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10EORDB/EORZDB 15EORDB/EORZDB 20EORDB/EORZDB

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1. a Engine End View With Radiator Removed Fuses F1 F2 and for 10 15 20EOR Z DB and 9 12 5 16 5EFOR Z DB models Advanced Digital Control ADC 2100 Alternator cooling air inlet Run Off Reset Auto switch Fuse block inside junction box 30 40EORZDB and 25 33EFORZDB models Runtime hour display Air intake silencer cleaner Fuel inlet connection Fuel water separator Lifting eye Fuel return connection Fuel filter Oil fill engine top Mechanical governor Coolant overflow tube Figure 1 1 Service Views Typical TP 6551 4 08 Pressure cap at radiator Oil fill front gear cover Radiator V belt Oil check dipstick Coolant overflow bottle Lube oil filter Oil drain Fuel feed pump Nameplate Circuit breaker location Remote customer interface connector Load lead connection Water inlet connection Water outlet connection Exhaust outlet ADV7031 A Section 1 Service Views 11 Notes 12 Section1 Service Views TP 6551 4 08 21 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule
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3. WaysAs i plougjos y JOY ON y Jo 1911 JON UONISOd NO 0 jan jan 1046 Jan Jo Adwa yue any 10 sasney ON asiou JO Jamod 3227 Ajueppns 4015 10 Spes peys 1 6551 4 08 34 Section 4 Troubleshooting Section 5 Wiring Diagrams A 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 connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Discon
4. Py A 10 10 sasney ON asiou JO aunssaid Jamod 3227 10 prey spes yeys 15 15 120 3 Section 4 Troubleshooting 33 TP 6551 4 08 ayewo y 104 y 10 8913S SIU 9 9 4 2945 2905 5 5 enuen enuen enuen 499 uag 5 siy 295 x 49840 syeo 10 195 Joodsu 0
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6. 11 14 8 01 129 92 20 LOANNOOSIG 310 3 10 20EOR Z DB 9 16 5EFOR Z DB Figure 5 1 6551 4 08 36 Section 5 Wiring Diagrams 49018 5011 191 GIONS10S 15 SS 15 WS YSISLLOSY NOOMIS HOS SOVIYSLNI 818 LOANNOOD 90 9 55 10 540 HOLIMS 110 5 01 X08 01 INSNI HATIOULNOOD NI T1Nd 5 7905 dS4 1803 0 8106 1905 3 TAN 5 SYNLVYSdWAL 1491009 SLO LINDUIO 80 HHY anaga 00120 FIGOW ASANVLS 02
7. Replace the lube filter element Check the coolant level and fill as necessary Before operation x Break in period Adjust the water pump belt tension Clean the radiator fins and inspect the hoses Replace the coolant Consult your local distributor dealer for service Read the WARNING found at the beginning of the manual regarding moving parts 20 Section Scheduled Maintenance TP 6551 4 08 Service Schedule continued Perform Service at Intervals Indicated INTAKE EXHAUST SYSTEM Inspect the exhaust system components Reference Section Before operation Every 250 Hrs or3 Months Every 500 Hrs or6 Months Every 1000 Hrs or Yearly Check the exhaust gas condition If the exhaust is blue or black contact your local distributor dealer During operation Replace the air cleaner element Check the breather pipe for obstructions Clean the turbocharger blower if equipped ELECTRICAL SYSTEM Keep the battery charged and in good condition Before operation Check adjust the alternator driving belt tension Check and tighten the electrical connections Clean the battery cables ENGINE AND MOUNTING Check for water fuel coolant and oil leakage operation Retighten any loose nuts and bolts Before operation C
8. 80 219 94 2 22 20 PW bd 260 1 219 94 1 9 92 SS 5 EN020 2 20 95 2 169 9 Ted 5 814 7 SNOLLOANNOO Old 118A 2 z 4 2 18 18 IHM 9 6 04 6 2 8 j TBA ev 87064 22271 e088 1 2 61 19 2983 old OD SNOLLOANNOO 02400 ord SNOLLOANNOO 189 8 14 819 963 9164 pd SNOLLOSNNOD 02 pW 81d NOLLOANNOO 024 09 60 21 28 d IHM 4 OL SNOLLOANNOO 624 SNOLLOANNOO ozr 1 vie em 4 133 5 30 N b Nid 61 fr SNOLLOSNNOO 224 2 gt 4 814 814 8 ef 8ia MA T 7 SNOLLOANNOO SNOLLOSNNOO Weed n 0 4 214
9. Figure 3 1 Engine Oil Selection 22 Section 3 Scheduled Maintenance 3 3 2 Check Check the oil level in the crankcase daily or before each startup to ensure that the level is in the safe range To check the oil level remove the dipstick and wipe the end clean reinsert as far as possible and remove Maintain the oil level between the Min and Max marks on the dipstick as shown in Figure 3 2 See Section 1 for dipstick location 1 O 1 Max level 2 Min level Figure 3 2 Oil Level Check Note Do not operate the set if the oil level is below the Min mark or above the Max mark 6551 4 08 3 3 3 Oil Change Change the oil more frequently if the generator operates under dirty dusty conditions See Figure 3 3 for oil capacities Model 10EOR Z DB 9EFOR Z DB 15EOR Z DB 12 5EFOR Z DB L Qts 3 6 3 8 47 20EOR Z DB 16 5EFOR Z DB 5 8 6 1 30EORZDB 25EFORZDB 40EORZDB 33EFORZDB 10 2 10 8 10 2 10 8 Figure 3 3 Oil Capacities Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Drain the oil a Place the generator set master switch in the OFF position b Disconnect the power to the battery charger if equipped c Disconnect the generator set engine starting battery negative lead first d Place an oil collection container below the oil drain and remove the oil drain plug e
10. NOONIS HOS MOV VE LOANNOO 090 HOLOANNOO 10 540 HOLIMS 10 401 GION310 1905 53 Tans 04 8 5 9334 3 SVD 15 HDS 104109 SNIDNS SYNLVYAdWAL 1 1009 SLO HOLIMS LNV1009 510 HHY 21339501 L 2 133HS OL amp 514 gt 8 8 4 1 98 21 OL 6 ma un 9 94 734 99 940 99 8 914 J 2133 OL 172 9 6 4 9314915 ATH NNE Ld ATH 174 WOO Z t Ldt 1 9 ATH 9 19 ATH 1 18 8 014 LYSA 9 Id 8 6N 9 02 14 HOSNAS SHNSSAud 16 14 6 08 14 HOSNAS 61 19 12 19 1497009
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12. MO 4 sy uauodwoo 146 9 W S 1704045 ay Jo pue 159 20215 W S ued 170401 2 10 159 uado 10101 W S 10 Y20490 uado Jo BULIM W O 517 101504 2U 0 139 AAO 991 Ul YOUMS 159 YOUMs J JSULIL 2y 1 1105 ureBe 19594 Jo apis au 10 9 pue uado oy y 10 10 4 y ysnipy juauujsnipe jo no jana 159 Ajuo Jo
13. 271 81 973 4 mee ZZA Sarid ae 3 9 vara 3 21 Sd 9 8 18 6N e 1 24 eza 2 02 14 24 4 cs 2208 z ULAR AA 9 aM 13 2109 23 S19 SIN EM 6 124 OLN zana 81 93 Ss 1401 8 84 002 43 1090 1 SNINN 9S 13 1 4 983 ENOL 23 219 94 gt gt SNINN 9S TIA 88 1 81 73A 0 69 ee seh 832 05890 14 96 1 8M 140 103 vog im 2 81 123 SNOLLOANNOO Sed W 6ld 73A 5 8 6 4 ss 4 SNOLLOANNOO 6551 4 08 Figure 5 5 Wiring Diagram 30 40 and 25 33EFORZDB 40 Section 5 Wiring Diagrams ANIONS 9011 191 90 370 431813 SS 15 WS
14. 41383u 440 Now 5 6 14 8 14 4 2 1 9 HSYT4 9 5 15 6 74 11074 4 1 1 SNOILOSNNOO ON LINVANOWWOD 9 81 S Eld AVISH 97 614 ON LINYA ld NOWWOO 11074 2 1 NOY 1 61 SNOILLOANNOO 614 1 8 5 8 6A 2 91 LIZA 6 SNOILOSNNOO 917 99 LAdNIDNIGNIM XNY 9 914 9 94 4 SANIN 91314 914 89 XNY 919 1 1 2 914 9 01914 1 914 SNOLLOANNOO 917 824 199795 3QOW SNONNILNOO 2 44 SNOLLOANNOO 2 6 8 64 21 84 9 9 84 8 5 5 2 84 1 64 SNOLLOANNOO Sd 26258 86 14 LYSA 66 14 26 14 TWNDIS 568 16 14 HOSNAS 553
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16. 8018 1 01 07 Ar INSNI GION310S 7804 3 aSN4 03 ANIONS 0984 5 1491009 SLO 80 99 HHY GN39371 5 99 0 8 5 ss 9 899 818 9 SNOLLOANNOO 914 385 SNOLLOSNNOO SON avaz 8 4 6A 514 91 ZA 9 06 1 5 99 Se ove Std 11 HOLVLS vis Sh ial 14 Sid 2A 2 8 99 9 9 4 ss 8 9 4 99 831411038 YALVSH Uvis
17. SNOLLOSNNOO 184 8 39 Section 5 Wiring Diagrams Figure 5 4 Wiring Diagram 30 40 and 25 33EFORZDB TP 6551 4 08 GM58298B 5 5 aod OE 99 OOOO 08 vw 8 63000 in ved 684 a ot om SNOLLOANNOO LIOA 21 om HOS gt NYO SLAN 180 e ea 830 H108 OL 2 92038 N OD SAYMTY GINOHS LAN 1 0 21 9 fd 149 1 79 LNN 184 3018 LAN SNOILOJNNOO LIOA KINO 2 01 97 03 07 05 63 09 219 y NI 5 SHY3LY3H 3105 310 ZHOS HOS uw SNOILOANNOO 614 LOANNOOSIG 1 310 ZNOOD 8 85 0 r 4 7
