must not exceed the relay contact ratings.
Connect to the normally open (NO) or normally closed (NC) terminals as required for each accessory. The relay contacts (K1 to
K14) are rated:
 10 amp @ 120 VAC
 10 amp @ 28 VDC (max.)
 0.01 amp @ 28 VDC (min.)
The common fault relay contact (K15) is rated:
 500 mA @ 125 VAC
 2 amp @ 30 VDC
80–300 kW models, controller area 350–500 kW models, junction box
Controller location
Controller location
Junction box location
GM105002
GM105680
4-input/15-output module
Figure 116 Optional 4-Input/15-Output Module Location (80-500 kW generator sets)
128 TP-5700 8/20

CAN connections (TB5-CAN (+)/-CAN (-) TB6 8-position terminal block,

digital inputs/digital returns
Common fault RDO K15
(D11, D12, D13 and D14)
connections (TB5-C/NO)
Battery positive (+) connections P36 8-position pin,

(TB5-42A) analog inputs
TB7 through TB13, connections for relays K1 through K14 with GM97144
Normally Open (NO) and Normally Closed (NC) contacts
Figure 117 4-Input/15-Output Module Customer Connections
For field connections, read the entire Electrical Connection procedure and perform the steps in the order shown. Observe
applicable local and national electrical codes when installing the wiring system.
Observe the following safety precautions while making connections to the kit.

TP-5700 8/20 129

Connections
Leads 42A and 2 provide power to the relays. Do not use terminals 42A (+) or 2 (GND) on the controller connection kit terminal
strip to supply voltage to user-supplied accessories. User-supplied DC accessories require separate leads connected directly to
the battery for the voltage supply. Attach user-supplied 12/24-volt DC accessories to the battery positive (+) connection at the
starter solenoid and to the battery negative (-) connection at the engine ground. The 120 VAC accessories require a user-
supplied voltage source.
Note:
A maximum of three inputs may be connected to a single relay driver output. Inputs include dry contacts, remote annunciator,
common failure alarm, A/V alarm, and shunt trip line circuit breaker.
Note:
Only one 4-input/15-output module can be connected to the controller.
Electrical Connection Procedure
1. Press the generator set master control OFF/RESET button.
2. Disconnect the power to the battery charger, if equipped.
3. Disconnect the generator set engine starting battery(ies), negative (-) lead first.
4. Remove the top panel of the controller connection box.
a. 80–300 kW models: Remove the top panel of the controller connection box.
b. 350–500 kW models: Remove the front panel from the junction box below the controller.
5. See Figure 118 for connections of analog inputs.
6. Select the normally open (NO) contacts of the relay, Form A dry contact, depending upon the application. Use a two-
wire harness for the NO connections.
7. Supply two lengths of stranded wire to make leads long enough to connect the user-supplied device to the dry contact
terminals and power supply. Use color-coded wire for easy identification. Make leads long enough to allow for walls,
ductwork, and other obstructions. Use separate conduit for the dry contact wiring.
8. 12/24-Volt DC Devices. Attach the user-supplied 12/24-volt DC accessories to the starting battery positive (+)
connection at the starter solenoid and to the battery negative (-) connection at the engine ground. Otherwise, use a
separate 12/24-volt DC supply. Do not use terminals 42A and 2 on the controller connection kit terminal strip to supply
the voltage to the relay contacts. Supply separate leads connected directly to the battery for the supply voltage. The
circuit must include fuse or circuit breaker protection.
9. 120-Volt AC Devices. Connect the user-supplied accessories to a separate 120-volt AC power supply. The circuit must
include fuse or circuit breaker protection.
10. Connect the user-supplied device per the Instructions and/or schematic supplied with the device to a power source and
to the dry contact terminals. Cut the user-supplied leads to length, strip lead ends, crimp on spade terminals (not
supplied), and connect the leads to the relay contact screw terminals. Route the wiring for the relay dry contacts away
from the generator set output leads.
11. Repeat 6 for the remaining dry contact relays.
12. Replace the cover on the controller connection box.
13. Check that the generator set is in the OFF mode.
14. Reconnect the generator set engine starting battery, negative (-) lead last.
15. Reconnect power to the battery charger, if equipped.
130 TP-5700 8/20

+5 +5 +5
VPx VPx + VPx
GND GND GND
GND
50 mA max. current
Figure 118 Input/output Module Analog Input Connections, P36
Program the inputs and outputs using SiteTech™
Use a computer with Kohler SiteTech™ software to assign functions to digital and analog inputs and outputs. Each input and
output corresponds to a controller connection. Verify that the settings are appropriate for the connected sensor, switch, or
equipment. Do not change factory-set inputs and outputs without verifying the input and output connections.
Refer to Introduction-List of Related Materials for the SiteTech™ Software Operation Manual part no.
SiteTech™ input and output parameters C1 through C14 are designated for use on the optional 15-relay dry contact board. See
Figure Optional Inputs and Outputs with I/O Module Board.
Note:
See the previous figure, Input/15-Output Module Customer Connections, for P36 and TB7-TB13 locations.
Test the relays
Verify the dry contact relay function by using the following procedure when troubleshooting.
1. Remove the user-supplied device wiring from the relay dry contact terminals.
2. Test the relay operation by connecting an ohmmeter across the NO and C terminals on the relay terminal strip.
3. Use a jumper wire to ground the selected fault terminal on the controller connection terminal strip. The relay contacts
should close and the ohmmeter should display a low resistance reading (continuity).
4. Install the user-supplied device wiring on the relay dry contact output terminals
Optional Dry Contact Board
SiteTech I/O Name
Connection
Analog Input 1 P36 Analog Input VN1/VP1
Analog Input 2 P36 Analog Input VN2/VP2
Digital Input 1 TB6 DI1
Digital Output K1 TB7 K1
Figure 119 Optional Inputs and Outputs with I/O Module Board
TP-5700 8/20 131

9.2.5 Fuel Level Sender and Fuel Leak Alarm
Fuel Level Sender
The fuel level sender is included with the subbase fuel tank. The fuel level sender connects to quick connects QCON5 and
QCON6 in the generator set junction box. See Figure 120 and Figure 121 for the connections.
Fuel Leak Alarm
If the tank is equipped with an optional fuel leak alarm, connect the alarm to quick connects QCON7 and QCON8 in the generator
set junction box. See Figure 120 for the wiring recommendations and Figure 121 for the connections.
Gauge mm(ft.)
18-20 30.5(100)
14 153(500)
10 305(1000)
Figure 120 Wiring Recommendation
Fuel Level Sender (Optional) Fuel Tank Level and Leak Alarms (Optional)
Fuel Leak Alarm (Optional)
ADV-9078C-3
Figure 121 Low Fuel Level Sender and Fuel Leak Alarm Connections
132 TP-5700 8/20

A-222654 GM103743
TP-5352-1 TT-1736
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.
TP-5700 8/20 133

details.
LED.

Wiring
III.
Note:
134 TP-5700 8/20

both ends.

both ends.


connections

TP-5700 8/20 135

trip mechanism. This feature allows the circuit breaker to be tripped by the common fault. Connection requires a shunt-trip wiring
kit, which includes a shunt trip wiring harness and a dry contact kit.
The relay has contacts rated at 10 amps at 28 VDC or 120 VAC and is used to trigger the shunt-trip line circuit breaker kit.
GM105223C-7
Figure 128 Shunt-Trip Wiring (80–500 kW generator sets)
9.2.9 Power Distribution Switchboards
Power Distribution Switchboards
Power distribution switchboards (PDS) for paralleling systems are available. Refer to the PDS specification sheet for switchboard
and circuit breaker information. The installation manual provided with the switchboards contains instructions for switchboard
installation and maintenance.
136 TP-5700 8/20

9.3.1 Controller Connections
Controller Connections
All customer connections to the controller are made to terminal strips or quick-connect terminals. Do not attempt to connect
customer equipment directly to the controller.
Connectors inside the controller box provide connections for optional accessories. See Figure 129.
Terminal block TB12 provides customer connection points for emergency stop, remote start/stop, Modbus devices including the
RSA III, and standard inputs and outputs. See Figure 130.
Note:
Do not apply voltage to dry contact inputs. Provide proper circuit protection to relay connections.
instruction sheet accompanying the kit.
Control Box Connectors
Ethernet module RJ45 connector Ethernet
Quick-Connects
QCON5 63C
Fuel level sender
QCON6 N17
QCON7 64
Fuel leak alarm
QCON8 N18
Connecting Plugs
PB1 Bus voltage sense
PR1 Common fault relay
PR2 Factory only
PR3 Factory only
P15 4-in/15-out module
P23 Crank relay
P24 Run relay
P30 Breaker close
P31 Breaker open
PK1 Manual key switch
PX1 Breaker control
TX1 Remote EOB
TX5 Remote breaker bus sense
Figure 129 Control Box Connectors
TP-5700 8/20 137

TB12 Terminal Strip
Position Description
TB12-1 Remove jumper if using E-
Emergency stop Use dry contact
TB12-2 stop
TB12-3
Remote start Use dry contact Use dry contact
TB12-4
TB12-5 Fused battery power 10 A fused @ 24VDC Nominal
TB12-6 Battery positive during crank and run 10 A fused @ 24VDC Nominal
TB12-7 Battery negative 0 VDC
TB12-8 A (- )
PGEN
TB12-9 B (+) For paralleling generators
Isolated RS-485 #2
TB12-10 Shield
TB12-11 Signal Use dry contact
Low fuel level switch Diesel models only
TB12-12 Return
No connection for gas models
TB12-13 Signal
Battery charger fault Use dry contact
TB12-14 Return
TB12-15 Signal
Auxiliary warning Use dry contact
TB12-16 Return
TB12-17 Signal
Auxiliary fault Use dry contact
TB12-18 Return
TB12-19 A (- )
Modbus Isolated
TB12-20 B (+) For Modbus RTU, RSAIII
RS-485 #3
TB12-21 Shield
TB12-22 RSA A (- )
TB12-23 Non-isolated RS-485 B (+) For Modbus RTU, RSAIII
TB12-24 #4 Shield
TB12-25 Common 10A @28 VDC max.
TB12-26 Run relay dry contacts NO 10 A @120 VAC max.
TB12-27 NC 6.66 A @ 250 VAC max
TB12-28 (+) Signal
+30 VDC/- 15 VDC
TB12-29 Speed bias (- ) Signal
Requires controller range setup
TB12-30 Shield
TB12-31 (+) Signal
+30 VDC/- 15 VDC
TB12-32 Voltage bias (- ) Signal
Requires controller range setup
TB12-33 Shield
TB12-34 Use dry contact
Dual Fuel Natural Gas Contacts Gas models only
TB12-35 No connection for diesel models
Isochronous Governor JP2 Installed Diesel models only
TB12-36
Droop Governor JP2 Removed No connection for gas models
TB12-37 +5 VDC (ref) Diesel models only
TB12-38 Analog Throttle Control Signal (+2.5VDC Norm) No connection for gas models
TB12-39 Sensor Return Remove resistors if paralleling
TB12-40 Diesel models only
Idle Mode Consult Factory
TB12-41 No connection for gas models
TB12-42 No Connection
Figure 130 Terminal Strip TB12 Customer Connections (80–500 kW Models)
138 TP-5700 8/20

