Kohler 6.5RMY Operation Manual Download Page 3

Page: 3 / 59

Table of Contents

SUBJECT

PAGE

SUBJECT

PAGE

Safety Precautions and Instructions

. . . . . . .

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance

. . . . . . . . . . . . . . . . . . . . . . .

Section 1. Specifications

1-1

. . . . . . . . . . . . . . . . .

Introduction

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator

1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller

1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Features

1-2

. . . . . . . . . . . . . . . . . . . . . . . .

Relay Controller

1-2

. . . . . . . . . . . . . . . . . . . . . . . .

5-Light Controller

1-2

. . . . . . . . . . . . . . . . . . . . . . .

Accessories

1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overvoltage Kit

(microprocessor controller)

1-3

. . . . . . . . . . . . . . . .

Run Relay Kit

1-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Annunciator Kit

(microprocessor controller)

1-4

. . . . . . . . . . . . . . . .

Audio-Visual (A/V) Alarm

(microprocessor controller)

1-5

. . . . . . . . . . . . . . . .

Line Circuit Breaker

1-5

. . . . . . . . . . . . . . . . . . . . . . .

Remote Emergency Stop Kit

(microprocessor controller)

1-6

. . . . . . . . . . . . . . . .

Single-Relay Dry Contact Kit

(microprocessor controller)

1-6

. . . . . . . . . . . . . . . .

Ten-Relay Dry Contact Kit

(microprocessor controller)

1-7

. . . . . . . . . . . . . . . .

Accessory Connection

(microprocessor controller)

1-7

. . . . . . . . . . . . . . . .

Section 2. Operation

2-1

. . . . . . . . . . . . . . . . . . . . .

Prestart Checklist

2-1

. . . . . . . . . . . . . . . . . . . . . . . . .

Exercising the Generator

2-1

. . . . . . . . . . . . . . . . . . .

Microprocessor Controller Operation

2-2

. . . . . . . . .

5-Light Microprocessor Controller

2-2

. . . . . . . . . . .

Microprocessor Controller Features

2-3

. . . . . . .

Start/Stop Procedure

2-6

. . . . . . . . . . . . . . . . . . . .

Stopping

2-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Circuit Protection

(microprocessor controller)

2-7

. . . . . . . . . . . . .

Fault Shutdowns

2-8

. . . . . . . . . . . . . . . . . . . . . . .

Controller Resetting Procedure

(Following Fault Shutdown)

2-9

. . . . . . . . . . . .

Resetting Emergency Stop Switches

2-9

. . . . . .

Relay Controller Operation

2-10

. . . . . . . . . . . . . . . . . .

Starting/Stopping Procedure

(relay controller)

2-11

. . . . . . . . . . . . . . . . . . . . . . . . .

Starting

2-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping

2-11

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Shutdowns (relay controller)

2-11

. . . . . . . . . . .

Circuit Protection (relay controller)

2-12

. . . . . . . . . . .

Voltage Regulator Fuse

2-12

. . . . . . . . . . . . . . . . .

Controller Resetting Procedure

(following fault shutdown)

2-13

. . . . . . . . . . . . . . . . .

Section 3. Scheduled Maintenance

3-1

. . . . . . . .

Fuel Regulators

3-2

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Carburetor Adjustments (LP/Natural Gas)

3-2

. . . .

LP Liquid Withdrawal Fuel System

3-2

. . . . . . . . . . .

Electronic Governor

3-3

. . . . . . . . . . . . . . . . . . . . . . .

Battery

3-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charging Systems

3-3

. . . . . . . . . . . . . . . . .

6.5 kW

3-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-18 kW

3-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning

3-4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Electrolyte Level

3-4

. . . . . . . . . . . . . . . . .

Checking Specific Gravity

3-5

. . . . . . . . . . . . . . . . . .

Generator Service

3-6

. . . . . . . . . . . . . . . . . . . . . . . . .

Storage Procedure

3-6

. . . . . . . . . . . . . . . . . . . . . . . .

Engine oil

3-6

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel (gasoline-fueled engines)

3-6

. . . . . . . . . . . .

Fuel (gaseous-fueled engines)

3-6

. . . . . . . . . . .

Coolant (liquid-cooled models only)

3-6

. . . . . . .

Lubricate Cylinders

3-6

. . . . . . . . . . . . . . . . . . . . .