18. 08 14 HOSNAS 62 14 1 82 14 12 14 24016 1 16 SLOWSY 92 14 9015 1915 SLOWSY 82 14 1 14 22 19 12 14 02 14 YOSNIS 55 61 14 81 14 5 35 YA 41 14 91 14 HOLIMS SYNSSAYd 91 14 100 91 14 61 14 NMOGLNHS 21 14 11 14 NYO 01 MO1HOSNAS dW3L 1491009 6 19 5 4 31 1491009 8 19 92 9 42 14 8 9 NOWWOO 1109 OL 1 915 100 AY734 HALYVLS SNOILOSNNOO 14 YATIOULNOD 0012 ADV7030B D Figure 5 3 Wiring Diagram Schematic 10 20EOR Z DB and 9 16 5EFOR Z DB TP 6551 4 08 38 Section 5 Wiring Diagrams GM58298A Yn 8 1 16 6 1919 6A 2 ZA 5 Sid 4 for O v d LHM 8 44 610 we 2 v _ 1 514 1353 50 099 33 OLLVWSHOS HOS 59 D a 6 MOTIZA 79
19. 3 4 3 Fuel Water Separator These model generator sets includes fuel water separator The fuel water separator helps to remove water and sediment from the fuel system 1 Air bleed screw 2 Drain plug 3 Drain valve Figure 3 4 Fuel Water Separator 24 Section Scheduled Maintenance Fuel Water Separator Draining Procedure At the interval specified in the service schedule drain the water from the fuel water separator Hold a suitable container beneath the fuel water separator and push up on the drain valve See Figure 3 4 Release the valve when fuel free of water flows from the fuel water separator Fuel Water Separator s Element Replacement Procedure At the interval specified in the service schedule replace the fuel water separator element 1 Close the fuel valve at the nearest point to the water filter inlet or at the fuel tank 2 Remove the water drain plug or push up the drain valve and allow water and fuel to flow into a suitable container Note Depending upon the location of the fuel valve a considerable amount of fuel may drain out 3 Remove the separator s element from the mounting head by twisting in a counterclockwise direction 4 Remove the bowl from the fuel water separator element Wipe the excess fuel from the bowl and the O ring Do not discard the bowl or O ring 5 Inspect the comp
20. 335 85 HOLWHANAD ALON YOLVLS 988 NIV 2 99 L 33S SNOLLO3NNOO YOLVUSNSO 3LON 6 11 3011 t 8 15 4 4 x v 9ld gt 1 818 9 19 9 78 99 9 014 9 940 98 5 94 ATH Ltd JOULNOD 1 4 WOO Z Y to 21 6 719 1903 ATH HSY 5 14 ATH 1 16 Laf 02 14 TVN9IS HOSNSS 3YNSSIHd 16 14 SOWNOS JHNSSIHd 06 14 5 5 61 19 12 14 MO1HOSNAS dWAL 1491009 6 14 HOIH HOSNAS 1 8 14 HOLIMS ADV7030A D WNOLWdO SSNS NOLLISOd OLY NOLLISOd ASNAS OV SSNS OV NMOGLLAHS 21 14 1 4016 18 16 88 14 8 4016 18 16
21. RAD FAN 2 25 AMP ER ER RAD FAN RELAY RELAY 1 G H ACTUATOR RAD FAN RELAY RELAY 2 GM59203 Figure 2 7 Fuse Block 30 40 0 and 25 33EFORZDB Section 2 Operation 17 Notes 18 Section 2 Operation TP 6551 4 08 3 1 General Maintenance WARNING 9 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 connected equipment 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 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set onl
22. SNOLLOANNOO Std YOLVLS 7 oLnv 5 119 99 19 05 9 1919 818 9 914 4 918 d 21 810 da NWS env 04 304 SNOILOANNOO 24 U ss 40 6 19 Whe 1 18 2 9 499 9 Uvis 8A Uvis 6A z Uvis SNOLLOANNOO Std YOLVLS 1 5 6989 33 SNOLLOANNOO 23 803 13838440 Sd 001 0 580 LHM 840 1989 N 2 8 124 GALVINSNINN 519 1 640 v sdo gov SNOLLOANNOO 14 95 55 48 zz le th 02 14 44 ta 489 5 1 5 5 590 N voz 2
23. 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 A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates installation operation or maintenance information that is safety related but not hazard related 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 6551 4 08 Accidental Starting WARNING 7 aS 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
24. 10 15 20EOR Z DB and 9 12 5 16 5EFOR Z DB Models 17 2 5 3 Fuse Block 30 40EORZDB and 25 33EFORZDB Models 17 Section Scheduled Maintenance 19 31 General Maintenance 19 3 2 Service Schedule 20 33 Lubrication System ca deemed eee eee 22 3 3 1 Oil Specifications 22 33 2 OUCHECK ahah aia ele edie 22 333 Oil Changes thd add ead leaded 23 34 Fuel SYStem resi wad debe saw ee 23 3 4 1 Fuel Specifications 23 3 4 2 ae 24 3 4 3 Fuel Water Separator 24 344 Bleeding the Fuel System 25 3 5 26 3 6 Exhaust Systemi 27 37 Cooling System 28 3 7 1 Checking the Cooling System 28 3 7 2 Draining the Cooling System 28 3735 Filling the Cooling System 28 3 7 4 Flush
25. in cw CWC cyl D A DAC dB dBA DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E emer EDI EFR e g EG EGSA EIA emiss eng EPA EPS ER ES ESD est E Stop etc exh ext center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so
26. polyvinyl chloride quart quantity replacement emergency power source radiator radius random access memory relay driver output reference remote radio frequency interference round head round head machine screw relay rms root mean square rnd round ROM read only memory rot rotate rotating rpm revolutions per minute RS right side RTV room temperature vulcanization SAE Society of Automotive Engineers scfm standard cubic feet per minute SCR silicon controlled rectifier s sec second Sl Systeme international d unites International System of Units SI EO side in end out sil silencer SN serial number SPDT single pole double throw SPST single pole single throw spec specs specification s sq square sq square centimeter sq in square inch 55 stainless steel std standard stl steel tach tachometer TD time delay TDC top dead center TDEC time delay engine cooldown TDEN time delay emergency to normal TDES time delay engine start TDNE time delay normal to emergency TDOE time delay off to emergency TDON time delay off to normal temp temperature term terminal TIF telephone influence factor TIR total indicator reading tol tolerance turbo turbocharger typ typical same in multiple locations UF underfrequency UHF ultrahigh frequency UL Underwriter s Laboratories Inc UNC unified coarse thread was NC UNF unified fine thread was NF univ uni
27. for the drain opening Notice NOTICE Canadian installations only standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 NOTICE This generator set does not comply with United States Coast Guard USCG requirements and musi not be used for marine applications For marine installations use only generator sets specified for marine use USCG Regulation 33CFR183 requires that a generator set must ignition protected when used in gasoline fueled environment NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions 7 Notes 8 Safety Precautions and Instructions TP 6551 4 08 This manual provides operation instructions for 10 40EORDB EORZDB and 9 33EFORDB EFORZDB model generator sets Refer to the engine operation manual for generator set engine scheduled maintenance information 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 Preca
28. forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft Ibs ft min 9 genset GFI GND gov gph gpm gr GRD gr wt fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HD HET hex Hg HH hr HS hsg HVAC HWT Hz IC ID IEC 1 H20 in Hg in Ibs Inc ind int int ext ISO J JIS k K kA KB hex cap high cylinder head temperature heavy duty high exhaust temperature hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese In
29. frequently generator sets that are subject to extreme weather or dusty or dirty conditions Service Log Use the Operating Hour Service Log located in the back of this manual to document performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on Section 3 Scheduled Maintenance 19 3 2 Service Schedule Perform Service at Intervals Indicated Check the fuel level and fill as necessary Reference Section Before operation Every 250 Hrs or3 Months Every 500 Hrs or 6 Months Every 1000 Hrs or Yearly Check for any unusual noise During operation Remove the sediment from the fuel tank and drain the fuel tank Bleed the fuel system if encountering hard starting Replace the fuel filter element Fuel water separator draining Fuel water separator cleaning Inspect the fuel injection nozzle pressure Adjust the fuel injection timing 2000 hrs 2 Inspect and adjust the fuel injection pump 2000 hrs or 2 yrs LUBRICATION SYSTEM Check the crankcase oil level and add oil as necessary Before operation Replace the oil in the crankcase