Four Input/Fifteen Output Module
The optional four input/ fifteen output module provides additional inputs and outputs.
4 Input/15 Output Module Connections
P35 Connector
P35 Controller Connection
P36 Connector
Differential (±3 V) Analog Input Connections
P36-+5V Supply (50 mA max.)
P36-GND Supply (50 mA max.)
TB5 Terminal Block
K15 Relay Output, 5 VDC, 2A
Common fault
TB5-C Common
relay K15 output
Common fault
TB5-NO Normally open
relay K15 output
All other TB5
Factory only
connections
TB6 Terminal Block
DI1 - DI4 Digital Inputs
TB6-DI1 Digital Input 1
TP-5700 8/20 139

TB7 Terminal Block
K1 - K14 Relay Outputs, 10 A, 12VDC
TB7 K1-NO Normally open
TB7 K1-C Common K1 relay output
TB7 K1-NC Normally closed
Figure 131 Input/Output Module Connections
140 TP-5700 8/20

Section 10. APM603 and APM802 Controller Accessories, KD800–
KD3250
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 132. Do not attempt to connect directly to the controller.
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.
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 132 APM603 and APM802 Controller and Customer Connection Box
TP-5700 8/20 141

10.1 Input/Output Modules
The following factory-installed modules are available as optional accessories.
 Analog Input/Output Module
 Digital I/O Module
 Thermocouple Input 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 two diagnostic LEDs that can be used for troubleshooting. See Figure 133.
LED Description LED Operation

1 Power LED Green: The module is correctly powered.
Off: Module is not powered.
2 Can bus 1 Communication LED Flashing green: CAN communication is consistent.
Steady green: No CAN communication.
Off: No CAN communication.
Figure 133 Module Diagnostic LEDs
10.1.1 Analog Input/Output Module
The Analog Input/Output (I/O) Module provides two output connections and four input connections. See Figure 134 for I/O
specifications and Figure 135 for connections.
The factory default input and output settings are undefined. I/O settings can be loaded by an authorized service technician.
Contact your Kohler distributor with your requirements for inputs and outputs.
Input/Output Specifications Connection

Input 0 – 20 mAmps 0.75 to 1.5 mm2
Impedance 100 ohms
Output 0 – 20 mAmps 0.75 to 1.5 mm2
100 – 600 ohms
Figure 134 Analog Input/Output Specifications
Factory connections or settings
Analog output connections 0 and 1
Analog input connections 0 – 3
Figure 135 Analog Input/Output Module
142 TP-5700 8/20

10.1.2 Digital Input/Output Module
Factory
connections or
settings
Digital input
connections 0 – 7
Digital (relay) output

connections 0 – 3
31613391201
Figure 136 Digital Input/Output Module

The Digital Input/Output Module (DIOM) provides 8 digital inputs and 4 digital (relay) outputs. See Figure 137 for contact
specifications and Figure 136 for input and output connections.
Input/Output Contacts Connection

Input contacts Normally open (NO). Activates on 0.75 to 1.5 mm2
ground connection.
Output contacts 240 VAC / 8 A 0.75 to 1.5 mm2
30VDC / 8A
48VDC / 0.5 A
Figure 137 Digital Input/Output Contact Specifications
TP-5700 8/20 143

Digital Input/Output Module with the APM603
The KD series generator sets (KD800-KD3250) with the APM603 controller have one factory installed base DIOM with
designated inputs and outputs. Two additional optional DIOMs can be installed in the customer connection area of the junction
box.
 Base DIOM: Digital inputs and outputs are factory defined. Connections are available on TB10.
 DIOM1: Inputs are undefined; outputs are factory defined. Connect directly to the DIOM.
 DIOM2: Inputs and outputs are undefined. Connect directly to the DIOM.
Figure 138 shows the factory settings as well as the undefined digital inputs and outputs. Different I/O settings for the optional
I/O modules can be loaded by an authorized service technician. Contact your Kohler distributor with your requirements for digital
inputs and outputs.
Digital Inputs/ Outputs Base Module Optional Module 1 Optional Module 2

Input DI0 Low fuel level Undefined Undefined
Input DI1 Undefined Undefined Undefined
Input DI2 Remote reset Undefined Undefined
Input DI3 Auxiliary shutdown Undefined Undefined
Input DI4 High fuel warning Undefined Undefined
Input DI5 Auxiliary warning Undefined Undefined
Input DI6 Low oil level Undefined Undefined
Input DI7 Keyswitch enable Undefined Undefined
Output DO0 System ready Low oil pressure Undefined
Output DO1 Low coolant temperature High coolant temperature Undefined
Output DO2 Not in auto Low coolant level Undefined
Output DO3 EPS supplying load Low fuel level Undefined
Figure 138 Optional Digital I/O Module 1 Default Settings
Digital Input/Output Module with the APM802
The Module #0 position is reserved for the optional Manual Key Switch/Load Shed module.
Factory input settings are undefined. Outputs are factory-set to the default settings shown in Figure 139. Different I/O settings
for the optional I/O module can be loaded 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) Module 1
Input DI0 Keyswitch AUTO Undefined
Input DI1 Keyswitch Manual Undefined
Input DI2 Keyswitch OFF Undefined
Input DI3 Start/Stop Button Undefined
Input DI4 Reserved Undefined
Output DO0 Load 1 Undefined
Figure 139 Digital I/O Module Default Settings
144 TP-5700 8/20

10.1.3 Thermocouple Input Module
Up to three thermocouples can be connected to the Thermocouple Module. Type K or PT100 thermocouples can be connected.
See Figure 140 for thermocouple specifications. See Figure 141 and Figure 142 for connections.
Medium voltage (larger than 600 volts) units are equipped with two thermocouple modules with the settings shown in Figure
141.
Temperature data can be viewed using the Custom View button on the controller. If no thermocouple modules are installed, all
temperatures will display 32°F (0°C). If nothing is connected to a channel on a thermocouple module, - 58°F (- 50°C) is displayed.
Thermocouple Type Temperature Range Connection

PT100 0 – 200°C (32 – 392°F) 0.75 to 1.5 mm2
K Thermocouple -20 – 1000°C (-4 – 1832°F) 0.75 to 1.5 mm2
Figure 140 Thermocouple Types and Connections
Thermocouple Module 1 Thermocouple Module 2
Phase A Temp Front Bearing Temp
Phase B Temp Rear Bearing Temp
Phase C Temp User PT100 Temp
Figure 141 Thermocouple Module Default Settings for Medium Voltage Generators
Ground 2X
24VDC Power Supply +

24
(9 – 40 VDC) -
Factory connections
or settings +
0 – 20mA
-
1
+ 2
Thermocouple PT100
- 3
connections 0 – 2, Shielding
Type K or PT100 4 Connection
Note: Cable shields must be

+ 2
grounded as shown.
K -
31613391201/301/401 3 31613391201
Figure 142 Thermocouple Module Connections
TP-5700 8/20 145

10.2 Remote Emergency Stop Kit
A-222654 GM103743
TP-5352-1 TT-1736
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.
146 TP-5700 8/20

10.3 Remote Serial Annunciator (RSA III)
details.
LED.

Wiring
III.
Note:
TP-5700 8/20 147

both ends.

both ends.


connections

148 TP-5700 8/20

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 101
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 130.
Note:
Do not apply voltage to any dry contact inputs. Provide proper circuit protection to relay connections.
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
TB10–14 Auxiliary shutdown TB10–14 Auxiliary shutdown Auxiliary shutdown
return
TB10–15 High fuel TB10–15 High fuel High fuel
return
TB10–16 Auxiliary warning TB10–16 Auxiliary warning Auxiliary warning
return
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
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
TB10–32 Common 10 A @ 28 VDC max TB10–32 Horn negative
TP-5700 8/20 149

TB10 Terminal Strip
APM603 APM802
Position Function Signal Description Position Function Signal Description
10 A @ 120 VAC max
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 149 Terminal Strip TB10 Customer Connections (APM603, KD800–KD3250)
150 TP-5700 8/20

Section 11. Decision-Maker 550 Controller Accessories
compliance.
the figure below, Optional Accessories, for a list of available kits. Obtain the most current accessory information from your local
authorized service distributor/dealer.
Kit Description
Audiovisual Alarm
Common Failure Relay (Terminal 32A)
Controller (Customer) Connection
Ground Fault Annunciation
Idle (Speed) Mode Feature
Prime Power Switch
Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring
Single-Relay Dry Contact
Ten-Relay Dry Contact
Twenty-Relay Dry Contact
11.1.1 Audiovisual Alarm Kit
An audiovisual alarm warns the operator at a remote location of fault shutdowns and prealarm conditions. Audiovisual alarms
include an alarm horn, an alarm silence switch, and common fault lamp. See the figures below for connections. See the following
subsection, “Accessory Connections,” for terminal identification.
Note:
Use the audiovisual alarm with a dry contact kit
Figure 151 Audiovisual Alarm
TP-5700 8/20 151

Optional Common A/V
Alarm Connections
Controller Connection Kit Mounted in Junction Box
Figure 152 Audiovisual Alarm Connections
11.1.2 Common Failure Relay Kit
The common failure relay kit provides one set of contacts to trigger user-provided warning devices if a fault occurs. The common
failure relay faults are user-defined. See the respective operation manual for status and faults available for this function.
Connect up to three common failure relay kits to the controller output. See the figures below for connections. See the following
subsection on “Accessory Connections” for terminal identification.
Common
Failure Relay
Common
Failure Relay
Figure 153 Common Failure Relay Kit Connections
152 TP-5700 8/20

