Kohler RZ Series

Table of Contents
SUBJECT PAGE SUBJECT PAGE
Safety Precautions and Instructions I. . . . . . .
Introduction i. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Assistance ii. . . . . . . . . . . . . . . . . . . . . . .
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. . . .