30. fuel oil Note Do not crank the engine to prime the fuel system Use the following procedure Fuel System Priming Procedure 1 Press and hold Select button located on ADC See Figure 3 5 Move the generator set master switch to the RUN position to enter the programming mode Continue to hold the Select button for 10 seconds The ADC will display Fuel and the fuel priming pump will start Continue to hold the Select button for as long as you want the fuel priming pump to function typically 10 seconds Release the Select button and move the Master switch to the OFF position Place the Master switch to the RUN position to start the unit TP 6551 4 08 ADV7031 A 3 1 ADC control 2 Select button 3 Generator set master switch Figure 3 5 ADC Control Section 3 Scheduled Maintenance 25 3 5 Air Cleaner At the interval specified in the service schedule inspect clean or replace the air cleaner element Clean the element more frequently if the generator operates in dirty dusty conditions Check the element accumulated oil or dirt that could cause poor performance Replace a damaged air cleaner element Follow the procedure described below At the time of service clean the air cleaner breather pipe and remove all dust and foreign matter from the air cleaner housing Air Cleaner Element Cleaning or Replacement Procedure 1
31. last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment 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 froma remote computer Engine Backfire Flash Fire WARNING Lh 4 Can cause severe injury death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the fuel injection system fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize
32. 1 6 219 468 1 0 8 0 ss 5 1 15 SS vie er HALUVLS WS 81d ey 9 NOONIS 49S 64 6 40 818 65 ov 1 HOVE VE ATSWSSSV HOLSISSY SNOILOANNOO Ed 1 18 sv See 193NN09 128889 HOLOSNNOO 68584 Wisdo 9 0 da A HOLIMS 9 8 1915 3 Nid 902 188519 2 3 24 SNOILOSNNOO 214 HOSNAS 53 AWA 59 1 INI NI 993 b bd Wor 36 LNV1009 519 rid NOL 01800 z HOLVNUSLTY bla HIV HHY SNOLLOANNOO 14 831LV3H og TEGER vead anoa awg 95 wor nee 13A
33. 110 of the system s frequency setpoint for more than 5 seconds This protection becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service if problem continues Overspeed shutdown Shutdown occurs if the engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service if problem continues Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the voltage regulator setpoint for more than 2 seconds Contact an authorized distributor dealer for service if problem continues Underfrequency shutdown Shutdown occurs when the governed frequency falls below 90 of the system s frequency setpoint for more than 5 seconds This protection becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Undervoltage shutdown Shutdown occurs if the voltage falls below 80 of the voltage regulator setpoint for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service if problem continues Figure Controller error 2 5 ADC 2100 Fault Indicates a software or communication problem within the ADC 2100 Fault Shutdown Codes Description Contact an authorized di
34. 34 vee 983 ea 21 190 06 2140 95 92 140 6 14 O1 OL 9 011400 SNOILOSNNOO 124 914 GM39874 J 802 8 18 202 SNOILOANNOO 14 va voa dot 9 4 a 08 02 al 18 020 521 12 YOZ 02 02 21 IK voz 59 4 SNOILOANNOO Nid ma coz _ 3 Owe H 4 8d a e983 gs 42 1 1 2 og 0 amp 590 06 14 61 18 6 4 IHM NO00 04 Y 1983 N ANO HOLVIOVH 04 8 DOL OLNI SMa 8 SAYFI 6 1 8 19 SNOILOSANNOO Vdd Vit Nid N SNOLLOANNOO 519 SNOILOANNOD 40
35. 4 Ss 8 9 2 224 814 Weed 59 218 SAL GIONS1OS 81 14 814 8 AV 61 814 8 624 8 24 133 OL 1 5 OL 2 84 041 53 814 1 8 SLO 8rd V OND 8 4 823 0081 HOS LOANNOOSIG 193135 81 4 63 gt 2099 19998 1 1 8 444 04 9 NYS LASHS OL H NYO 13 81 413 8 619 H 619 WHO 02 6551 4 08 Figure 5 7 Wiring Diagram Schematic 30 40EORZDB and 25 33EFORZDB 42 Section 5 Wiring Diagrams Appendix Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC A D ADC adj ADV AHWT AISI ALOP alt Al ANSI AO API approx AR AS ASE ASME assy ASTM ATDC ATS auto aux A V avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk htr BMEP bps br Btu Btu min cal CARB CB cc CCA cow CEC cfh cfm TP 6551 ampere after bottom dea
36. 6 14 978 HOSNAS AWIL 141009 8 19 NOWWO9 SSN3S NOLLISOd OLN NOLLISOd NMOGLOHS 21 1 4 08 1 9015 1 15 0 92 19 4 384 OV dOLS LUVLS 92 1 4 v OV NYO TWNYALXA 2214 88 25 11 14 3535 OV NYO 1 01 14 HOLIMS 81 14 LAAN XNY 819 6 124 2128 304 1 8 gt 44 97 28 1 1 12d 1 4018 18 18 SLOWSY dOLS LHW1S SLOWSY 9 12 NYO 1 NOLLOANNOO 124 21339501 HOLIMS LNV1009 82 14 AVEAt 14 4 22 19 4 2 510 NYO Z d AVEAt 1 64 100 HSW14 9109 AVISH H3LV3H HIV OL TVNDIS 2 14 28 1 1 19 LNO 1903 6 19 LNO LINY NOWWOO 1 19 LNO 15 00 2 L n Z133HS 01 ADV7460A 5804 01 214 10
37. 6264 6455 TP 6551 4 08 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 Introduction 9 Maintenance and Service Parts Related Literature Maintenance and Service Parts Figure 1 identifies maintenance and service parts for your generator set Obtain a complete list of maintenance and service parts from your authorized generator distributor dealer Part Description Models 10EORDB 10EORZDB 9EFORDB 9EFORZDB 15EORDB 15EORZDB 12 5EFORDB 12 5EFORZDB 20EORDB 20EORZDB 16 5EFORDB 16 5EFORZDB 30EORZDB 25EFORZDB 40EORZDB 33EFORZDB Air Cleaner Element GM42265 GM42265 GM42266 GM16944 GM42266 Belt 225428 225428 225428 GM46865 GM46865 Fuel Filter Element GM32359 GM32359 GM32359 GM32359 GM32359 Fuel Water Separator Element 225259 225259 225259 Fuse Auxiliary Winding F1 12 Lead Generator Sets 20 amp 4 Lead Generator
38. 88 844 4 1 4 HV HHV rid Z133HSOL 4 9 80 214 9 21 21 60 21 938 gt 94 4 66 4 Z 133 5 OL 4 86 98 84 214 9 14 84 9 ISNA 21 30 40EORZDB 25 33EFORZDB IC Schemat iagram D iring Figure 5 6 41 Section 5 Wiring Diagrams TP 6551 4 08 ADV7460B 8 88 33 SNOILOJNNOO HOS 21 8 4 573 18 193135 03395 are d 0N9 11 81 173 40 4 8 bd HOLIMS 1891 814 133 OL 9 8 446 NIVW 10 8 4 NOVY 102 8 4 eeg 59 85 9 94 4 SNOLLOSNNOO 8 15 27 814 824 4 yyy 9 15 81 S d 4 gt O Wd LS 59 814 7 4 V WALS 14 8 4 9 884 gt S d 493 2 133HS OL 9 LNW 8Ldf 873 19 089 1 81
39. Allowtime for the engine oil to drain completely f Replace the oil drain plug 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Apply a light coat of clean oil to the rubber seal of the new oil filter c Install the new oil filter following the instructions provided with the filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner TP 6551 4 08 3 Fill with oil Add new oil of the weight grade and quantity specified in Section 3 3 4 Check for leaks a Check that the generator set master switch is in the OFF position b Reconnect the generator set engine starting battery negative lead last c Reconnect the power to the battery charger if equipped d Start the generator set and check for leaks around the oil filter Stop the generator set and tighten the oil filter to stop any leaks x sm 001 003 3 4 Fuel System 341 Fuel Specifications Use a clean good quality diesel fuel oil with a cetane number of 45 or greater Clean fuel prevents the diesel fuel injectors and pumps from clogging Fuel Recommendations No 2 0 No 1 0 ASTM 0975 94 United States United Kingdom BS 2869 A1 or A2 European Union EN590 96 Japan JIS No K2204 2 Note Never store diesel fuel in galvanized containers diesel fuel and the galvanized coating react chemically t