11.1.3 Controller (Customer) Connection Kit
The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip. The
supplied wiring harness connects controller connector P23 and terminal strips TB1-3 and TB1-4 to the controller connection kit
connector P25 and terminal strips TB6, TB7, TB8, and TB9. Connect all accessories (except the emergency stop kit) to the
controller connection kit terminal strips. See the figure below. See the following section, “Accessory Connections,” for terminal
identification.
TB1 TB4
Engine Start Digital Input
& E-Stop Connections
Connections
Controller
Interconnection
Board
TB2 TB3
Analog Input Output
Connections Connections
P23
Output
Connections
Customer
Connection Board
Figure 154 Controller (Customer) Connection Kit
TP-5700 8/20 153

11.1.4 Float/Equalize Battery Charger Kit with Alarm Option
The float/equalize battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects
to the controller for fault detection. Battery chargers for 12- or 24-volt models are available as a generator set accessory. See
the figure below for connection details. See the following subsection, “Accessory Connections,” for terminal identification.
Battery Charger Connections (Optional)
Charger Malfunction
LV HV CM Battery Charger Alarm

Terminal Strip
Figure 155 Float/Equalize Battery Charger Connections
11.1.5 Ground Fault Annunciation

A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. See the figure
below for electrical connections and the steps in the following procedure for controller setup. Use the instructions with the kit
when provided to install and setup this accessory.
154 TP-5700 8/20

Power Supply Generator
DC 12 -- TB3-9 N
or 24 V + TB3-4
See assembly drawing and pick

GFA 300 list for neutral to ground cable
Generator system
ground connect to
ground bus
TB4-6 (DCH6) GFI Wired to the Controller

TB4-27 (GND)
Figure 156 Ground Fault Connections
Ground Fault Controller Setup Procedure
1. Reconnect battery, if not already done.
2. Place the controller master switch to the AUTO position.
3. Press the Alarm Off key to silence the alarm horn, if necessary.
4. If the programming mode LED is not flashing, go to the step 5. If the programming mode LED is flashing, go to step 6.
5. Set Programming Mode to Local.

ENTER MENU
RESET
MENU 1 4  
a. Press keys
MENU

b. Press key until Programming Mode- Local is displayed.
ENTER
7
YES 
c. Press the YES key.
0 ENTER ENTER
LAMP
 
d. When the Enter Code displays, press the factory default TEST
or the user password keys and
The programming mode LED should be flashing.
6. Set digital input #6 to ground fault.

RESET ENTER
MENU 9 
a. Press Menu 9 Input Setup should be displayed.
MENU

b. Press until Digital Input 06 warning is displayed.
MENU

c. Press once to select this input.
TP-5700 8/20 155

MENU

d. Press until Ground Fault is displayed.
ENTER
7
YES 
e. Press to define Digital Input #06 as ground fault. Entry Accepted is displayed.
MENU

f. Press to display Digital Input #06 Inhibit Time.
0 ENTER
LAMP

g. Press TEST
to enter the inhibit time. Entry Accepted is displayed and the inhibit time 0:00 is now
displayed.
MENU

h. Press display Digital Input #006 Delay Time.
ENTER
5 
i. Press enter delay time. Entry Accepted is displayed. Default delay time is 5 sec.
RESET
MENU
j. Press .
7. Verify Programming.
a. Move handle of ground fault circuit breaker at generator set to simulate a ground fault.
b. Verify that display shows D06 Ground Fault. The System Warning LED should be illuminated and the alarm horn
should sound. If these indicators are not present, recheck steps 6a. through 6j.
c. Return handle of ground fault circuit breaker to the non-ground fault position. D06 Ground Fault display should
now be cleared.
8. Set Programming Mode to Off.

ENTER
RESET
MENU 1 4 
a. Press .
MENU

b. Press key until Programming Mode Off is displayed.
ENTER
7
YES 
c. Press the YES key .
0 ENTER ENTER
LAMP
 
. The programming mode LED should now be off.
9. Place the controller master switch to the OFF/RESET position.
10. Disconnect the battery negative (-) lead to power down the generator set.
11. After 2–3 minutes, reconnect the battery negative (-) lead.
12. Reset the controller clock. See Menu 6 – Time and Date.
156 TP-5700 8/20

11.1.6 Idle (Speed) Mode Feature
The idle (speed) mode feature provides the ability to start and run the engine at idle (reduced) speed for a selectable time period
(0-10 minutes) during warm-up. The controller will override the idle speed mode if the engine reaches the preprogrammed engine
warmed-up temperature before the idle mode times out. See the figure below for user-supplied switch connection.
TB1
Engine Start TB4
& E-Stop Digital Input
Controller
Interconnection
Board
TB2
Analog Input
Connections TB3
Output
Connections Idle Mode Switch
(Customer Provided)
P23
Output
Connections
Figure 157 Idle (Speed) Mode Switch
TP-5700 8/20 157

Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the gasoline-fueled
models. See the figures below for connection details. See the following subsection, “Accessory Connections, for terminal
identification.
Note:
level switch.

TB1 Provided by Fuel Tank Supplier
TB4
Engine Start &
Digital Input
E-Stop
Connections
Connections
Controller Battery Ground

Interconnection
Board
TB2
TB3
Analog Input
Output
Connections
Connections
P23
Output
Connections

Gauge mm (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 159 Switch Rating and Wiring Recommendations
158 TP-5700 8/20

The prime power switch kit prevents battery drain during generator set nonoperation periods and when the generator set battery
cannot be maintained by an AC battery charger. See the figures below for an illustration of the kit and the electrical connections

Prime Power
Figure 160 Prime Power Switch Installation Location
TB1
Engine Start &
E-Stop
Connections TB4
Digital Input
Connections
Controller
Interconnection
Board
TB2
Analog Input TB3
Connections Output
Connections
P1
Engine Harness
P3 Connections P23
DC Input Output Connections
Connections
To Engine Harness Toggle switch shown in the prime power

Prime Power mode off position (contacts open)
Switch
Figure 161 Prime Power Switch Connection

Stop the generator set using the stopping procedures in the respective operation manual before placing the generator set in the
prime power mode. Move the prime power switch located on the back of the controller to the DOWN position. The controller
including the digital display, LEDs, and alarm horn does not function when the generator set is in the prime power mode.
Move the prime power switch located on the back of the controller to the UP position and reset the controller time and date
before attempting to start the generator set.
TP-5700 8/20 159

A-222654 GM103743
TP-5352-1 TT-1736
See the figure below for typical connections. Refer to the generator set wiring diagram for your model.
TB1
Engine Start and
Local Emergency E-Stop Connections TB4
Stop Switch Digital Input
(Standard) Connections
Controller
Interconnection
Remote Local Emergency Board
Emergency Stop Stop Switch
Switch (Optional) (Standard) TB1 TB2
Analog Input
Connections
TB3
Output Connections
Connections
DCB2
P23
Output Connections
160 TP-5700 8/20

The remote reset switch provides generator set resetting after a fault shutdown at a remote location. See the following figures
for user-supplied switch connection.
Remote Reset Switch Contacts Normally

Open Momentary Closed to Activate
Battery
Ground
TB1
Engine Start TB4
Controller
Interconnection
Board
TB2 TB3
Analog Input Output
P23
Output
Connections

Gauge Mm (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
TP-5700 8/20 161

details.
LED.

Wiring
III.
Note:
162 TP-5700 8/20

both ends.

both ends.


connections

TP-5700 8/20 163

Line circuit breaker

(optional)
Shunt trip coil
DCB3
(Shunt trip wiring,
optional)
Fuse, 10 amp
Connect to “P” of starter relay
Typical Connection:
TB6-RDO1 Overspeed (39),
TB8-RDO18 Defined Common Fault (32A),
TB8-RDO20 Overvoltage (26), or
TB9-RDO30 Load Shed kW Overload
GM16088A-H
Figure 170 Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring Kit Connections
164 TP-5700 8/20

11.1.13 Single-Relay Dry Contact Kit
The single-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning
devices and other user-provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible alarms,
or other devices signal faults or status conditions. Connect any controller fault output to the single-relay dry contact kit.
A total of three dry contact kits may connect to a single controller output. See the figures below. See the following subsection,
“Accessory Connections,” for terminal identifications.
Connect to controller connection kit

using the lead numbers shown.
Optional
One Isolated Alarm
Contact Kit
Connections
Overspeed
(Typical
Connection)
GM16088A-A
A-273945
Single-Relay Dry Contact Kit, Typical
Figure 171 Single-Relay Dry Contact Kit Connections
TP-5700 8/20 165

11.1.14 Ten-Relay Dry Contact Kit
The ten-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning
devices and other user-provided accessories allowing remote monitoring of the generator set. Connect any controller fault output
to the ten-relay dry contact kit. Typically, lamps, audible alarms, or other devices signal the fault conditions.
Refer to the figure, “Ten-Relay Dry Contact Kit” for an internal view of the contact kit. See the figure, “Ten-Relay Dry Contact Kit
Connections,” for electrical connections. See the following subsection, “Accessory Connections,” for terminal identifications.
A-273936
Figure 172 Ten-Relay Dry Contact Kit
Circle
Connect to controller connection kit as needed using

descriptions and leads shown in 6.2 Accessory connections
10 Relay
Dry Contact Kit
Optional Ten isolated Alarm Contacts Kit Connections
GM13984-/354246B
Figure 173 Ten-Relay Dry Contact Kit Connections
166 TP-5700 8/20

11.1.15 Twenty-Relay Dry Contact Kit
The twenty-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate
warning devices and other user-provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible
alarms, or other devices signal faults or status conditions. Connect any generator set fault output to the dry contact kit.
Refer to the figure below, Twenty-Relay Dry Contact Kits” for an internal view of the contact kit. See the figure, “Twenty-Relay
Dry Contact Relay Kit Connections” for electrical connections. See the following subsection, “Accessory Connections,” for
terminal identifications.
D-294303-D
Figure 174 Twenty-Relay Dry Contact Kits
Inner Panel
Twenty Relay
(GM16755) (GM16756)
(GM10182)
Customer Connection Board
GM16759D-C
Figure 175 Twenty-Relay Dry Contact Relay Kit Connections
TP-5700 8/20 167

The controller contains circuit boards equipped with terminal strip(s) for use in connecting a controller connection kit. Do not
connect accessories directly to the controller terminal strip(s). Connect accessories to either a controller connection kit or a dry
contact kit. Connect the dry contact kit(s) to the controller connection kit. Connect alarms, battery chargers, remote switches,
and other accessories to the dry contact kit relay(s).
Top of Controller Back Panel
TB1 Terminal Strip TB1

