Industrial Diesel Generator Set - KD3500

Tier 2 EPA-Certified for Stationary Emergency Applications

KDxxxx designates a generator set with a Tier 2 EPA-Certified engine.

KDxxxx-F designates a 60 Hz generator set with a fuel optimized engine.

Ratings Range
60 Hz
Standby: kW 3500
kVA 4375
Prime: kW 3180
kVA 3975

Standard Features General Specifications

D Kohler Co. provides one-source responsibility for the Orderable Generator Model Number GMKD3500
generating system and accessories.
Manufacturer Kohler
D The generator set and its components are prototype-tested,
Engine: model KD103V20
factory-built, and production-tested.
Alternator Choices KH07632TO4D
D The 60 Hz generator set offers a UL 2200 listing. KH09370TO4D
D The generator set accepts rated load in one step. KH10171TO4D
D The 60 Hz generator set meets NFPA 110, Level 1, when Performance Class Per ISO 8528-5
equipped with the necessary accessories and installed per One Step Load Acceptance 100%
NFPA standards. Voltage 4160V, 6600V, 12470V,
13200V, 13800V
D A standard three-year or 1000-hour limited warranty for
Controller APM603, APM802
standby applications. Five-year basic, five-year
comprehensive, and ten-year extended limited warranties Fuel Consumption, L/hr (gal./hr)
100% at Standby 915 (241.8)
are also available.
Fuel Consumption, L/hr (gal./hr)
D A standard two-year or 8700-hour limited warranty for prime 100% at Prime Power 832 (219.8)
power applications. Emission Level Compliance (KDxxxx) Tier 2
D Other features: Open Unit Noise Level @ 7 m dB(A) at
d Kohler designed controllers for one-source system Rated Load 99
integration and remote communication. See Controllers Data Center Continuous (DCC) Rating Same as the Standby
(Refer to TIB-101 for definitions) Rating below
on page 4.
d The low coolant level shutdown prevents overheating
(standard on radiator models only).

Generator Set Ratings

130_C Rise 105_C Rise
Standby Rating Prime Rating
Alternator Voltage Ph Hz kW/kVA Amps kW/kVA Amps
2400/4160 3 60 3500/4375 607 3180/3975 552
3810/6600 3 60 3500/4375 383 3180/3975 348
KH07632TO4D 7200/12470 3 60 3500/4375 203 3180/3975 184
7620/13200 3 60 3500/4375 191 3180/3975 174
7970/13800 3 60 3500/4375 183 3180/3975 166
2400/4160 3 60 3500/4375 607 3180/3975 552
3810/6600 3 60 3500/4375 383 3180/3975 348
KH09370TO4D 7200/12470 3 60 3500/4375 203 3180/3975 184
7620/13200 3 60 3500/4375 191 3180/3975 174
7970/13800 3 60 3500/4375 183 3180/3975 166
2400/4160 3 60 3500/4375 607 3180/3975 552
3810/6600 3 60 3500/4375 383 3180/3975 348
KH10171TO4D 7200/12470 3 60 3500/4375 203 3180/3975 184
7620/13200 3 60 3500/4375 191 3180/3975 174
7970/13800 3 60 3500/4375 183 3180/3975 166

RATINGS: All three-phase units are rated at 0.8 power factor. Standby Ratings: The standby rating is applicable to varying loads for the duration of a power outage. There is no overload capability for
this rating. Prime Power Ratings: At varying load, the number of generator set operating hours is unlimited. A 10% overload capacity is available for one hour in twelve. Ratings are in accordance with
ISO-8528-1 and ISO-3046-1. For limited running time and continuous ratings, consult the factory. Obtain technical information bulletin (TIB-101) for ratings guidelines, complete ratings definitions, and
site condition derates. The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever.
G5-591 (KD3500) 9/20a Page 1
523 (29742)651 (37021)
Industrial Diesel Generator Set - KD3500
Tier 2 EPA-Certified for Stationary Emergency Applications