40. In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Air Shrouding Check for securely installed and positioned air shrouding Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater Drive Belt s Check the belt condition and tension of the water pump and battery charging alternator belt s Exhaust System Check for exhaust leaks and blockages Check the muffler and piping condition and check for tight exhaust system connections Inspect the exhaust system components for cracks and corrosion exhaust manifold exhaust line exhaust clamps and muffler e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed Check that the ex
41. Loosen the eyebolt and clamp to remove the air cleaner cover 2 Remove the wing nut and slide the air cleaner element from the threaded rod 3 Tap the element lightly against a flat surface to dislodge loose surface dirt Do not clean the element in any liquid or use compressed air as these will damage the filter element 4 Wipe the cover and base with clean rag to remove any dirt 5 Ensure tight clamps at the inlet outlet connections 26 Section Scheduled Maintenance 6 Install the air cleaner element on the threaded rod Tighten the wing nut 7 Position the cover with the arrow up place the clamp over the base and cover and tighten the eyebolt 6 5 Eyebolt clamp Base Cover Element Threaded rod Wing nut Figure 3 6 Air Cleaner Components 6551 4 08 3 6 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the vehicle s occupants install a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use At the interval specified in the service schedule inspect the exhaust system See Section 1 for the exhaust outlet location TP 6551 4 08 Inspec
42. Operation Commercial Recreational Mobile Generator Sets pss online POWER SYSTEMS SIEKMANN GMBH Auf der Haar 101 33332 G tersloh Telefon 49 0 5241 300 76 0 49 0 5241 300 76 29 email info pss online de http www pss online de Models 10EORDB EORZDB 15EORDB EORZDB 20EORDB EORZDB 30EORZDB 40EORZDB 9EFORDB EFORZDB 12 5EFORDB EFORZDB 16 5EFORDB EFORZDB 25EFORZDB 33EFORZDB 29001 NATIONALLY REGISTERED KOHLER POVVER SYSTEMS asst California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number x in 007 001 6551 4 08 Table of Contents Pro
43. SLOWSY 92 14 OV 22 19 9S 11 1 1 1 9 NYO 01 14 H NYO HOLIMS SHNSSAHd 91 19 SNNIW Ald ONIGNIM 6 124 N 2 128 AWat 8 1 4 9 124 8 124 4 15 1 15 SLOWSY 12 dOLS LUVLS SLOWSY m 98 09 129 CISIHS NOLLOANNOO bed 6 44 2011 SNONNLLNOD 108138 SNONNILNOD 2 24 1 1 49 14 300W 8 4d 170 HSY LVEA 22 14 1 19 LNO TANS 12 19 8 14 100 LINY NOWWOO 1 14 LNO 9311 109 OL 2 19 26 00 2 IWAN 9 4 8 1 1 Figure 5 2 Wiring Diagram Schematic 10 20EOR Z DB and 9 16 5EFOR Z DB 37 Section 5 Wiring Diagrams TP 6551 4 08 aim
44. Section Scheduled Maintenance Thermostat Rating 82 C 179 F All Models Figure 3 8 Thermostat Rating Engine amp Unit Mounted Radiator L Qts Engine Model L Qts 10EOR DB 9EFOR Z DB 1 8 1 9 4 1 43 15EOR Z DB 12 5EFOR Z DB 2 0 2 1 9 1 9 6 20EOR Z DB 16 5EFOR Z DB 30EORZDB 25EFORZDB 40EORZDB 33EFORZDB 2 7 2 8 9 3 9 8 4 2 4 4 15 16 4 2 4 4 15 8 16 7 Figure 3 9 Coolant Capacities 3 7 2 Draining the Cooling System The radiator contains a coolant drain valve to drain the cooling system When draining the coolant remove the radiator s pressure cap this will allow the entire system to drain and will prevent air pockets from forming and restricting coolant passage to the block Note Pay special attention to the coolant level After the coolant drains allow time for complete refill of the engine water jacket Check the coolant level as described earlier 3 7 3 Filling the Cooling System 1 Remove the radiator s pressure cap 2 Close the radiator s and or engine block s coolant drain valve s and tighten the hose clamps Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until engine has cooled 3 Fill the radiator with the recommended coolant mixture of 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and preven
45. Sets 10 amp GM39266 223316 GM39266 223316 GM39266 223316 Fuse Relay Interface Board F2 10 amp 223316 223316 223316 Fuse Controller F3 10 amp 223316 Fuse SCR F1 10 amp Fuse Radiator Fan 1 F2 25 amp Fuse Radiator Fan 2 F3 25 amp Fuse Battery F4 10 amp Fuse Sub Relay F5 10 amp Fuse Battery Charging Alternator 10 amp Oil Filter 252834 223316 GM47465 223316 252834 225259 GM58256 225259 GM58256 GM59206 GM59206 GM59206 GM59206 GM58921 GM58921 GM58921 GM58921 GM58921 GM58921 GM47465 GM47465 Spray Paint Black Figure 1 List of Related Literature 221292 Maintenance and Service Parts 221292 221292 221292 221292 Figure 2 identifies related literature available for the generator sets covered in this manual Only trained and qualified personnel should install or service the generator set Part Number TP 6552 TP 6551 TP 6596 TP 6554 TP 6553 TP 6597 One manual combines Generator and Engine information Literature Type Installation Manual Operation Manual Generator Operation Manual Engine Parts Catalog Service Manual Generator Service Manual Engine Figure 2 Generator Set Literature 10 Introduction TP 6551 4 08 Section 1 Service Views Service Side View 11
46. Switch functions as the generator set operation and controller reset switch TP 6551 4 08 242 Starting the Generator Set The following procedures describe the actions required to start the generator set Action Fuel shut off valve Open the manual fuel shut off valve if equipped Starting Place the generator set master switch in the RUN position The controller attempts to start the generator set three times If the generator set does not start in three attempts the system shuts down on an overcrank fault Local Starting Move the generator set master switch to the RUN position The ADC 2100 attempts to start the generator set in three crank cycles crank cycle time is pre programmed Remote Starting Move the generator set master switch to the AUTO position to allow startup by the ATS remote start stop switch or remote digital gauge A remote start stop switch or digital gauge can be connected to the customer interface connection P21 connector leads 4 See the wiring diagrams in Section 5 See Section 2 4 4 Note The ADC 2100 allows three crank cycle attempts before the overcrank shutdown occurs 243 Stopping the Generator Set The following procedures describe the actions required to stop the generator set Local Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET positi
47. ace the belt if necessary Section 3 Scheduled Maintenance 29 3 9 Consult the battery manufacturer s instructions regarding battery care and maintenance 3 10 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system and internal engine component storage 3 10 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Remove and replace the oil filter 5 Refill the crankcase with oil suited to the climate 6 Run the generator set for two minutes to distribute the clean oil 7 Stop the generator set 8 Check the oil level and adjust if needed 3 10 2 Cooling System Prepare the cooling system for storage as follows 1 Check the coolant freeze protection using a coolant tester 2 Add or replace coolant as necessary to ensure adequate freezing protection Use the guidelines included in the engine operation manual 3 Run the generator set for 30 minutes to redistribute added coolant 30 Section Scheduled Maintenance 3 10 3 Fuel System Prepare the fuel system for storage as follows Diesel Fueled Engines 1 Fill
48. aults and suggests likely causes and remedies The table also refers you to more detailed information including sections of this manual the generator set service manual S M the generator set installation manual I M and the engine service manual Engine S M to correct the indicated problem Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment x gt 001 002a Possible Cause Controller LED display No power to the controller is off Problem Controller fuse F3 is blown Low or no battery voltage 4 1 Fault Codes The Advanced Digital Control displays fault codes to aid in troubleshooting Fault codes descriptions and recommended actions are listed in Figure 2 5 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 4 6 4 2 Controller Troubleshooting Figure 4 1 contains troubleshooting diagnostic and repair information for the Advanced Digital Control Corrective Action Replace the fuse If the fuse