Engine Start & E-
Stop Connections TB4 Digital Input
Connections
TB3 Terminal Strip
Controller
TB2 Terminal Strip Interconnection
TB4 Terminal Strip
Board
TB2 Analog Input

Connections TB3 Output
Connections
P23 Connector
P1 Engine Harness
P3 DC Input Connections P23 Output Connections
Connections
GM16088A-A/GM10193B-A
Figure 176 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)
168 TP-5700 8/20

TB1 Terminal Strip—Engine Start and TB4 Terminal Strip—Input Factory Connections
Emergency Stop Connections
Term. Description Term. Description
1 Emergency stop ground 1 DCH1 Battery charger fault
1A Emergency stop 2 DCH2 Low fuel
3 Remote start 3 DCH3 Low coolant temp. with ECM models or
4 Remote start warning default with non-ECM models
4 DCH4 Field overvoltage with M4/M5/M7
alternators or warning default with
TB2 Terminal Strip—Analog Input Connections non-M4/M5/M7 alternators
Term. Description 5 DCH5 Breaker Closed, Paralleling Applications
1 ACH1 (CTS) Signal (non-ECM including Waukesha) 6 DCH6 Enable Synch, Paralleling Applications
2 ACH1 (CTS) Supply (non-ECM including Waukesha) 7 DCH7 Warning
3 ACH2 (OPS) Signal (non-ECM including Waukesha) 8 DCH8 Warning
4 ACH2 (OPS) Supply (non-ECM including Waukesha 9 DCH9 Warning
5 ACH3 Signal (air intake temp. for Waukesha) 10 DCH10 Warning
6 ACH3 Supply (air intake temp. for Waukesha) 11 DCH11 AFM Shutdown, Waukesha engine
7 ACH4 Signal (oil temp. for Waukesha) 12 DCH12 Detonation Warning, Waukesha engine
8 ACH4 Supply (oil temp. for Waukesha) 13 DCH13 Detonation Shutdown, Waukesha engine
9 ACH5 Signal 14 DCH14 Warning
10 ACH5 Supply 15 DCH15 Remote shutdown
11 ACH6 Signal 16 DCH16 Remote reset
12 ACH6 Supply (VSG for Volvo, GM, Doosan) 17 DCH17 VAR PF mode
13 ACH7 Signal (optional analog voltage adjust signal) 18 DCH18 Voltage lower
14 ACH7 Supply 19 DCH19 Voltage raise
15 N/C 20 DCH20 Air damper
16 ACH1 (CTS) Return (non-ECM) 21 DCH21 Idle mode functional with ECM-equipped
17 ACH1 (CTS) Shield ground (non-ECM) engines only
18 ACH2 (OPS or OPS2) Return (non-ECM) 22 DCH1 Return
19 ACH2 (OPS) Shield ground (non-ECM) 23 DCH2 Return
20 ACH3 (IAT or OPS1) Return 24 DCH3 Return
21 ACH3 Shield ground 25 DCH4 Return
22 ACH4 (Oil Temp) Return 26 DCH5 Return
24 ACH5 Return 28 DCH7 Return
30 N/C 34 DCH13 Return
35 DCH14 Return
36 DCH16 Return
TB3 Terminal Strip-Accessory Power Output Connections 37 DCH16 Return
Term. Description 38 DCH17 Return
1 +12 VDC (OEM use only) 39 DCH18 Return
4 Fused battery (+) (42A) (5 amp) 42 DCH21 Return
5 Fused battery (+) (42A) (5 amp)
6 Fused battery (+) (42A) (5 amp) Note: TB4-1 through TB4-21 are user definable with
7 Battery (-) factory defaults listed. Terminals TB4-3, TB4-4,
8 Battery (-) TB4-14, and TB4-21 have different functions
9 Battery (-) depending upon the generator set configuration.
10 Battery (-) See comments above.
11 Battery (-) See Menu 9-Input Setup for changing inputs.
12 Panel lamp output
Figure 177 Controller Terminal Strip Identification
TP-5700 8/20 169

GM13984-
Figure 178 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box
TB6 Terminal Strip—RDOs 1-7 TB9 Terminal Strip—RDOs 24 – 31

42A Battery (+) RDO24 Speed sensor fault
GND Battery (-) RDO25 Loss of AC sensing
N/C RDO26 ECM loss of communication
RDO1 Overspeed (lead 39) RDO27 Undervoltage
RDO2 Overcrank (lead 12) RDO28 Overfrequency
RDO3 High coolant temperature shutdown (lead 36) RDO29 Underfrequency
RDO4 Low oil pressure shutdown (lead 38) RDO30 Load shed kW overload
RDO5 Low coolant temperature (lead 35) RDO31 Load shed underfrequency
RDO6 High coolant temperature warning (lead 40) 3 Remote start
RDO7 Low oil pressure warning (lead 41) 4 Remote start
TB7 Terminal Strip—RDOs 8-17
Term. Description Note: Lead numbers shown in parentheses are the factory
RDO8 Low fuel (lead 63) default wire designations.
RDO9 Master switch not in auto ( lead 80)
RDO10 NFPA 110 common alarm (lead 32)* Note: RDO-1 though RDO-31 are user definable with the
RDO11 Battery charger fault (lead 61) following factory defaults: emergency stop, high coolant
RDO12 Low battery voltage (lead 62) temperature, low oil pressure, overcrank, and overspeed
RDO13 High battery voltage
RDO14 Emergency stop (lead 48) *NFPA-110 common alarm faults include:
RDO15 Generator set running (lead 70R) Air damper indicator (RDO-23)
RDO16 Time delay engine cooldown (TDEC) (lead 70C) Battery charger fault (RDO-11)
RDO17 System ready (lead 60) EPS supplying load (RDO-22)
TB8 Terminal Strip—RDOs 18-23 High battery voltage (RDO-13)
Term. Description High coolant temperature warning (RDO-06)
42A Battery (+) High coolant temperature shutdown (RDO-03)
42A Battery (+) Low battery voltage (RDO-012)
GND Battery (-) Low coolant level (RDO-19)
GND Battery (-) Low coolant temperature warning (RDO-05)
RDO18 Defined common fault (lead 32A) Low fuel (level or pressure) (RDO-08)
RDO19 Low coolant level Low oil pressure warning (RDO-07)
RDO20 Overvoltage (lead 26) Low oil pressure shutdown (RDO-04)
RDO21 Idle mode Master switch not in auto (RDO-09)
RDO22 EPS supplying load Overcrank (RDO-02)
RDO23 Air damper indicator (lead 56) Overspeed (RDO-01)
Figure 179 Controller (Customer) Connection Kit Terminal Strip Identification with Relay Driver Outputs (RDOs)
170 TP-5700 8/20

compliance.
Figure 180 for a list of available kits. Obtain the most current accessory information from your local authorized service
distributor/dealer.
See the following subsection, Accessory Connections, for terminal identification.

Kit Description
Fifteen-Relay Dry Contact
TP-5700 8/20 171

12.1.1 Fifteen-Relay Dry Contact Kit
The 15-relay dry contact board has four digital inputs and two analog inputs. There are 14 individual relay driver outputs (RDOs)
with one common fault RDO.
See Figure 181 for circuit board components and electrical connections to the controller. See Figure 182 for connections of
analog inputs.
See the following subsection, “Accessory Connections,” for terminal identification.
The normally open (NO) relay contacts are rated:
 10 amp @ 120 VAC
 10 amp @ 28 VDC (max.)
 10 amp @ 28 VDC (min.)
CAN connections (TB5-CAN (+)/-CAN (-) Digital Input Connections

(TB6-D11, -D12, -D13, -D14)
Common fault RDO K15
Analog input
connections (TB5-C/NO)
connections
Battery positive (+) connections (P36-V1/-V2)
(TB5-42A)
RDOs K1-K14 (TB7-1 to TB7-28) (NO/C)
GM84063-B
Figure 181 15-Relay Dry Contact Board

+5 +5 +5
VPx VPx + VPx

GND GND GND
GND
50 mA max. current
Figure 182 Analog Input Connections P36
172 TP-5700 8/20

A-222654 GM103743
TP-5352-1 TT-1736
See Figure 184 for typical connections. Refer to the generator set wiring diagram for your model. See the following subsection,
Figure 184 Remote E-Stop Kit Connections
TP-5700 8/20 173

details.
LED.

Wiring
III.
Note:
174 TP-5700 8/20

both ends.

both ends.


connections

TP-5700 8/20 175

The controller contains a circuit board equipped with connectors for use in connecting external optional accessories including
alarms, battery chargers, and remote switches. The optional fifteen relay dry contact board provides an additional four digital
inputs and two analog inputs.
Circuit Board Connections (see Figure 189)
DEC 3500 Controller Front Panel (see Figure 190)
Panel Power Connections (see Figure 190)
P1 (35-Pin) Connector for engine/generator wiring harness.
P2 (14-Pin) Connector for sensor input connections and relay driver output connections.
P3 (8-Pin) Connector for generator set output voltage connection and paralleling bus voltage sensing connections.
P4 (Ethernet) RG 45 Connector connects to a network communication line.
P7 (10-Pin) Connector for factory use only.
Mini USB Connector for connection of a PC with SiteTech™ software programming or for firmware updates.
TB10 Terminal Strip for CAN, remote emergency stop, and remote start connections.
See Figure 191 for controller circuit board connections. See the appendix, Wiring Diagrams, for accessory connection wiring
diagrams.
P7
Figure 189 Main Circuit Board Connectors (Back of DEC 3500 Controller)
Mini USB connector
Figure 190 DEC 3500 Controller Front Panel
176 TP-5700 8/20