Engine Specifications 60 Hz Fuel Consumption 60 Hz

Manufacturer Kohler Diesel, Lph (gph) at % load Standby Rating
Engine: model KD103V20 100% 915 (241.8)
Engine: type 4-Cycle, Turbocharged, 75% 753 (198.8)
Intercooled
50% 519 (137.2)
Cylinder arrangement 20-V
25% 295 (78.0)
Displacement, L (cu. in.) 103 (6304)
Diesel, Lph (gph) at % load Prime Rating
Bore and stroke, mm (in.) 175 x 215 (6.89 x 8.46)
100% 832 (219.8)
Compression ratio 16.0:1
75% 675 (178.4)
Piston speed, m/min. (ft./min.) 774 (2539)
50% 476 (125.8)
Main bearings: quantity, type 9, Precision Half Shells
Rated rpm 1800 25% 274 (72.5)
Max. power at rated rpm, kWm (BHP) 3758 (5040) 60 Hz
Cylinder head material Cast Iron Radiator System Low NOx EPA Tier 2
Crankshaft material Steel Ambient temperature, _C (_F) 50 (122)
Valve (exhaust) material Steel Engine jacket water capacity, L (gal.) 400 (106)
Governor: type, make/model KODEC Electronic Control Radiator system capacity, including
engine, L (gal.) 1217 (321)
Frequency regulation, no-load to-full load Isochronous
Engine jacket water flow, Lpm (gpm) 2420 (640)
Frequency regulation, steady state 0.25% Heat rejected to cooling water at rated
Frequency Fixed kW, dry exhaust, kW (Btu/min.) 1280 (72794)
Air cleaner type, all models Dry Charge cooler water flow, Lpm (gpm) 830 (220)
Heat rejected to charge cooling water at
Lubricating System 60 Hz rated kW, dry exhaust, kW (Btu/min.) 1120 (63894)
Type Full Pressure Water pump type Centrifugal
Oil pan capacity with filter (initial fill), Fan diameter, including blades, mm (in.) 2438 (96)
L (qt.) w 700 (740) Fan, kWm (HP) 120 (160.9)
Oil filter: quantity, type w 10, Spin- On Max. restriction of cooling air, intake and
discharge side of radiator, kPa (in. H2O) 0.125 (0.5)
Oil cooler Plate Exchanger
w Kohler recommends the use of Kohler Genuine oil and filters.
Remote Radiator System[ 60 Hz
Fuel System 60 Hz Exhaust manifold type Dry
Fuel supply line, min. ID, mm (in.) 25 (1.0) Connection sizes: Class 150 ANSI Flange
Water inlet/outlet, mm (in.) 216 (8.5) Bolt Circle
Fuel return line, min. ID, mm (in.) 19 (0.75)
Intercooler inlet/outlet, mm (in.) 178 (7.0) Bolt Circle
Max. fuel flow , Lph (gph) 1200 (317)
Static head allowable
Min./max. fuel pressure at engine supply above engine, kPa (ft. H2O) 250 (83.6)
connection, kPa (in. Hg) - 30/30 (- 8.8/8.8)
[ Contact your local distributor for cooling system options and
Maximum diesel fuel lift, m (ft.) 3.7 (12) specifications based on your specific requirements.
Max. return line restriction, kPa (in. Hg) 30 (8.9)
Fuel filter: quantity, type 3, Primary Engine Filter
2, Fuel/Water Separator
Recommended fuel #2 Diesel ULSD

G5-591 (KD3500) 9/20a Page 2

 Industrial Diesel Generator Set - KD3500
Tier 2 EPA-Certified for Stationary Emergency Applications