49. blows again contact the distributor dealer Check connections Check generator set battery position Generator set master switch is in the OFF RESET Move generator set master switch to the AUTO or RUN position reset Figure 4 1 Controller Troubleshooting Chart TP 6551 4 08 Generator set master switch in AUTO but no start command has been received since last controller No action required Controller display will activate when a remote start command is received or the generator set master switch is moved to the RUN position Use the remote switch to start generator set and activate the controller display if desired Section 4 Troubleshooting 31 Z asnj y 1 24 y 10 24 08 SIU woad 89S 2 4 3 4 9 5 5 enuen enuen enuen 1 Bugz yoyms
50. d center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only American Petroleum Institute approximate approximately as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code cubic feet per hour cubic feet per minute 4 08 CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu cu
51. duct Identification Information 2 Safety Precautions and Instructions 5 9 Service ASSISTANCE eee ees 9 Maintenance and Service Parts Related Literature 10 Section 1 Service VIEWS cece ances 11 Section 2 Operation tmi anian see see nesses ous 13 21 Prestart Checklist 13 2 2 Angular Operation 13 2 3 Load Profile wise rete tans dale dees 13 24 Advanced Digital Control 14 2 4 1 Controls and Indicators 14 2 4 2 Starting the Generator 15 243 Stopping the Generator 15 244 Power MOdeS RES 15 245 Fault Shutdowns 15 2 4 6 Resetting the Controller after Fault Shutdown 17 25 Circuit Protection wa dea eae eee 17 2 5 1 Line Circuit Breaker 17 2 5 2 Fuses
52. dustry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Appendix 43 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm KQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical L liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft8 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display 14 shd load shed LED light emitting diode Lph liters per hour liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 109 when used with SI units male ms cubic meter m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCM one thousand circular mils MCCB molded case circuit breaker meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm MQ milliohm MOhm MQ megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m sec meters per second MTBF mean time between failure MTBO mean time b
53. els The junction box contains three inline fuses See Figure 1 1 for locations Always identify and correct the cause of a blown fuse before restarting the generator set Refer to section 4 Troubleshooting for conditions that may indicate a blown fuse Obtain service from an authorized distributor dealer Controller Fuse A replaceable 10 amp fuse protects the controller circuitry If the controller display is dark check the battery and battery connections and then check the controller fuse Replace the fuse if it is blown Relay Fuse A replaceable 10 amp fuse protects the engine relays Ifthe generator set does not crank check the battery and battery connections and then check the relay fuse Replace the fuse if it is blown Auxiliary Winding Fuse A replaceable 10 amp fuse for 4 lead generator sets 20 amp fuse for 12 lead generator sets protects the alternator 2 5 3 Fuse Block 30 40EORZDB 25 33EFORZDB Models The junction box contains the fuse block See Figure 1 1 for locations Always identify and correct the cause of a blown fuse before restarting the generator set Refer to section 4 Troubleshooting for conditions that may indicate a blown fuse Obtain service from an authorized distributor dealer See Figure 2 7 SCR 5 10 BATTERY 250 RAD FAN 1 SUB RELAY 25 AMP 10 10 00 BATTERY CHARGING ALTERNATOR 10 AMP
54. els 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 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place WARNING Hazardous voltage Backfeed to the utility system can cause severe injury death or property damage Connect the generator set to the building s electrical system only through an approved device and after the building s main switch is turned off TP 6551 4 08 J Welding the generator set Can cause severe electrical equipment damage Never weld components of the generator set without first disconnecting the battery controller wiring harness and engine electronic control module ECM Servicing the generator set when it is operating Exposed moving parts can 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 cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes standards Electrically gr
55. etween overhauls mtg mounting 44 Appendix MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns opt OS OSHA OV oz PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi PTC PTO PVC qty rad RAM RDO ref rem rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pint positive temperature coefficient power takeoff
56. f inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Installing the exhaust tail pipe Carbon monoxide can cause severe nausea fainting or death Install the exhaust system tail pipe to prevent the drawing of discharged exhaust gases into the vehicle interior through windows doors air conditioners and other openings Do not use flexible tail piping because it could crack and allow lethal exhaust fumes to enter the vehicle 6 Safety Precautions and Instructions Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the vehicle s occupants install a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use Fuel System A WARNING 4 Explosive fuel vapor
57. haust outlet is unobstructed Check the exhaust gas color If the exhaust is blue or black contact your local distributor dealer TP 6551 4 08 Section 2 Operation Visually inspect the exhaust system for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Ensure that the carbon monoxide detector is 1 in the vehicle 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 2 Angular Operation See Figure 2 1 for angular operation limits Intermittent Continuous 3 minutes or less 25 30 Maximum value for all directions Figure 2 1 Angular Operation 2 3 Load Profile Whenever operating the generator set Kohler Co recommends maintaining the minimum load profile indicated in Figure 2 2 Maintaining the load profile prevents corrosion formation internal engine components when they
58. heck the mounting bolts vibromounts and tighten if necessary Adjust the intake exhaust valve clearance Check the compartment condition fuel oil or water leaks REMOTE START PANEL Check the remote start panel operation if equipped GENERATOR Test run the generator set Before operation Break in period Blow dust out of the generator Clean the slip rings and inspect the brushes if equipped Consult your local distributor dealer for service Read the WARNING found at the beginning of the manual regarding moving parts Consult the battery manufacturer s instructions TP 6551 4 08 Section 3 Scheduled Maintenance 21 3 3 Lubrication System See the Scheduled Maintenance section for oil change and oil filter replacement intervals See Section 1 for the oil drain oil check oil fill and oil filter locations x sm 001 002 3 3 1 Use oil that meets the American Petroleum Institute API classification of CD or CF Using an unsuitable oil or neglecting an oil change may result in damage and a shorter engine life Figure 3 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for given operating temperature ranges Oil Specifications Note Failure to observe the oil specifications may cause inadequate lubrication oil pressure and cold starting difficulties SAE Service Grade 0 20 40 60