P1 35-Pin Connector P2 14-Pin Connector
Analog/Digital Input and Relay Driver Output
Engine/Generator Wiring Harness
Connections
Terminal Description Connection Terminal Description Connection
P1-1 71 P31-3 (71) P2-1 Open -
P1-2 RTC P48-23 (RTC) P2-2 Open -
P1-3 N10 P48-31 (14N1) P2-3 Open -
P1-4 3B P7-8 (3B) P2-4 Open -
P1-5 YEL P48-34 (YEL) P2-5 Open -
P1-6 GRN P48-33 (GRN) P2-6 Open -
P1-7 Open - P2-7 Open -
P1-9 YEL TB10-CAN (+) P2-9 Open -
P1-10 GRN TB10-CAN (-) P2-10 SS3 P7-7
P1-11 Open - P2-11 SS2 P7-6
P1-12 Open - P2-12 SS1 P7-5
P1-13 70 P30-3 (70) P2-13 AHN P4B-1
P1-14 1 ESS-1 (local E- P2-14 Open
-
stop)
P1-15 3 TB10-3 P3 8-Pin Connector
P1-16 IR Output Voltage and Paralleling Bus Voltage Sensing
P7-4 (IR)
Connections
P1-17 12 P7-2 (I2) Terminal Description Connection
P1-18 7 P48-22 (7) P3-1 A IS15
P1-19 63 P48-21 (63) P3-2 B IS16
P1-22 Open - P3-5 C IS17
P1-23 Open - P3-6 NEU IS18
P1-24 P2 P4B-9 (P1) P3-7 Open -
P1-25 31A P48-15 (31A) P3-8 Open -
P1-26 1A TB10-1A TB10 8-Position Terminal Strip
P1-27 Open - CAN, Remote E-Stop, and Remote Start Connections
P1-28 13 P7-3 (I3) Terminal Description Connection
P1-29 11 P7-1 (I1) TB10-1 P 42A Battery (+)
P1-30 35A P48-14 (35A) TB10-2 7N 2 Battery (-)
P1-31 BGA P48-31 (14N1) TB10-3 CAN (+) P1-9
P1-32 Open - TB10-4 CAN (-) P1-10
P1-33 64 P7-11 (64) TB10-5 1A Remote E-Stop
P1-34 Open - TB10-6 ESS Remote E-Stop
P1-35 Open TB10-7 3 Remote start
-
(ATS)
TB10-8 4 Remote start
(ATS)
P4 Connector
RJ45 Ethernet
Open Network communications
Figure 191 Controller Connections
TP-5700 8/20 177

178 TP-5700 8/20
compliance.
the figure below, Optional Accessories, for a list of available kits. Obtain the most current accessory information from your local
authorized service distributor/dealer.
Kit Description
Audiovisual Alarm
Common Failure Relay (Terminal 32A)
Controller (Customer) Connection
Ground Fault Annunciation
Idle (Speed) Mode Feature
Prime Power Switch
Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring
Single-Relay Dry Contact
Ten-Relay Dry Contact
Twenty-Relay Dry Contact
13.1.1 Audiovisual Alarm Kit
An audiovisual alarm warns the operator at a remote location of fault shutdowns and prealarm conditions. Audiovisual alarms
include an alarm horn, an alarm silence switch, and common fault lamp. See the figures below for connections. See the following
subsection, “Accessory Connections,” for terminal identification.
Note:
Use the audiovisual alarm with a dry contact kit
Figure 193 Audiovisual Alarm
TP-5700 8/20 179

Optional Common A/V
Alarm Connections
Figure 194 Audiovisual Alarm Connections
13.1.2 Common Failure Relay Kit
The common failure relay kit provides one set of contacts to trigger user-provided warning devices if a fault occurs. The common
failure relay faults are user-defined. See the respective operation manual for status and faults available for this function.
Connect up to three common failure relay kits to the controller output. See the figures below for connections. See the following
subsection on “Accessory Connections” for terminal identification.
Common
Failure Relay
Common
Failure Relay
Figure 195 Common Failure Relay Kit Connections
180 TP-5700 8/20

13.1.3 Float/Equalize Battery Charger Kit with Alarm Option
The float/equalize battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects
to the controller for fault detection. Battery chargers for 12- or 24-volt models are available as a generator set accessory. See
the figure below for connection details. See the following subsection, “Accessory Connections,” for terminal identification.
Battery Charger Connections (Optional)
Charger Malfunction
LV HV CM Battery Charger Alarm

Terminal Strip
Figure 196 Float/Equalize Battery Charger Connections
13.1.4 Ground Fault Annunciation

A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. See the figure
below for electrical connections and the steps in the following procedure for controller setup. Use the instructions with the kit
when provided to install and setup this accessory.
TP-5700 8/20 181

Power Supply Generator
DC 12 -- TB3-9 N
or 24 V + TB3-4
See assembly drawing and pick

GFA 300 list for neutral to ground cable
Generator system
ground connect to
ground bus
TB4-6 (DCH6) GFI Wired to the Controller

TB4-27 (GND)
Figure 197 Ground Fault Connections
Ground Fault Controller Setup Procedure
13. Reconnect battery, if not already done.
14. Place the controller master switch to the AUTO position.
15. Press the Alarm Off key to silence the alarm horn, if necessary.
16. If the programming mode LED is not flashing, go to the step 5. If the programming mode LED is flashing, go to step 6.
17. Set Programming Mode to Local.

ENTER MENU
RESET
MENU 1 4  
a. Press keys
MENU

b. Press key until Programming Mode- Local is displayed.
ENTER
7
YES 
c. Press the YES key.
0 ENTER ENTER
LAMP
 
The programming mode LED should be flashing.
18. Set digital input #6 to ground fault.

RESET ENTER
MENU 9 
a. Press Menu 9 Input Setup should be displayed.
MENU

b. Press until Digital Input 06 warning is displayed.
MENU

c. Press once to select this input.
182 TP-5700 8/20

MENU

d. Press until Ground Fault is displayed.
ENTER
7
YES 
e. Press to define Digital Input #06 as ground fault. Entry Accepted is displayed.
MENU

f. Press to display Digital Input #06 Inhibit Time.
0 ENTER
LAMP

g. Press TEST
to enter the inhibit time. Entry Accepted is displayed and the inhibit time 0:00 is now
displayed.
MENU

h. Press display Digital Input #006 Delay Time.
ENTER
5 
i. Press enter delay time. Entry Accepted is displayed. Default delay time is 5 sec.
RESET
MENU
j. Press .
19. Verify Programming.
a. Move handle of ground fault circuit breaker at generator set to simulate a ground fault.
b. Verify that display shows D06 Ground Fault. The System Warning LED should be illuminated and the alarm horn
should sound. If these indicators are not present, recheck steps 6a. through 6j.
c. Return handle of ground fault circuit breaker to the non-ground fault position. D06 Ground Fault display should
now be cleared.
20. Set Programming Mode to Off.

ENTER
RESET
MENU 1 4 
a. Press .
MENU

b. Press key until Programming Mode Off is displayed.
ENTER
7
YES 
c. Press the YES key .
0 ENTER ENTER
LAMP
 
. The programming mode LED should now be off.
21. Place the controller master switch to the OFF/RESET position.
22. Disconnect the battery negative (-) lead to power down the generator set.
23. After 2–3 minutes, reconnect the battery negative (-) lead.
24. Reset the controller clock. See Menu 6 – Time and Date.
TP-5700 8/20 183

13.1.5 Idle (Speed) Mode Feature
The idle (speed) mode feature provides the ability to start and run the engine at idle (reduced) speed for a selectable time period
(0-10 minutes) during warm-up. The controller will override the idle speed mode if the engine reaches the preprogrammed engine
warmed-up temperature before the idle mode times out. See the figure below for user-supplied switch connection.
TB1
Engine Start TB4
Controller
Interconnection
Board
TB2
Analog Input
Connections TB3
Output
Connections Idle Mode Switch
(Customer Provided)
P23
Output
Connections
Figure 198 Idle (Speed) Mode Switch
184 TP-5700 8/20

Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the gasoline-fueled
models. See the figures below for connection details. See the following subsection, “Accessory Connections, for terminal
identification.
Note:
level switch.

TB1 Provided by Fuel Tank Supplier
TB4
Engine Start &
Digital Input
E-Stop
Connections
Connections
Controller Battery Ground

Interconnection
Board
TB2
TB3
Analog Input
Output
Connections
Connections
P23
Output
Connections

Gauge mm (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 200 Switch Rating and Wiring Recommendations
TP-5700 8/20 185

The prime power switch kit prevents battery drain during generator set nonoperation periods and when the generator set battery
cannot be maintained by an AC battery charger. See the figures below for an illustration of the kit and the electrical connections

Prime Power
Figure 201 Prime Power Switch Installation Location
TB1
Engine Start &
E-Stop
Connections TB4
Digital Input
Connections
Controller
Interconnection
Board
TB2
Analog Input TB3
Connections Output
Connections
P1
Engine Harness
P3 Connections P23
DC Input Output Connections
Connections
To Engine Harness Toggle switch shown in the prime power

Prime Power mode off position (contacts open)
Switch
Figure 202 Prime Power Switch Connection

Stop the generator set using the stopping procedures in the respective operation manual before placing the generator set in the
prime power mode. Move the prime power switch located on the back of the controller to the DOWN position. The controller
including the digital display, LEDs, and alarm horn does not function when the generator set is in the prime power mode.
Move the prime power switch located on the back of the controller to the UP position and reset the controller time and date
before attempting to start the generator set.
186 TP-5700 8/20

A-222654 GM103743
TP-5352-1 TT-1736
See the figure below for typical connections. Refer to the generator set wiring diagram for your model.
TB1
Engine Start and
Local Emergency E-Stop Connections TB4
Stop Switch Digital Input
(Standard) Connections
Controller
Interconnection
Remote Local Emergency Board
Emergency Stop Stop Switch
Switch (Optional) (Standard) TB1 TB2
Analog Input
Connections
TB3
Output Connections
Connections
DCB2
P23
Output Connections
TP-5700 8/20 187

The remote reset switch provides generator set resetting after a fault shutdown at a remote location. See the following figures
for user-supplied switch connection.
Remote Reset Switch Contacts Normally

Open Momentary Closed to Activate
Battery
Ground
TB1
Engine Start TB4
Controller
Interconnection
Board
TB2 TB3
Analog Input Output
P23
Output
Connections

Gauge Mm (ft.)
18-20 30.5 (100)
14 153 (500)
10 305 (1000)
188 TP-5700 8/20

details.
LED.