Exterior Preparation

3-6

. . . . . . . . . . . . . . . . . . . .

Section 4. Troubleshooting

4-1

. . . . . . . . . . . . . . .

General Troubleshooting Chart

(Sheet 1 of 2)

4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . .

General Troubleshooting Chart

(Sheet 2 of 2)

4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5. Generator Reconnection

5-1

. . . . . . .

Voltage Reconnection Procedure

5-1

. . . . . . . . . . . .

Four-Lead (Single-Phase) Generator Sets

5-2

. . . .

100-120 Volt Configurations

5-2

. . . . . . . . . . . . . .

100-120/200-240 Volt

5-3

. . . . . . . . . . . . . . . . . . .

200-240 Volt

5-3

. . . . . . . . . . . . . . . . . . . . . . . . . . .

12-Lead (Three-Phase) Generator Sets

5-4

. . . . . .

Reconnection Procedure

(Microprocessor Controller only)

5-5

. . . . . . . .

Section 6. Installation

6-1

. . . . . . . . . . . . . . . . . . . .

General

6-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Requirements

6-1

. . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Requirements

6-2

. . . . . . . . . . . . . . . . . . . . .

Fuel System

6-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections

6-3

. . . . . . . . . . . . . . . . . . . . .

Battery

6-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Electrical Connections

6-3

. . . . . . . . . . .

AC Load Lead Connections

6-4

. . . . . . . . . . . . . . . .

Appendix A. Glossary of Abbreviations

A-1

. . . .

Summary of Contents for 6.5RMY

Page 1: ...Operation Manual Industrial Generator Sets Models 6 5RMY 10 18RY RZ TP 5631 7 96 Controllers Decision Makert 3 5 Light Relay...

Page 2: ...Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING California Proposition 65...

Page 3: ...r 2 11 Starting 2 11 Stopping 2 11 Fault Shutdowns relay controller 2 11 Circuit Protection relay controller 2 12 Voltage Regulator Fuse 2 12 Controller Resetting Procedure following fault shutdown 2...

Page 4: ...ANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage WARNING Warning indicates the presence of a hazard that can cause severe per...

Page 5: ...abling generator set Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative...

Page 6: ...e 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 gases Explosion can cause severe injury or dea...

Page 7: ...ng fuel system A flash fire can cause severe injury or death Do not smoke or permit flame or spark to occur near carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuel o...

Page 8: ...that it can cause death if inhaled for even a short time Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas which is present in exha...

Page 9: ...han air install propane gas detectors low in room Inspect detectors often Natural Gas Adequate ventilation is mandatory Natural gas rises install natural gas detectors high in room Inspect detectors o...

Page 10: ...TP 5631 7 96 Safety Precautions and Instructions VII Hazardous Noise Hazardous noise Can cause loss of hearing Never operate generator set without a muffler or with a faulty exhaust system CAUTION...

Page 11: ...ve install an equipment grounding conductor with circuit conductors and connect to equipment grounding terminal or lead on battery charger Perform battery charger installation as prescribed in equipme...

Page 12: ...and Instructions IX Heavy Equipment WARNING Unbalanced weight Improper lift can cause severe injury or death and or equipment damage Do not use lifting eyes Lift generator set using lifting bars inse...

Page 13: ...eld and exciter armature when shorted become hot enough to cause severe burns Checking coolant level Hot coolant can cause severe injury or death Allow engine to cool Release pressure from cooling sys...

Page 14: ...d rotor hardware after servicing Do not loosencrankshaft hardware or rotor thrubolt when making adjustments or servicing generator set Rotate crankshaft manually in a clockwise direction only Turning...

Page 15: ...e both American Standard and metric hardware Use the correct size tools to prevent rounding of bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws...

Page 16: ...eration therefore inspect parts often and perform required service at the prescribed intervals An authorized service distributor dealer should perform required service to keep equipment in top conditi...

Page 17: ...address or number KOHLER CO Kohler Wisconsin 53044 U S A Phone 414 565 3381 Fax 414 459 1646 U S A Sales 414 459 1614 International To ensure supply of correct parts or information make note of the fo...

Page 18: ...ual installation manual engine operation manual and engine service manual for additional specifications Generator The generator is equipped with Kohler s PowerBoostt voltage regulation system which pr...