59. ing and Cleaning 29 3 5 5 IPFESSUPE 29 38 Belt Check ces 29 39 30 3 10 Storage Procedure 30 3 10 1 Lubricating System 30 3 10 2 Cooling System 30 3 10 3 30 3 10 4 caste 30 3 10 5 cess dias 30 Section 4 Troubleshooting 31 4 1 Fault Codes Sedu ted oe Saw ee eee 31 4 2 Controller Troubleshooting 31 TP 6551 4 08 Table of Contents 3 Table of Contents continued Section 5 Wiring Diagrams dee inden oa 35 Appendix A Abbreviations 43 Appendix Operating Hour Service Log 45 4 Table of Contents TP 6551 4 08 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories
60. ircuit breaker or ATS See the safety precautions at the beginning of this manual before proceeding 3 Identify and correct the cause of the fault shutdown See the safety precautions at the beginning of this manual before proceeding Refer to Section 4 Troubleshooting 4 Start the generator set by moving the generator set master switch to RUN Test operate the generator set to verify that the cause of the shutdown has been corrected 5 Shut the generator off by moving the generator set master switch to the OFF RESET position 6 Reconnect the generator set to the load using the line circuit breaker or ATS 7 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Note The controllers LED display remains off until an engine start command is received Opening and closing the remote start stop contact also resets the controller 2 5 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly see Section 4 Troubleshooting for possible causes 251 Line Circuit Breaker A circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load The line circuit breaker location is shown in Figure 1 1 If the circuit breaker trips reduce the load and switch the breaker back to the ON position TP 6551 4 08 2 5 2 Fuses 10 15 20EOR Z DB and 9 12 5 16 5EFOR Z DB Mod
61. jury or death Connect the generator set to the building campground electrical system only through an approved device and after the building campground main switch is turned off Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a transfer switch to prevent interconnection of the generator set power and other sources of power Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Combustible materials Fire can cause severe injury or death A hot exhaust system can ignite adjacent combustible materials Do not locate electrical wiring fuel lines combustible materials above the exhaust muffler Exercise caution when parking your vehicle to prevent the exhaust system and hot exhaust gases from starting grass fires Combustible materials Fire can cause severe injury or death A hot generator set can ignite debris in the compartment Keep the compartment and generator set clean and free of debris and combustible materials to minimize the possibility of fire Do not block the fuel oil drain opening in the generator set mounting tray Cut a corresponding hole in the subfloor if used
62. ll not start when the fault is active input is grounded This protection becomes active 3 seconds after crank disconnect Check the cause of the auxiliary fault High engine temperature shutdown Shutdown occurs if the engine coolant temperature exceeds the maximum temperature for more than 5 seconds This protection becomes active after the engine reaches the crank disconnect speed Note The high engine temperature shutdown functions only when the coolant level is in the operating range Check for a low engine coolant level Loss of coolant shutdown Not used Low oil pressure shutdown Shutdown occurs if a low oil pressure condition exists for more than 5 seconds This protection becomes active 30 seconds after the engine has reached crank disconnect speed 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Check for leaks in the lubrication system Check the oil level and add oil if the level is low Overcrank shutdown Shutdown occurs after 3 unsuccessful starting attempts The crank cycle is set for three starting attempts Check the fuel supply and battery If there is no output voltage check the line circuit breaker Also check for loose connections Contact an authorized distributor dealer for service if problem continues Overfrequency shutdown Shutdown occurs when the governed frequency exceeds
63. nect 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 TP 6551 4 08 A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can 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 transfer switch 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 Section 5 Wiring Diagrams 35 050 93 OLLWWAHOS HOS 92 079 93 WWHOVIG 55 4 2 HOS HOLVLS 1915 GIONS10S 15 SS 1 15 NS 431411034 811081 NOOMIS 95 AVISH 1 3 NODD 094 5 5 10 90 HOLIMS 110 MOT
64. o produce flaking that quickly clogs filters or causes fuel pump or injector failure Note Avoid storing fuel for more than one month Take special precautions to keep all dirt water and other contaminants out of fuel to prevent the growth of microbes Microbes form slime that clogs the fuel filter and lines Note Do not run the generator set out of fuel because the fuel lines will draw in air and necessitate bleeding the fuel system before restarting the unit Section 3 Scheduled Maintenance 23 3 4 2 Fuel Filter The quality and condition of the fuel largely determine the filter s useful life Replace the fuel filter element as listed in the service schedule Section 1 shows the typical location of a fuel filter Use the applicable procedure below to replace the fuel filter Fuel Filter Cleaning Replacement Procedure 1 Close the fuel supply valve 2 Loosen the fuel filter by turning it counterclockwise Remove the fuel filter and use rags to clean up spilled fuel oil Dispose of the fuel filter in an approved manner 3 Clean the contact surface of the fuel oil filter adapter 4 Lightly lubricate the gasket surface of the new fuel filter with fresh fuel oil Thread the filter on the adapter until the gasket makes contact hand tighten the filter an additional one half turn Wash hands after any contact with fuel oil 5 Open the fuel supply valve 6 Bleed the system See Section 3 4 4 Bleeding the Fuel System
65. on The engine stops Remote Stopping 1 Run the generator set at no load for at least 2 minutes to ensure adequate engine cooldown 2 With the generator set master switch in the AUTO position the generator set stops when the remote start stop switch contacts close momentarily See Section 2 4 4 TP 6551 4 08 2 4 4 Power Modes The ADC 2100 controller s communication parameter can be set for three different power modes Note Consult an authorized Kohler dealer distributor for parameter adjustments e Continuous power mode The ADC 2100 is powered continuously to allow communication with the remote gauge at all times In this configuration use the remote gauge for remote start and stop as well as generator set monitoring A battery charger is recommended to maintain the battery Note The controller is powered by the generator set engine starting battery Remote communications require an active powered up controller Be advised that the ADC consumes 250 mA when the master switch is in the AUTO position If you do not plan to use your generator set for long period of time Kohler recommends moving the master switch to the OFF RESET position 0 mA draw e One hour power down mode The ADC 2100 powers down after 1 hour of inactivity In this mode use a remote start stop switch or the generator set master switch to activate the controller after it has powered down The remote gauge is powered during generator set c