Wiring
III.
Note:
TP-5700 8/20 189

both ends.

both ends.


connections

190 TP-5700 8/20

13.1.11 Shunt Trip Line Circuit Breaker
Line circuit breaker

(optional)
Shunt trip coil
DCB3
(Shunt trip wiring,
optional)
Fuse, 10 amp
Connect to “P” of starter relay
Typical Connection:
TB6-RDO1 Overspeed (39),
TB8-RDO18 Defined Common Fault (32A),
TB8-RDO20 Overvoltage (26), or
TB9-RDO30 Load Shed kW Overload
GM16088A-H
Figure 211 Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring Kit Connections
TP-5700 8/20 191

13.1.12 Single-Relay Dry Contact Kit
The single-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning
devices and other user-provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible alarms,
or other devices signal faults or status conditions. Connect any controller fault output to the single-relay dry contact kit.
A total of three dry contact kits may connect to a single controller output. See the figures below. See the following subsection,
Connect to controller connection kit

using the lead numbers shown.
Optional
One Isolated Alarm
Contact Kit
Connections
Overspeed
(Typical
Connection)
GM16088A-A
A-273945
Single-Relay Dry Contact Kit, Typical
Figure 212 Single-Relay Dry Contact Kit Connections
192 TP-5700 8/20

13.1.13 Ten-Relay Dry Contact Kit
The ten-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning
devices and other user-provided accessories allowing remote monitoring of the generator set. Connect any controller fault output
to the ten-relay dry contact kit. Typically, lamps, audible alarms, or other devices signal the fault conditions.
Refer to the figure, “Ten-Relay Dry Contact Kit” for an internal view of the contact kit. See the figure, “Ten-Relay Dry Contact Kit
Connections,” for electrical connections. See the following subsection, “Accessory Connections,” for terminal identifications.
A-273936
Figure 213 Ten-Relay Dry Contact Kit
Circle
Connect to controller connection kit as needed using

descriptions and leads shown in 6.2 Accessory connections
10 Relay
Dry Contact Kit
Optional Ten isolated Alarm Contacts Kit Connections
GM13984-/354246B
Figure 214 Ten-Relay Dry Contact Kit Connections
TP-5700 8/20 193

13.1.14 Twenty-Relay Dry Contact Kit
The twenty-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate
warning devices and other user-provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible
alarms, or other devices signal faults or status conditions. Connect any generator set fault output to the dry contact kit.
Refer to the figure below, Twenty-Relay Dry Contact Kits” for an internal view of the contact kit. See the figure, “Twenty-Relay
Dry Contact Relay Kit Connections” for electrical connections. See the following subsection, “Accessory Connections,” for
terminal identifications.
D-294303-D
Figure 215 Twenty-Relay Dry Contact Kits
Inner Panel
Twenty Relay
(GM16755) (GM16756)
(GM10182)
Customer Connection Board
GM16759D-C
Figure 216 Twenty-Relay Dry Contact Relay Kit Connections
194 TP-5700 8/20

The controller contains circuit boards equipped with terminal strip(s) for use in connecting a controller connection kit. Do not
connect accessories directly to the controller terminal strip(s). Connect accessories to either a controller connection kit or a dry
contact kit. Connect the dry contact kit(s) to the controller connection kit. Connect alarms, battery chargers, remote switches,
and other accessories to the dry contact kit relay(s).
Top of Controller Back Panel
TB1 Terminal Strip TB1

Engine Start & E-
Stop Connections TB4 Digital Input
Connections
TB3 Terminal Strip
Controller
TB2 Terminal Strip Interconnection
TB4 Terminal Strip
Board
TB2 Analog Input

Connections TB3 Output
Connections
P23 Connector
P1 Engine Harness
P3 DC Input Connections P23 Output Connections
Connections
GM16088A-A/GM10193B-A
Figure 217 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)
TP-5700 8/20 195

TB1 Terminal Strip—Engine Start and TB4 Terminal Strip—Input Factory Connections
Emergency Stop Connections
1 Emergency stop ground 1 DCH1 Battery charger fault
1A Emergency stop 2 DCH2 Low fuel
3 Remote start 3 DCH3 Low coolant temp. with ECM models or
4 Remote start warning default with non-ECM models
4 DCH4 Field overvoltage with M4/M5/M7
alternators or warning default with
TB2 Terminal Strip—Analog Input Connections non-M4/M5/M7 alternators
Term. Description 5 DCH5 Breaker Closed, Paralleling Applications
1 ACH1 (CTS) Signal (non-ECM including Waukesha) 6 DCH6 Enable Synch, Paralleling Applications
2 ACH1 (CTS) Supply (non-ECM including Waukesha) 7 DCH7 Warning
3 ACH2 (OPS) Signal (non-ECM including Waukesha) 8 DCH8 Warning
4 ACH2 (OPS) Supply (non-ECM including Waukesha 9 DCH9 Warning
5 ACH3 Signal (air intake temp. for Waukesha) 10 DCH10 Warning
6 ACH3 Supply (air intake temp. for Waukesha) 11 DCH11 AFM Shutdown, Waukesha engine
7 ACH4 Signal (oil temp. for Waukesha) 12 DCH12 Detonation Warning, Waukesha engine
8 ACH4 Supply (oil temp. for Waukesha) 13 DCH13 Detonation Shutdown, Waukesha engine
9 ACH5 Signal 14 DCH14 Warning
10 ACH5 Supply 15 DCH15 Remote shutdown
11 ACH6 Signal 16 DCH16 Remote reset
12 ACH6 Supply (VSG for Volvo, GM, Doosan) 17 DCH17 VAR PF mode
13 ACH7 Signal (optional analog voltage adjust signal) 18 DCH18 Voltage lower
14 ACH7 Supply 19 DCH19 Voltage raise
15 N/C 20 DCH20 Air damper
16 ACH1 (CTS) Return (non-ECM) 21 DCH21 Idle mode functional with ECM-equipped
17 ACH1 (CTS) Shield ground (non-ECM) engines only
18 ACH2 (OPS or OPS2) Return (non-ECM) 22 DCH1 Return
19 ACH2 (OPS) Shield ground (non-ECM) 23 DCH2 Return
20 ACH3 (IAT or OPS1) Return 24 DCH3 Return
22 ACH4 (Oil Temp) Return 26 DCH5 Return
30 N/C 34 DCH13 Return
35 DCH14 Return
36 DCH16 Return
TB3 Terminal Strip-Accessory Power Output Connections 37 DCH16 Return
Term. Description 38 DCH17 Return
4 Fused battery (+) (42A) (5 amp) 42 DCH21 Return
5 Fused battery (+) (42A) (5 amp)
6 Fused battery (+) (42A) (5 amp) Note: TB4-1 through TB4-21 are user definable with
7 Battery (-) factory defaults listed. Terminals TB4-3, TB4-4,
8 Battery (-) TB4-14, and TB4-21 have different functions
9 Battery (-) depending upon the generator set configuration.
10 Battery (-) See comments above.
11 Battery (-) See Menu 9-Input Setup for changing inputs.
12 Panel lamp output
Figure 218 Controller Terminal Strip Identification
196 TP-5700 8/20

GM13984-
Figure 219 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box
TB6 Terminal Strip—RDOs 1-7 TB9 Terminal Strip—RDOs 24 – 31

42A Battery (+) RDO24 Speed sensor fault
GND Battery (-) RDO25 Loss of AC sensing
N/C RDO26 ECM loss of communication
RDO1 Overspeed (lead 39) RDO27 Undervoltage
RDO2 Overcrank (lead 12) RDO28 Overfrequency
RDO3 High coolant temperature shutdown (lead 36) RDO29 Underfrequency
RDO4 Low oil pressure shutdown (lead 38) RDO30 Load shed kW overload
RDO5 Low coolant temperature (lead 35) RDO31 Load shed underfrequency
RDO6 High coolant temperature warning (lead 40) 3 Remote start
RDO7 Low oil pressure warning (lead 41) 4 Remote start
TB7 Terminal Strip—RDOs 8-17
Term. Description Note: Lead numbers shown in parentheses are the factory
RDO8 Low fuel (lead 63) default wire designations.
RDO9 Master switch not in auto ( lead 80)
RDO10 NFPA 110 common alarm (lead 32)* Note: RDO-1 though RDO-31 are user definable with the
RDO11 Battery charger fault (lead 61) following factory defaults: emergency stop, high coolant
RDO12 Low battery voltage (lead 62) temperature, low oil pressure, overcrank, and overspeed
RDO13 High battery voltage
RDO14 Emergency stop (lead 48) *NFPA-110 common alarm faults include:
RDO15 Generator set running (lead 70R) Air damper indicator (RDO-23)
RDO16 Time delay engine cooldown (TDEC) (lead 70C) Battery charger fault (RDO-11)
RDO17 System ready (lead 60) EPS supplying load (RDO-22)
TB8 Terminal Strip—RDOs 18-23 High battery voltage (RDO-13)
Term. Description High coolant temperature warning (RDO-06)
42A Battery (+) High coolant temperature shutdown (RDO-03)
42A Battery (+) Low battery voltage (RDO-012)
GND Battery (-) Low coolant level (RDO-19)
GND Battery (-) Low coolant temperature warning (RDO-05)
RDO18 Defined common fault (lead 32A) Low fuel (level or pressure) (RDO-08)
RDO19 Low coolant level Low oil pressure warning (RDO-07)
RDO20 Overvoltage (lead 26) Low oil pressure shutdown (RDO-04)
RDO21 Idle mode Master switch not in auto (RDO-09)
RDO22 EPS supplying load Overcrank (RDO-02)
RDO23 Air damper indicator (lead 56) Overspeed (RDO-01)
Figure 220 Controller (Customer) Connection Kit Terminal Strip Identification with Relay Driver Outputs (RDOs)
TP-5700 8/20 197

198 TP-5700 8/20
Section 14. 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.

(APM802 Controller)
TP-5700 8/20 199

14.1 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.
14.2 APM402 and Decision-Maker 3000 Controller Voltage Regulator
The controller has a voltage regulation function that is internal to the processor.
See the APM402/Decision-Maker® 3000 Controller and SiteTech™ Operation Manuals for further details regarding voltage
adjustment setup.
14.3 APM603 Controller Voltage Regulator
See the APM603 Controller and SiteTech™ Operation Manuals for further details regarding voltage adjustment setup.
14.4 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.
14.5 Decision-Maker 550 Controller, Voltage Regulator and Paralleling Applications
See the Decision-Maker® 550 Controller Operation Manual for further details regarding voltage adjustment and paralleling
operation setup.
200 TP-5700 8/20