Exhaust System 60 Hz Alternator Specifications 60 Hz

Exhaust flow at rated kW, m3/min. (cfm) 812 (28664) Type 4-Pole, Rotating-Field
Exhaust temperature at rated kW at Exciter type Brushless, Permanent-
25_C (77_F) ambient, dry exhaust, Magnet Pilot Exciter
_C (_F) 460 (860) Voltage regulator Solid-State, Volts/Hz
Maximum allowable back pressure, Insulation: NEMA MG1, UL 1446,
kPa (in. Hg) 8.5 (2.5) Vacuum Pressure
Exh. outlet size at eng. hookup, mm Impregnated (VPI)
(in.) See ADV drawing Material Class H, Synthetic,
Nonhygroscopic
Electrical System 60 Hz Temperature rise 130_C, 150_C Standby
Battery charging alternator: Bearing: quantity, type 2, Sealed
Ground (negative/positive) Negative Coupling type Coupling
Volts (DC) 24 Amortisseur windings Full
Ampere rating 140 Alternator winding type Form Wound
Starter motor qty. at starter motor Standard: 2 @ 9 kW, 24; Rotor balancing 125%
power rating, rated voltage (DC) Redundant (optional);
2 @ 15 kW, 24 Voltage regulation, no-load to full-load 0.25%
Battery, recommended cold cranking Unbalanced load capability 100% of Rated
amps (CCA): Standby Current
Quantity, CCA rating each, type Peak motor starting kVA: (35% dip for
(with standard starters) 4, 1110, AGM voltages below)
Quantity, CCA rating each, type 13800 V KH09370TO4D 11673
(with redundant starters) 8, 1110, AGM 12470 V KH10171TO4D 12179
Battery voltage (DC) 12

Air Requirements 60 Hz
Alternator Standard Features
Radiator-cooled cooling air, D The pilot-excited, permanent magnet (PM) alternator
m3/min. (scfm)] 4106 (145000) provides superior short-circuit capability.
Cooling air required for generator set
when equipped with city water cooling
D All models are brushless, rotating-field alternators.
or remote radiator, based on 14_C D NEMA MG1, IEEE, and ANSI standards compliance for
(25_F) rise, m3/min. (scfm)] 1362 (48103)
temperature rise and motor starting.
Combustion air, m3/min. (cfm) 315 (11135)
Heat rejected to ambient air: D Sustained short-circuit current of up to 300% of the rated
Engine, kW (Btu/min.) 190 (10805) current for up to 10 seconds.
Alternator, kW (Btu/min.) 193.3 (11000) D Sustained short-circuit current enabling downstream circuit
] Air density = 1.20 kg/m3 (0.075 lbm/ft3) breakers to trip without collapsing the alternator field.
D Self-ventilated and dripproof construction.
D Superior voltage waveform from two-thirds pitch windings
and skewed stator.
D Brushless alternator with brushless pilot exciter for excellent
load response.
NOTE: See TIB- 102 Alternator Data Sheets for alternator
application data and ratings, efficiency curves, voltage dip with
motor starting curves, and short circuit decrement curves.

G5-591 (KD3500) 9/20a Page 3

 Industrial Diesel Generator Set - KD3500
Tier 2 EPA-Certified for Stationary Emergency Applications