66. onents for wear or damage Replace parts as necessary 6 Lubricate the O ring with clean diesel fuel and replace it in the bowl 7 Install the bowl onto a new fuel water separator filter element 8 Lubricate the bowl element assembly with clean fuel Install the bowl element onto the filter mounting head 9 Replace the water drain plug if removed and close the vent 10 Remove the air bleed screw from the fuel water separator 11 Open the fuel supply valve 12 After fuel fills the water separator allow fuel to flow from the air bleed hole until all air is displaced fuel flows free of air bubbles 13 Replace the air bleed screw TP 6551 4 08 3 4 4 Bleeding the Fuel System Bleed air from the fuel system to prevent starting failures and or erratic operation One or more of the following causes air to collect in the fuel system e Operating the generator set until it runs out of fuel e Developing air leaks in the plumbing between the fuel tank and the engine mounted fuel pump e Replacing the fuel filter Note If the ADC 2100 indicates an overcrank fault during this procedure disconnect the negative wire from the fuel solenoid allowing the fuel injection pump to fill with fuel and repeat this procedure after allowing the starter motor to cool down Note Have rag handy during the bleeding procedure Wipe up all spilled diesel fuel after bleeding the system Wash hands after any contact with
67. oolant drain valve and let the system drain completely Remove the pressure cap to simplify draining 2 Drain clean and flush the coolant overflow bottle 3 Flush the system with clean water 4 Close the radiator s coolant drain valve 5 Fill the system with the recommended coolant 6 Replace the pressure cap TP 6551 4 08 3 7 5 Pressure Cap The cooling system utilizes a pressure cap to raise the boiling point of the coolant enabling higher operating temperatures If the cap leaks replace it with a cap of the same rating 3 8 Belt Check Check the belt tension at the intervals specified in the service schedule If the tension is not within specification adjust as necessary using the following procedure Adjust the tension of the alternator fan belt so that the belt can be depressed about 12 7 mm 0 5 in when applying finger pressure Use the following procedure to adjust the belt 1 Battery charging alternator pulley 2 Adjusting screw 3 Check the alternator belt tension here 4 Alternator pivot screw Figure 3 10 Belt Tension Belt Tensioning Procedure 1 Disconnect the battery negative lead first 2 Loosen the pivot and adjusting screws 3 While prying the battery charging alternator outward tighten the adjusting screw 4 Tighten the pivot screw 5 Recheck and adjust as necessary 6 Reconnect the battery negative lead last Note Also check the fan belt for cracks or tears and repl
68. ound the generator set transfer switch and related equipment and electrical circuits Turn offthe 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 Welding on the generator set Can cause severe electrical equipment damage Before welding 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 TP 6551 4 08 Short circuits Hazardous voltage current can 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 repairs Remove all jewelry before servicing the equipment Engine block heater Hazardous voltage can 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 in
69. r The LED display indicates generator set status as shown in Figure 2 4 The display is activated by a start or run command and remains active until the generator set master switch is moved to the OFF RESET position or the power to the controller is removed The buttons on the controller keypad are used only for system configuration and adjustment The controller is factory set and should not require configuration or adjustment under normal operating conditions If the generator set is reconnected to a different voltage and or frequency refer to an authorized Kohler distributor dealer for system configuration and adjustment instructions LED display Runtime hours Displays total generator set runtime hours Crank indication Displays 1 2 or to indicate the first second or third attempt to start the engine The last digit flashes during the crank cycle rest periods Fault codes Flashes a 2 or 3 letter fault code to indicate various fault conditions See Section 2 4 5 Software version See the Generator Set Installation Manual Select and arrow buttons Keypad The keypad is used for controller setup and adjustment only Have setup and adjustments performed only by an authorized distributor dealer The setup and adjustment functions are password protected Generator set master Three position switch switch Figure 2 4 ADC 2100 Controls and Indicators 14 Section 2 Operation
70. rank and run only In this configuration the drain on the battery is reduced but the remote gauge cannot be used for remote start stop Install a separate start stop switch if remote start stop capability is required e 48 hour power down mode Ifthe ADC 2100 is not configured for a CAN gauge the controller will power down after 48 hours of inactivity If the generator set has been started the controller will power down 48 hours after the generator set stops 2 4 5 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2 5 and the controller displays a fault code The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 4 6 to reset the controller after a fault shutdown The controller resets automatically after a battery voltage fault condition is corrected Shutdown switches on the generator set automatically reset when the problem is corrected The high engine temperature switch automatically resets when the generator set cools However the fault does not clear until the controller is reset The controller displays a fault code but the generator set does not shut down under the conditions shown in Figure 2 6 Section 2 Operation 15 Auxiliary fault input shutdown Description Input from a customer supplied switch that closes when the fault is active Shutdown occurs 0 3 seconds after the fault is detected and wi
71. re cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank 3 7 1 Checking the Cooling System To prevent generator shutdown or damage because of overheating keep the cooling air inlets clean and unobstructed at all times Inspect the radiator s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins Check the hoses and connections for leaks and replace any cracked frayed or spongy hoses When checking the coolant level also check the rubber seal of the radiator s pressure cap and replace a cracked or deteriorated cap The pressure cap raises the boiling point of the coolant enabling higher operating temperatures If the cap leaks replace it with the same rating type of cap See Figure 3 7 Remove dirt and other debris from the pressure cap and filler neck See Figure 3 8 for thermostat rating See Figure 3 9 for coolant capacities Pressure Cap Rating 97 kPa 14 psi 83 110 kPa 12 16 psi 48 kPa 7 psi 10EOR Z DB and 9EFOR Z DB 15EOR Z DB and 12 5EFOR Z DB 20EOR Z DB and 16 5EFOR Z DB 30 40EORZDB and 25 33EFORZDB Figure 3 7 Pressure Rating For Inline Radiator Models 28
72. re exposed to the breakdown of exhaust gases Minimum Ideal Load Requirement Load Requirement 30 load 7096 load or more Figure 2 2 Load Profile Section 2 Operation 13 The operator should perform all of the prestart checks Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks 2 4 Advanced Digital Control Operation Figure 2 3 illustrates the user interface on the Advanced Digital Control ADC 2100 Note Have setup and adjustments of the ADC 2100 performed only by authorized Kohler distributor dealer The setup and adjustments are password protected KOHLER ADVANCED DIGITAL CONTROL CODE DEFINITION Auxillary Fault Crank cle High Battery Voltage High Enging Temp Low Battery Voltage Low Coolant Level Loss of Coolant Low Pressure Over Crank Over Frequency Over Spee Over Voltage Under Frequency Under Voltage OFF RESET AUTO 3 GM28707A C 1 LED display 2 Up and down arrow buttons use for setup and adjustment only 3 Generator set master switch 4 Select button use for setup and adjustment onl Figure 2 3 ADC 2100 Control Control Indicator Item Description 241 Controls and Indicators Figure 2 4 describes the controls and indicators located on the controlle