14.6 Decision-Maker 3500 Controller Voltage Regulator
See the Decision-Maker® 3500 Controller and SiteTech™ Operation Manuals for further details regarding voltage adjustment
setup.
14.7 Decision-Maker 6000 Controller Voltage Regulator and Paralleling Applications
See the Decision-Makerr 6000 Controller,Decision-Maker® Paralleling (DPS), and SiteTech™ Operation Manuals for further
details regarding voltage adjustment and paralleling operation setup.
14.8 Decision-Maker 8000 Controller Voltage Regulator and Paralleling Applications
The generator set uses a Marathon® DVR® 2000EC voltage regulator.
See the Decision-Maker® 8000 Controller Operation Manual and TP-5579 Operation Manual, DVR® 2000 Voltage Regulator for
further details regarding voltage adjustment and paralleling operation setup.
14.9 Remote Speed Adjustment
This kit provides remote engine speed adjustments with an approximate range of ±5% at 1800 rpm. This kit requires a generator
set with an electronic governor. See Figure 221 and Figure 222.
Notes:
 Wire number is 542 on 2000/4000 series
engine or 545 on 60 series engine (for DDEC GM31213 potentiometer assembly ref.
connections only).
 Remove and tape wire 542 (545) when
installing manual speed adjust kits.
Existing Existing terminal block

See notes terminal
block
Existing engine wiring harness
Existing engine wiring harness
DDEC MDEC
Figure 221 Remote Speed Adjusting Control Wiring Diagram
TP-5700 8/20 201

USEGM30860 BRACKET USEGM30860 BRACKET
USEGM30860 BRACKET EXISTING
Note: Dimensions shown in mm ASTEMPLATEFORDRILLING ASTEMPLATEFOR ASTEMPLATEFOR TERMINAL BLOCK
2X 6.40 HOLES DRILLING DRILLING
2X 6.40 HOLES 2X 6.40 HOLES
C.T. TERMINAL
254.0 REF. BLOCK
(INSIDEOF J--BOX) VOLTAGE
SEEDETAIL D
REGULATOR
102.0 REF.
SEEDETAIL D
305.0 REF.
76.2 REF.
EXISTING TERMINAL 123456
BLOCK
(INSIDEOF J--BOX)
GM30862 DECAL,
SPEED ADJUST
76.2 REF. EXISTING TERMINAL
SEEDETAIL D BLOCK 76.2 REF.
GM30860
VIEW A--A VIEW B--B VIEW C--C
38.0 REF.
GM31213
JUNCTION A
BOX B
RELAY PANEL
C C
A LO
M933--06014--60 (2) EXP

M6923--06--80 (2) EXP
B
DETAIL D
(INSIDEOF BOX)
GM30859-A 230--300 KW 350--400 KW 450--2000 KW
Figure 222 Remote Speed Potentiometer Installation

To program the 550 controller, MDEC-equipped DDC/MTU engines only, use the following instructions. See the 550 controller
operation manual for further information, if necessary.
1. Go to Menu 14 - PROGRAMMING MODE to enable LOCAL programming.
2. Go to Menu 7 - GENERATOR SYSTEM.

1
2
3. Press MENU Down ↓ Key to access ENABLE VSG (variable governor speed) data.
4. Press the YES Key.
5. Press the ENTER ← Key to confirm entry.

3
4
6. Verify ENABLE VSG code YES appears
4 on the display.
7. Go to Menu 14 - PROGRAMMING MODE

7 to change to programming mode OFF.
6
5 TT-919
3.51 mm
1.27 mm
(0.50 in.)
(1.38
in.)
1.03 mm (0.046 in.)
0.48 mm (0.188 in.)
0.40 mm (0.156 in.)
3.35 mm (1.32 in.)

6.67 mm (2.625 in.)
TT-941
202 TP-5700 8/20

14.10 Remote Voltage Adjustment
This kit provides the ability to fine adjust the generator output voltage from a remote location. The maximum recommended wire
length from the potentiometer to the generator set is 15 ft. (4.6 m); 18-gauge twisted pair wire is recommended. See Figure 223
and Figure 224.
3.51 mm (1.38 in.)
1.27 mm (0.50 in.)

Potentiometer
Panel
Ø1.03 mm (0.046 )
Ø0.48 mm (0.188 in.)
Nameplate
Nut
Nut Ø0.40 mm (0.156 in.)
Washer
Screw
3.35 mm (1.32 in.)
Knob
6.67 mm (2.625 in.)
Figure 223 Potentiometer Installation
TP-5700 8/20 203

Figure 224 Disconnection of Controller Voltage Adjusting Potentiometer
204 TP-5700 8/20

14.11 Remote Wiring
Figure 225 is the accessory interconnection diagram showing the remote wiring for the 550 controller.
GM16088A-F
Figure 225 550 Controller Remote Wiring GM16088A-F
14.12 Voltage Regulator DVR 2000 / Remote Voltage Regulator Kit, 350 kW and Above
The DVR® 2000E is used with nonparalleling applications and the DVR ® 2000EC is used when paralleling is required.
If the voltage configuration is changed, make adjustments to the DVR ® 2000 voltage regulator at the voltage regulator. Remove
the junction box cover to adjust the DVR® 2000 voltage regulator. See Figure 226, Figure 227, and TP-5579 Operation Manual,
DVR® 2000 Voltage Regulator for more information.
Use Figure 227 for installation and troubleshooting of the electrical wiring system
BAF
CDE
BAF
CDE
GND
GND
1
DVR
1 2000 voltage regulator
GM16780-A
GM16780-A
Figure 226 DVR® 2000 Voltage Regulator Mounting Location
TP-5700 8/20 205

Junction Box L eg en d
PMG -- Permanent Magnet Generator
STAT -- Stator
TB5 -- Controller AC Fuse Block
QCON(#) -- Quick Connect
Generator
GM20500-
Figure 227 DVR® 2000 Voltage Regulator/Alternator Interconnection Wiring Diagram
206 TP-5700 8/20

Appendix A. Abbreviations
A, amp ampere blk. black (paint color), block (engine) D/A digital to analog
ABDC after bottom dead center blk. htr. block heater DAC digital to analog converter
AC alternating current BMEP brake mean effective pressure dB decibel
A/D analog to digital bps bits per second dB(A) decibel (A weighted)
ADC advanced digital control; br. Brass DC direct current
analog to digital converter
adj. adjust, adjustment BTDC before top dead center DCR direct current resistance
ADV advertising dimensional drawing Btu British thermal unit DEF diesel exhaust fluid
AGM absorbent glass mat Btu/min. British thermal units per minute deg., ° degree
Ah amp-hour C Celsius, centigrade dept. department
AHWT anticipatory high water cal. Calorie dia. Diameter
temperature
AISI American Iron and Steel Institute CAN controller area network DI/EO dual inlet/end outlet
ALOP anticipatory low oil pressure CARB California Air Resources Board DIN Deutsches Institut fur Normung e.
V. (also Deutsche Industrie
Normenausschuss)
alt. alternator CAT5 Category 5 (network cable) DIP dual inline package
Al aluminum CB circuit breaker DPDT double-pole, double-throw
ANSI American National Standards CC crank cycle DPST double-pole, single-throw
Institute (formerly American
Standards Association, ASA)
AO anticipatory only cc cubic centimeter DS disconnect switch
APDC Air Pollution Control District CCA cold cranking amps DVR digital voltage regulator
API American Petroleum Institute ccw. Counterclockwise E2PROM, electrically-erasable
EEPROM programmable read-only memory
approx. approximate, approximately CEC Canadian Electrical Code E, emer. emergency (power source)
APU Auxiliary Power Unit cert. certificate, certification, certified ECM electronic control module, engine
control module
AQMD Air Quality Management District cfh cubic feet per hour EDI electronic data interchange
AR as required, as requested cfm cubic feet per minute EFR emergency frequency relay
AS as supplied, as stated, as CG center of gravity e.g. for example (exempli gratia)
suggested
ASE American Society of Engineers CID cubic inch displacement EG electronic governor
ASME American Society of Mechanical CL centerline EGSA Electrical Generating Systems
Engineers Association
assy. Assembly cm centimeter EIA Electronic Industries Association
ASTM American Society for Testing CMOS complementary metal oxide EI/EO end inlet/end outlet
Materials substrate (semiconductor)
ATDC after top dead center com communications (port) EMI electromagnetic interference
ATS automatic transfer switch coml commercial emiss. Emission
auto. Automatic Coml/Rec Commercial/Recreational eng. Engine
aux. auxiliary conn. Connection EPA Environmental Protection Agency
avg. average cont. continued EPS emergency power system
AVR automatic voltage regulator CPVC chlorinated polyvinyl chloride ER emergency relay
AWG American Wire Gauge crit. Critical ES engineering special, engineered
special
AWM appliance wiring material CSA Canadian Standards Association ESD electrostatic discharge
bat. Battery CT current transformer est. estimated
BBDC before bottom dead center Cu copper E-Stop emergency stop
BC battery charger, battery charging cUL Canadian Underwriter’s etc. et cetera (and so forth)
Laboratories
BCA battery charging alternator cu. in. cubic inch exh. exhaust
BCI Battery Council International cw. Clockwise ext. external
BDC before dead center CWC city water-cooled F Fahrenheit, female
BHP brake horsepower cyl. Cylinder FHM flat head machine (screw)
TP-5700 8/20 207

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

gph gallons per hour KB kilobyte (210 bytes) max. maximum
gpm gallons per minute KBus Kohler communication protocol MB megabyte (220 bytes)
gr. grade, gross kg kilogram MCCB molded-case circuit breaker
2
GRD equipment ground kg/cm kilograms per square MCM one thousand circular mils
centimeter
gr. wt. gross weight kgm kilogram-meter meggar megohmmeter
HxWx height by width by depth kg/m3 kilograms per cubic meter MHz megahertz
D
HC hex cap kHz kilohertz mi. mile
HCHT high cylinder head temperature kJ kilojoule mil one one-thousandth of an inch
HD heavy duty km kilometer min. minimum, minute
HET high exhaust temp., high kOhm, kilo-ohm misc. miscellaneous
engine temp. kΩ
hex hexagon kPa kilopascal MJ megajoule
Hg mercury (element) kph kilometers per hour mJ millijoule
HH hex head kV kilovolt mm millimeter
HHC hex head cap kVA kilovolt ampere mOhm, milliohm
mΩ
HP horsepower kVAR kilovolt ampere reactive MOhm, megohm
MΩ
hr. hour kW kilowatt MOV metal oxide varistor
HS heat shrink kWh kilowatt-hour MPa megapascal
hsg. Housing kWm kilowatt mechanical mpg miles per gallon
HVAC heating, ventilation, and air kWth kilowatt-thermal mph miles per hour
conditioning
HWT high water temperature L liter MS military standard
Hz hertz (cycles per second) LAN local area network ms millisecond
IBC International Building Code LxWx length by width by height m/sec. meters per second
H
IC integrated circuit lb. pound, pounds mtg. mounting
ID inside diameter, identification lbm/ft3 pounds mass per cubic feet MTU Motoren-und Turbinen-Union
IEC International Electrotechnical LCB line circuit breaker MW megawatt
Commission
IEEE Institute of Electrical and LCD liquid crystal display mW milliwatt
Electronics Engineers
IMS improved motor starting LED light emitting diode µF microfarad
208 TP-5700 8/20