Controllers Codes and Standards

D Engine- generator set is designed and manufactured in
facilities certified to ISO 9001.
D Generator set meets NEMA MG1, BS5000, ISO, DIN EN,
and IEC standards, NFPA 110.
D Engine generator set is tested to ISO 8528-5 for transient
response.
D The generator set and its components are prototype-tested,
factory-built, and production-tested.
APM802 Controller
Provides advanced control, system monitoring, and system diagnostics Third-Party Compliance
for optimum performance and compatibility.
D 12-inch graphic display with touch screen and menu control provide D Tier 2 EPA-Certified for Stationary Emergency Applications
easy local data access
D Measurements are selectable in metric or English units Available Approvals and Listings
D User language is selectable - CSA Certified
D Two USB ports allow connection of a flash drive, mouse, or keypad
- IBC Seismic Certification
D Electrical data, mechanical data, and system settings can be saved to
a flash drive - UL 2200 Listing
D Ethernet port allows connection to a PC type computer or - cULus Listing (fuel tanks only)
Ethernet switch
D The controller supports Modbusr RTU and TCP protocols
D NFPA 110 Level 1 capability Warranty Information
Refer to G6-152 for additional controller features and accessories.
Modbusr is a registered trademark of Schneider Electric.
D A standard three-year or 1000-hour limited warranty for
standby applications. Five-year basic, five-year
comprehensive, and ten-year extended limited warranties are
also available.
D A standard two-year or 8700-hour limited warranty for prime
power applications.
Available Warranties for Standby Applications
- 5-Year Basic Limited Warranty
- 5-Year Comprehensive Limited Warranty
- 10-Year Major Components Limited Warranty
APM603 Controller
Provides advanced control, system monitoring, and system diagnostics Standard Features
for optimum performance and compatibility. D Closed Crankcase Ventilation (CCV) Filters
D 7-inch graphic display with touch screen and menu control provides
easy local data access D Customer Connection
D Measurements are selectable in metric or English units D Local Emergency Stop Switch
D Paralleling capability to control up to 8 generators on an isolated bus D Oil Drain and Coolant Drain Extension
with first-on logic, synchronizer, kW and kVAR load sharing, and D Operation and Installation Literature
protective relays D Fan Bearing Grease Extension
Note: Parallel with other APM603 controllers only
D Fuel/Water Separator
D Generator management to turn paralleled generators off and on
as required by load demand D Generator Heater
D Load management to connect and disconnect loads as required D Spring Isolation Under the Skid
D Controller supports Modbusr RTU, Modbusr TCP, SNMP
and BACnetr
D Integrated voltage regulator with 0.25% regulation
D Built-in alternator thermal overload protection
D UL-listed overcurrent protective device
D NFPA 110 Level 1 capability
Refer to G6-162 for additional controller features and accessories.
BACNetr is a registered trademark of ASHRAE.

G5-591 (KD3500) 9/20a Page 4

 Industrial Diesel Generator Set - KD3500
Tier 2 EPA-Certified for Stationary Emergency Applications

Available Options
Engine Type Electrical System
- KDxxxx-F Fuel Optimized Engine - Battery, AGM (kit with qty. 4, loose)
- KDxxxx Tier 2 NOx Optimized EPA-Certified Engine - Battery Charger (loose)
- Battery Racks (loose)
Approvals and Listings
- Battery Cables
- CSA Certified
- Redundant Starters
- IBC Seismic Certification
- UL 2200 Listing Fuel System
- cULus Listing (fuel tanks only) - Flexible Fuel Lines
- Restriction Gauge (for fuel/water separator)
Open Unit
- Exhaust Silencer, Hospital (kit: PA-361626) Literature
- Exhaust Silencer, Critical (kits: PA-361625 qty. 2) - General Maintenance
- Flexible Exhaust Connector, Stainless Steel - NFPA 110
- Overhaul
Controller
- Production
- Input/Output, Digital
- Load Shed (APM802 only) Miscellaneous
- Manual Key Switch - Air Cleaner, Heavy Duty (loose)
- Remote Emergency Stop Switch - Air Cleaner Restriction Indicator
- Lockable Emergency Stop Switch - Automatic Oil Replenishment System
- Remote Serial Annunciator Panel - Rated Power Factor Testing
Cooling System Warranty (Standby Applications only)
- Block Heater; 10500 W, 208 V, (Select 1 Ph or 3 Ph) * - 5-Year Basic Limited Warranty
- Block Heater; 12000 W, 240 V, (Select 1 Ph or 3 Ph) * - 5-Year Comprehensive Limited Warranty
* Required for Ambient Temperatures Below 5_C (41_F). - 10-Year Major Components Limited Warranty
Other
-
-

Dimensions and Weights

Overall Size, max., L x W x H, mm (in.): 8168 x 3172 x 3451
(321.6 x 124.9 x 135.9)
Weight, radiator model, max. wet, kg (lb.): 35199 (77631)

W L
NOTE: This drawing is provided for reference only and should not be used for planning
installation. Contact your local distributor for more detailed information.
G5-591 (KD3500) 9/20a Page 5
 Industrial Diesel Generator Set - KD3500
Tier 2 EPA-Certified for Stationary Emergency Applications
KOHLER CO., Kohler, Wisconsin 53044 USA
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales and service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com

DISTRIBUTED BY:

 2020 Kohler Co. All rights reserved.

G5-591 (KD3500) 9/20a Page 6