Page 19: ...engine water liquid cooled models only d Voltmeter DC only D Analog meters 3 5 in 89 mm d AC ammeter 2 full scale accuracy d AC voltmeter 2 full scale accuracy d Frequency meter 0 5 full scale accurac...

Page 20: ...roprocessor controller The overvoltage circuit immediately shuts down the engine when triggered by a DC signal from an overvoltage shutdown option The generator set automatically shuts down if output...

Page 21: ...ten relay dry contact kit is included with this kit See Figure 1 3 The remote annunciator includes alarm horn alarm silence switch lamp test and the same lamp indicators as the 5 light microprocessor...

Page 22: ...common fault lamp See Figure 1 4 NOTE Connect a maximum of three remote annunciators and or A V alarms in any combination to the generator set controller A 292887 Figure 1 4 Audio Visual Alarm Line C...

Page 23: ...6 Emergency Stop Kit Single Relay Dry Contact Kit microprocessor controller The single relay dry contact kit uses one set of relay contacts to trigger customer provided warning devices if a fault con...

Page 24: ...ontroller circuit board is equipped with a terminal strip TB1 for easy connection of generator set accessories Do not direct connect accessories to the controller terminal strip Connect all accessorie...

Page 25: ...Start Switch to TB1 3 and TB1 4 4 Remote Start Connect Remote Start Switch to TB1 3 and TB1 4 26 Auxiliary Indicator Aux 12 Overcrank Indicator OC 39 Overspeed Indicator OS 38 Low Oil Pressure Indicat...

Page 26: ...on manual for engine coolant specifications Do not add coolant to a hot engine Wait until engine has cooled Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Do not...

Page 27: ...liary light 7 Alarm horn 8 DC voltmeter 9 Voltage adjustment potentiometer 10 Oil pressure gauge 11 Engine water temperature gauge not used on 6 5 kW 12 Hourmeter 13 15 amp engine and accessories fuse...

Page 28: ...lts occur if so equipped These conditions are inhibited during first 30 seconds after crank disconnect D The auxiliary lamp lights and engine shuts down immediately if an overvoltage condition occurs...

Page 29: ...itched to a position with three circuit lead labels amperage is measured on the upper lead and voltage is measured between the lower two leads AC ammeter and voltmeter do no register with switch in th...

Page 30: ...art Switch to TB1 3 and TB1 4 4 Remote Start Connect Remote Start Switch to TB1 3 and TB1 4 26 Auxiliary Indicator Aux 12 Overcrank Indicator OC 39 Overspeed Indicator OS 38 Low Oil Pressure Indicator...

Page 31: ...s cranking or 75 seconds of cyclic cranking crank 15 seconds rest 15 seconds crank 15 seconds etc before overcrank shutdown Make the cranking mode cyclic or continuous selection on the controller circ...

Page 32: ...ories will not work and the battery connections appear okay one of these fuses may be blown Fuses V7 V8 and V9 on the AC terminal block TB2 protect the controller meters and lights If the controller l...

Page 33: ...fter 45 seconds of continuous cranking Shutdown occurs after 75 seconds of cyclic cranking crank 15 seconds reset 15 seconds crank 15 seconds etc for a total of 75 seconds Shutdown occurs after 15 sec...

Page 34: ...5 Verify that cause of shutdown has been corrected by test operating generator set 6 Reconnect generator set to load via line circuit breaker or automatic transfer switch 7 Place generator set master...

Page 35: ...lit after generator set shuts down Fault lamp lights as fault occurs Hourmeter Hourmeter records generator set operating hours for reference in maintenance scheduling Generator Master Switch Run Off...

Page 36: ...adequate cooling of the set 2 Place controller or remote start stop switch in the OFF RESET position The generator set shuts down Fault Shutdowns relay controller The generator set shuts down automati...

Page 37: ...heck the controller fuse if the generator set will not crank and the battery and or connections appear correct Replace fuse If fuse blows again see Section 4 Troubleshooting for possible causes Voltag...

Page 38: ...rator set master switch in the OFF RESET position until the fault lamp goes out See Safety Precautions before proceeding 2 Disconnect generator set from load with line circuit breaker or automatic tra...

Page 39: ...t last WARNING Disabling generator set Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cabl...