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-5700 8/20 209

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
210 TP-5700 8/20

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 228 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 228 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 229.
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 (see2above for exception).
c. Use a washer under a bolt when the female thread is fixed (weld nut).
5. Refer to Figure 229, which depicts the preceding hardware configuration possibilities.
TP-5700 8/20 211

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 229 Acceptable Hardware Combinations
212 TP-5700 8/20

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.)
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.)
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-5700 8/20 213

Appendix D. Fuel Physical Properties
Physical Property @ Manufactured or

15°C (60°F) Butane Propane Natural Gas Sewage Gas Gasoline Diesel Fuel
Normal atmospheric state Gas Gas Gas Gas Liquid Liquid
Boiling point,
Initial, °C (°F) - - - - 36 (97) 177 (350)
End, °C (°F) 0 (32) 42 (-44) -162 (-259) - 216 (420) 357 (675)
Heating value, Btu
/gal. (net, LHV*) 94670 83340 63310 - 116400 130300
/gal. (gross) 102032 91500 - - 124600 139000
/ft3 (gas) 3264 2516 1000 600-700 6390 -
Density,
ft3 of gas/gal. 31.26 36.39 57.75 - 19.5 -
Wt./gal. liquid, lb. 4.81 4.24 2.65 - 6.16 7.08
Octane Number
Research 94 110+ 110+ - 80-100 -
Motor 90 97 - - 75-90 -
* Lower Heating Value
Figure 230 Engine Fuels, Physical Properties
Characteristic, LP Gas* Butane Propane
Formula C4H10 C3H8
Boiling point, °C (°F) 0 (32) -42 (-44)
Specific gravity of gas (air = 1.00) 2.00 1.53
Specific gravity of liquid (water = 1.00) 0.58 0.51
Btu/lb. of gas 21221 21591
Ft3. of vapor at 16°C (60°F)/lb. of liquid at 16°C (60°F) 6.506 8.547
Latent heat of vaporization at boiling point, Btu/gal. 808.0 785.0
Combustion Data: 31.02 23.86
Ft3 air required to burn 1 ft.3 of gas N/A -104 (-156)
Flash point, °C (°F) 482-538 493-549
Ignition temperature in air, °C (°F) (9900-1000) (920-1020)
Max. flame temperature in air, °C (°F) 1991 (3615) 1979 (3595)
Limits of inflammability, percentage of gas in air mixture:
At lower limit, % 1.9 2.4
At upper limit, % 8.6 9.6
Octane Number (ISO-Octane = 100) 92 Over 100
* Commercial quality. Figures shown in this chart represent average values.
Figure 231 Additional LP Gas Characteristics
214 TP-5700 8/20

Appendix E. Gas Fuel Vapor Pressures
Vapor Pressure (Approximate Values)

14.06 kg/cm2 (200 psi)
12.65 kg/cm2 (180 psi)

Propane
11.25 kg/cm2 (160 psi)
9.84 kg/cm2 (140 psi)
8.44 kg/cm2 (120 psi)

Pressure
7.03 kg/cm2 (100 psi)
50-50 Mixture
5.62 kg/cm2 (80 psi)
4.22 kg/cm2 (60 psi)
2.81 kg/cm2 (40 psi) Butane
1.41 kg/cm2 (20 psi)
0 kg/cm2 (0 psi)
-40°C -28°C -18°C -7°C 4°C 15°C 27°C 38°C
(-40°F) (-20°F) (0°F) (20°F) (40°F) (60°F) (80°F) (100°F)
Temperature
Figure 232 Vapor Pressures of LP Gases Graph

Approximate Pressure, kg/m2 (PSIG)
50/50
Temperature, °C (°F) Propane Mixture Butane
-40 (-40) 0.1 (1) -
-36 (-33) 0.4 (5) -
-28 (-20) 0.7 (10) -
-23 (-10) 1.2 (17) 0.2 (3)
-18 (0) 1.7 (24) 0.4 (5)
-12 (10) 2.2 (32) 0.6 (8)
-7 (20) 3.0 (42) 0.9 (13)
-1 (30) 3.7 (52) 1.3 (19)
4 (40) 4.6 (65) 1.8 (26) 0.1 (2)
10 (50) 5.5 (78) 2.4 (34) 0.5 (7)
15 (60) 6.5 (93) 3.0 (42) 0.8 (12)
21 (70) 7.7 (109) 3.5 (50) 1.2 (17)
27 (80) 9.6 (136) 4.2 (60) 1.7 (24)
32 (90) 10.3 (147) 5.1 (72) 2.2 (32)
38 (100) 11.9 (169) 6.0 (85) 2.8 (40)
43 (110) 14.1 (200) 7.0 (100) 3.5 (50)
Figure 233 Vapor Pressures of LP Gases Table
TP-5700 8/20 215

Appendix F. Gas Fuel System Installation Planning
Determining Propane Cylinder Quantity
Guide for Installing 100 lb. Cylinders
For continuous draws where temperatures may reach –18°C (0°F). Assume the vaporization rate of 100 lb. cylinder as
approximately 50000 Btu/hr.
Number of cylinders/side = Total load in Btu

50000
Example:
Assume total load = 20000 Btu/hour.
Cylinders/side = 20000 = 4 cylinders/side

50000
The chart in Figure 234 shows the vaporization rate of containers in terms of the temperature of the liquid and the wet surface
area of the container. When the temperature is lower or if the container contains less liquid, the vaporization rate of the container
is a lower value.
Lb. of Propane in Maximum Continuous Draw In Btu/Hour At Various Temperatures in °C (°F)

Cyl. -18°C (0°F) -7°C (20°F) 4°C (40°F) 16°C (60°F) 21°C (70°F)
100 113000 167000 214000 277000 300000
90 104000 152000 200000 247000 277000
80 94000 137000 180000 214000 236000
70 83000 122000 160000 199000 214000
60 75000 109000 140000 176000 192000
50 64000 94000 125000 154000 167000
40 55000 79000 105000 131000 141000
30 45000 66000 85000 107000 118000
20 36000 51000 68000 83000 92000
10 28000 38000 49000 60000 66000
Figure 234 Vaporization Rate, 100 lb. Propane Cylinders, Approximate
Determining Propane Vaporization Capacity
Guide for ASME LP Gas Storage Containers
Propane* Vaporization
% of Container Capacity at -18°C (0°F) in
Filled K Equals Btu/Hr.**
60 100 D x L x 100
50 90 D x L x 90
40 80 D x L x 80
30 70 D x L x 70
20 60 D x L x 60
10 45 D x L x 45
* These formulae allow for the temperature of the liquid to refrigerate to -
29°C (-20°F), producing a temperature differential of -7°C (20°F) for the
transfer of heat from the air to the container’s wetted surface and then into
the liquid. The vapor space area of the vessel is not considered since its
effect is negligible.
** D=Outside diameter in inches
L=Overall length in inches
K=Constant for percent volume of liquid in container.
Figure 235 Propane Vaporization Capacity
216 TP-5700 8/20

Vaporizing Capacities for Other Air Temperatures
Multiply the results obtained with the formulae in Figure 235 by one of the factors in the following table for the prevailing air
temperature.
Prevailing Air Temperature Multiplier

-26°C (-15°F) 0.25
-23°C (-10°F) 0.50
-21°C (-5°F) 0.75
-18°C (0°F) 1.00
-15°C (5°F) 1.25
-12°C (10°F) 1.50
-26°C (15°F) 1.75
-7°C (20°F) 2.00
Figure 236 Propane Vaporization Capacity
TP-5700 8/20 217

218 TP-5700 8/20
TP-5700 8/20aa 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
© 1993 Kohler Co. All rights reserved. KOHLERPower.com

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Installation

Industrial Generator Sets

Product Identification Information

Generator Set Identification Numbers

Record the product identification numbers from the engine nameplate(s).

Model Designation _________________________________________________________

Specification Number _______________________________________________________

Serial Number: ____________________________________________________________

Record the product identification information from the engine nameplate.

Accessory Number Accessory Description Accessory Number Accessory Description

Safety Precautions and Instructions ........................................................................................................................................ 7

WARNING Accidental starting.

(Decision-Maker® 3+ and 550 Controllers)

(APM402, APM603 and Decision-Maker® 3000, 3500, and 6000 Controllers)

(Decision-Maker® 8000 Controller)

WARNING Sulfuric acid in batteries.

WARNING Risk of fire.

WARNING Carbon monoxide.

WARNING Explosive fuel vapors.

WARNING Avoid high pressure fluids.

Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.

CAUTION Hazardous noise.

Hazardous Voltage/Moving Parts

DANGER Hazardous voltage.

DANGER Hazardous voltage. Moving parts.

WARNING Hazardous voltage. Backfeed to the utility system.

WARNING Unbalanced weight.

WARNING Unbalanced and elevated weight.

WARNING Hot coolant and steam.

WARNING Hot engine and exhaust system.

For professional advice and conscientious service, please China

Fresh air intake Flexible sections

Figure 2 Typical Stationary-Duty Generator Set Installation

 NFPA 54 National Fuel Gas Code

 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 2200 Stationary Engine Generator Assemblies

 Exhaust outlet size and maximum allowable backpressure

 Battery CCA rating and quantity

WARNING Unbalanced and elevated weight.

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

Figure 3 Improper Lifting Hook Placement (above 1000 kW)

o Weight and center of gravity of the equipment being lifted

o Weight and center of gravity of the lifting device

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.

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

 Subbase fuel tank (lift only empty fuel tanks)

2.1.2 Lifting the Generator Set

 See Figure 4 for the spreader bar and hook methods.

Figure 4 Single and Double Spreader Bar and Hook Method

Spreader bar Spreader bar

20° 20° max.

Lifting bar Lifting bar

 Attach one or two spreader bars as shown.