73. s Can cause severe injury or death Use extreme care when handling storing and using fuels 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 Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise lev
74. sAQ 5 5 y 146 5 12998 Jou jsneyxy 9 1 5 12 9 4 5 Jo 995 peol aU w s 4 uossasdwoo ay yosUuD yeam 10 ULSD w s 15 10 5 ploug os 19 5 19 1915 Josey 4 1 JOsUUODSIG 1461 jou 1 S S 2 Bunel WOO 4 ay Jo Jo yeam 1961 1294409
75. stributor dealer for service Controller needs to be replaced Check High battery voltage warning Fault code is displayed if the engine starting battery voltage rises above 16 VDC for a 12 VDC system or above 30 VDC for a 24 VDC system for more than 2 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds Check the battery rating and condition Low battery voltage warning Fault code is displayed if the engine starting battery voltage falls below 9 5 VDC for a 12 VDC system or below 16 VDC for a 24 VDC system for more than 2 seconds when the engine is not running This fault condition does not inhibit engine starting The fault condition clears when the battery voltage returns to a voltage within the limits for more than 2 seconds Figure 2 6 ADC 2100 Fault Warning Codes 16 Section 2 Operation Check the battery rating and condition Charge or replace the battery TP 6551 4 08 246 Resetting the Controller after Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Use the following procedure to reset the generator set controller after a fault shutdown 1 Move the generator set master switch to the OFF RESET position 2 Disconnect the generator set from the load using the line c
76. t freezing TP 6551 4 08 Note coolant solution of 50 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F A coolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications 4 Replace the radiator s pressure cap 5 Operate the engine until the thermostat opens and the radiator upper hose becomes hot 6 Stop the engine and allow it to cool 7 Remove the radiator s pressure cap 8 Add coolant to the radiator to just below the overflow tube on the filler neck 9 Replace the radiator s pressure cap 10 Maintain the coolant level in the coolant overflow bottle between the High and Low markings Note Periodically check the coolant level by removing the radiator s pressure cap Do not rely solely on the level in the coolant overflow bottle Add fresh coolant until the level is just below the overflow tube opening 3 7 4 Flushing and Cleaning For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Flushing and Cleaning Procedure 1 Remove the pressure cap and open the radiator s c
77. the fuel tank with 2 diesel fuel 2 Condition the fuel system with compatible additives to control microbial growth 3 Change the fuel filter separator and bleed the fuel system 3 10 4 Exterior Prepare the exterior for storage as follows 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electrical connections 5 Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion 3 10 5 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to the battery manufacturer for the battery cleaning procedure 4 Place the battery in a cool dry location 5 Connect the battery to a float equalize battery charger or charge it monthly with a trickle battery charger Refer to the battery charger manufacturer s recommendations Maintain a full charge to extend battery life TP 6551 4 08 Section 4 Troubleshooting This section contains generator set troubleshooting diagnostic and repair information Use the following charts as a quick troubleshooting reference The table groups generator set f
78. 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 for electrical fires as recommended by the local fire code or an authorized agency Train personnel fire extinguisher operation fire prevention procedures Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Safety Precautions and Instructions 5 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 vehicle Do not obstruct the exhaust outlet when parking your vehicle The exhaust gases must discharge freely to prevent carbon monoxide from deflecting into the vehicle Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death i
79. tion Points Check for exhaust leaks and blockages Check the muffler and piping condition and check for tight exhaust system connections Inspect the exhaust system components for cracks and corrosion exhaust manifold exhaust line exhaust clamps and muffler e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed Check that the exhaust outlet is unobstructed Check the exhaust gas color If the exhaust is blue black contact your local distributor dealer Visually inspect the exhaust system for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed e Ensure that the carbon monoxide detector is 1 inthe vehicle 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others Section 3 Scheduled Maintenance 27 3 7 Cooling System A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Allow the engine to cool Release pressure from the cooling system before removing the pressu
80. utions and Instructions section at the Introduction beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service at the prescribed intervals Obtain service from authorized service distributor dealer to keep equipment in top condition Before installing a mobile generator set obtain the most current installation manual from your local distributor dealer Only qualified persons should install the generator set x in 001 002 a Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric Visit the Kohler Power Systems website KohlerPower com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65
81. versal US undersize underspeed UV ultraviolet undervoltage volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency WCR withstand and closing rating w with w o without wt weight xfmr transformer TP 6551 4 08 Appendix Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed Enter hours to the operating hours on your generator set and the dates nearest quarter hour OPERATING HOURS SERVICE RECORD DATE TOTAL SERVICE RUN HOURS DATE SERVICE TP 6551 4 08 Appendix 45 46 6551 4 08 6551 4 08 47 6551 4 08 2008 by Kohler All rights reserved pss online POWER SYSTEMS SIEKMANN GMBH Auf der Haar 101 33332 G tersloh Germany Telefon 49 0 5241 300 76 0 Telefax 49 0 5241 300 76 29 email info pss online de http www pss online de KOHLER SYSTEMS KOHLER Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
82. y when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set TP 6551 4 08 Section 3 Scheduled Maintenance Note The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized distributor dealer perform generator set service Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual If the generator set operates under dusty or dirty conditions use dry compressed air to blow dust out of the alternator With the generator set running direct the stream of air in through the cooling slots at the alternator end Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the runtime hours shown on the ADC 2100 to determine when to schedule routine maintenance Service more

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