Page 40: ...djust the carburetor run the generator set at approximately half load Rotate engine fuel mixture screw clockwise or counterclockwise until the engine runs smoothly See Figure 3 2 Applyvarying loadsand...

Page 41: ...tly connected and terminals are tight Battery Charging Systems 6 5 kW The battery charging circuit incorporates a winding in the generator set alternator and a rectifying module protected by a self re...

Page 42: ...d reconnect it last Sulfuric acid in batteries can cause severe injury or death Sulfuric acid in batteries can cause permanent damage to eyes burn skin and eat holes in clothing Always wear splash pro...

Page 43: ...tween specific gravities of each cell should not exceed 0 01 The battery should be charged if the specific gravity is below 1 215 at an electrolyte temperature of 80 F 26 7 C 10 20 30 40 50 60 70 80 9...

Page 44: ...oil having a viscosity appropriate for the particular climate 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the generator set Fuel gasoline fueled engines 1 To remove f...

Page 45: ...uel filter gasoline models only Replace fuel filter lacks power or operates erratically Air cleaner lever in the wrong temperature position 6 5 kW models only Place air cleaner lever in correct positi...

Page 46: ...r connections Check connections High output voltage or high frequency Governor misadjusted high frequency Check governor Faulty voltage regulator Check voltage regulator adjustment and or test voltage...

Page 47: ...NG Disabling generator set Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove ne...

Page 48: ...e circuit breaker are not to be connected together when a factory two pole circuit breaker is used see Figure 5 2 If the installation requires a 100 120 volt 2 wire system use a single pole circuit br...

Page 49: ...L0 L1 L0 L2 L1 L2 60 Hz 100 120 volt 100 120 volt 200 240 volt 50 Hz 100 120 volt 100 120 volt 200 240 volt 4 3 2 1 Stator Leads LO GRD L2 L1 LO Neutral Line Side Factory Two Pole Circuit Breaker Grou...

Page 50: ...ltage CT1 L1 7 10 12 9 11 8 CT2 L2 5 2 3 6 L0 1 4 60 HZ 120 240V 1PH 3 WIRE 50 HZ 110 220V 1 PH 3 WIRE USED ON GENERATORS 20 100 KW ONLY L3 CT3 3 6 L0 10 7 L1 CT3 NOT USED TB2 METER SCALE LAMP JUMPER...

Page 51: ...ler cover and reposition meter scale lamp jumper if necessary to match meter scale lamps with desired voltage See Figure 5 8 5 The jumper J1 must be in place on the overvoltage circuit board if the ge...

Page 52: ...ator Reconnection TP 5631 7 96 N VO C3 C2 C1 CO UPV7F LOW 1 TP 5631 5 1 Lamp jumper Figure 5 8 Meter Scale Lamp Jumper TP 5631 5 PH PH 1 1 Voltage adjustment potentiometer Figure 5 9 Voltage Adjustmen...

Page 53: ...r Requirements The generator set requires correct air flow for cooling and combustion The louvers on the upper portion of the weather housing and the cutouts in the skid provide the cooling and combus...

Page 54: ...engine Emission certified engines may be fitted with carburetors that have no possible adjustments The generator set can be fueled by gasoline LP gas or natural gas Gasoline requires a different fuel...

Page 55: ...Section 1 Accessories and an authorized service distributor dealer for a list of available accessories Most of the accessories operate on 12 volts DC and some may require AC line voltage Do not direc...

Page 56: ...l Code NEC and is done by a licensed electrician All applicable local and state codes must be followed See Wiring Diagram manual for more information regarding generator set electrical connections 1 C...

Page 57: ...before top dead center Btu British thermal unit _ C Celsius degree cc cubic centimeter CCA cold cranking amps CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CID cubic...

Page 58: ...l Electrical Manufacturers Association NFPA National Fire Protection Association Nm Newton meter s N O normally open no nos number numbers NPT National Standard taper pipe thread per general use N R n...

Page 59: ...hler Wisconsin 53044 Phone 414 565 3381 Fax 414 459 1646 U S A Sales Fax 414 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 PRINTED IN U S A T...

Search results

Summary of Contents for 6.5RMY

Reviews:

Related manuals for 6.5RMY

Brands by name

Popular brands

Kohler 6.5RMY, Operation Manual

Search results

Summary of Contents for 6.5RMY

Reviews:

Related manuals for 6.5RMY

Brands by name

Popular brands