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Kohler 10ERG Portable Generator User Manual

1. 26 8 2 Advanced Digital Control ADC 2100 28 8 2 1 Configuration Mode Time Out 28 8 2 2 Controller Software Version 28 8 2 3 Adjusting the Voltage Gain and Volts HZ 29 8 2 4 Voltage Adjustment 29 8 2 5 Controller Configuration 32 Appendix A Generator Selection and Wattage Requirements A 1 Appendix B Abbreviatlons cuota eee ND aa ana A 2 Notes Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice 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 substantia
2. ETTI ey 86711 2707 Ir 61 1766 lt S 131100 ISNVANI 1113 1NV1009 NOI 193NNO9 AY311V8 49115410 10 AAI LISOd 931714 1304 13N4 92 699 3S0H QUI 116701868 aa ala mul CDO u a En Esa Eno Eno TU on Eno ED n 804 1303 dl 5 6 6 1113 110 JIVW 2 1 1 0 ISAYAXI 187621 161 131100 1SAVHX3 Sa HILIMS dOLS LYVIS YITIOYLNOD JAY YINVI19 YIY 3S0H Q 804 LIINI NYNLIY 1304 61 ete 131N1 1313 011 Se 131110 15 9 5 erl 55322 4 31 4 01 83401502 NOI LIINNOD 39V48Y31NI 4IWOLSNI Dimension Drawing Gasoline Fuel System Figure 7 1 Installation Drawing 21 TP 6335 9 04 277 10 9 627 24 7 FUEL INLET 374 14 NPT FEMALE LP FUEL SYSTEM ADV 6816B A Figure
3. 8 4 3 Exhaust Piping If Used 8 Section 5 Fuel System 9 5 1 Ka ANA ie Bananen barn ahi 9 5 1 1 FUSILES vai ri 10 5 2 Fuel Filters or Strainers 10 EP IG88S ya ki 10 5 4 Fuel Pump Lift and Fuel Consumption 11 Section 6 Electrical System 13 6 1 Electrical Connections 13 6 2 AC Load Lead Connections 13 6 3 Circuit Protection ci pel a i ia ir 15 6 3 1 Circuit Breaker Considerations 15 6 3 2 Circuit Breaker Installation 16 6 4 ADC 2100 Continuous Power Mode 17 6 5 Battery and Connections 18 6 6 Remote Connection 19 Section 7 Installation Drawing 21 Section 8 Reconnection Adjustments 25 8 1 Four Lead Reconnection
4. Figure 8 7 Output Voltage Adjustments Continued TP 6335 9 04 Reconnection Adjustments 31 8 2 5 Controller Configuration The controller configuration for each generator model is set at the factory and should not normally require changes The controller s configuration mode allows adjustment of the system parameters listed in this section Use the instructions in this section to check the configuration after installation and change them to match the settings shown in Figure 8 8 if necessary The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure over again from the beginning ifthe controller exits the configuration mode before the settings have been saved Follow the instructions in Figure 8 9 to enter the configuration mode while the engine is not running and then step through the following parameters Use the up A and down v arrow buttons to select the appropriate setting for the application Voltage frequency setting Uu Select the system voltage and frequency from the table in Figure 8 8 For system voltages not listed in the table select the setting closest to the system voltage and then adjust the output voltage to the desired level using the instructions in Section 8 2 4 Note This parameter sets the nominal system voltage and frequency To adjust the output measured voltage see Section 8 2
5. The systems major components include an engine driven fan and circulating water pump a radiator and athermostat The pump circulates water through the engine until it reaches operating temperature Then the engine thermostat opens allowing water circulation through the radiator The thermostat restricts water flow as necessary to prevent overcooling The fan blows air from the engine side of the radiator across the cooling surface Cooling System 5 Notes 6 Cooling System TP 6335 9 04 Section 4 Exhaust System WARNING Carbon monoxide Can cause severe nausea fainting or death The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building or 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
6. Installation Commercial Mobile Generator Sets KOHLER POWER SYSTEMS Model 10ERG 13ERG 15ERG NATIONALLY REGISTERED TP 6335 9 04 Table of Contents Safety Precautions and Instructions I Section 1 Introduction vu u au i ie n pi i ini 1 TA Installation Standards E Eee 1 1 2 Generator Set Specifications 1 1 3 Generator Set Operation 1 Section 2 Location and Mounting 3 2 1 General Considerations 3 2 27 ULOCANON a sa en Raden AKA usa e 3 23 Vehicle Floor Mounting 3 Section 3 Cooling 5 3 1 AlrRequirements T u iaia RR RIA ii 5 32 Block Heaters 2 fees aos bit ern leeren 5 3 3 High Water Temperature Switch 5 34 Unit Mounted Radiator Cooling 5 3 4 1 System Features 5 Section 4 Exhaust System 7 41 Planning Ares essen een 8 4 2 Clearance Requirements
7. a Move the generator set master switch to the OFF RESET position b Disconnect power to the battery charger if equipped c Disconnect the generator set engine starting battery negative lead first 2 Remove the controller from the generator set a Disconnect the engine wiring harness connector P1 plug 35 pin from the controller Disconnect the J15 and J16 connectors See Figure 6 3 b Remove the controller from the generator set housing in order to access the back of the controller 3 Remove the controller s back cover to access the jumper a Note the labels on the three leads connected to the generator set master switch for reconnection later Disconnect the leads atthe pink connectors See Figure 6 3 b Remove the cover screws and remove the controller s back cover See Figure 6 3 TP 6335 9 04 4 Locate the P7 connector near the top of the controller See Figure 6 3 Remove the jumper from pins 1 and 2 of the P7 connector If the P7 connector has three pins connect the jumper across pins 2 and 3 for storage 7 5 4 Ly 1 Engine wiring harness connector plug P1 2 Continuous power mode jumper location P7 3 J15 connector 4 J16 connector 5 Generator set master switch connectors Figure 6 3 Advanced Digital Control Connections Shown with the Back Cover Removed 5 Replace the controller s back cover and secure the cover screws 6 Reconnect the three pink connectors to
8. gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ibs Inc ind int int ext 1 0 IP 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 Industry Standard kilo 1000 kelvin kiloampere kilobyte 210 bytes TP 6335 9 04 kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm k2 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 ft3 pounds mass per cubic feet LCB line circuit
9. no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours x in the runtime hours display above denotes any number from 0 to 9 Now move the master switch to OFF RESET Figure 8 11 Save Mode after configuring generator set parameters TP 6335 9 04 Reconnection Adjustments 35 Notes 36 Reconnection Adjustments TP 6335 9 04 Appendix A Generator Selection and Wattage Requirements General Wattage Requirements Consider the total wattage requirements lights motors appliances when selecting a generator set or when sizing wattage usage in which available space and construction limit the size of the generator set Motor Loads When figuring generator set capacity requirements for loads that include electric motors consider the high current demanded by the motors during startup The inrush or starting current is typically 2 to 3 times higher than that required when the motor reaches normal operating speed Allow a reserve for inrush demands plus other loads that could be on the line as the electric motor starts Use Figure 1 as a guide when selecting generator set capacity requirements involving motor loads Starting Inrush Watts Running Watts Figure 1 Motor Requirements Appliance Loads Generator sets often furnish AC for appliances such as TVs stereos and electric water
10. other openings Do not use flexible tail piping because it could crack and allow lethal exhaust fumes to enter the vehicle Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety ofthe vehicle s occupants install a carbon monoxide detector Consult the coach builder or dealer for approved detector location and installation Inspectthe detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manufacturer s instructions and keep the detector operational at all times TP 6335 9 04 Fuel System A WARNING Y Explosive fuel vapors 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 vib
11. 7 2 Dimension Drawing LP Fuel System 22 Installation Drawing TP 6335 9 04 ADV 6816C A YOLVIGVY JO LNOYS NI MIA 01 12 45 YIV 3333 OO EI 0 NI OS 952 OS 4991 30013 INIWLYVdAWOD NI 81V NIN 96 2 GL 13110 4 334I HIGIM 13H OV Ge H 3 3 0 0 X 1 LS 277 9 1 X INO YIY JOLVIOYY gt SITOH ONILNNON tve 986 X8 Fi IN3NLUVAWOI TIVM LNINIUYdNOI dAl fL 1 vr 117761 88 VIUV LIINI ILITAWOD INNOYV YIYY IE Il 077 1NINLIVANOO ILITAWOD ONNOYY OL 131 1 IYV INIWLYV dW0D i 7 YOLVYINI9 1938 OL HIV LEL 621 Ori YOLYY3N39 1V3S Figure 7 3 Dimension Drawing Floor Template Installation Drawing 23 TP 6335 9 04 Notes 24 Installation Drawing TP 6335 9 04 Section 8 Reconnection Adjustments WARNING Qe KO Accidental starting Can cause severe injury or death Disconnectthe 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 b
12. Figure 8 9 Configuration Mode system voltage unit configuration and engine type parameters 34 Reconmnection Adjustments TP 6335 9 04 Pressing the up arrow key at the Adnc display See Figure 8 9 puts you into the Advanced Configuration Mode Press NA or To set the engine data input type To enter battery voltage selection mode Ne N To toggle between 12 and 24 VDC To enter communications selection mode To set the communications parameter or N To enter SAVE mode Go to Figure 8 11 SIAIVIE Note Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed x denotes any number from 0 to 9 Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position Figure 8 10 Advanced Configuration Mode engine data input types battery voltage and engine communications There are 3 options when the display says SAVE Press To return to the first parameter system voltage frequency Uu to check or change settings before saving See Figure 8 9 Or To save changes To discard changes without saving Z Yes or
13. RUN position The generator set engine will not start Wait about 5 seconds until the display shows the program version number The number may be different than the one shown here Press the down arrow key and then the up arrow key 3 times to enter the configuration mode This is the controller password Now release the Select button Press To set the voltage frequency setting for 60 Hz models sx or To step to the next parameter unit configuration Uc 22 To set the unit configuration setting to Uc02 if necessary To step to the next parameter engine type Ec NGA or To set the engine type if necessary To step to the next parameter advanced configuration mode or save mode selection Now either save your settings or enter the Advanced Configuration Mode to set the engine data inputs battery voltage and communications Press To enter advanced configuration mode Go to Figure 8 10 OR or To proceed to the save mode without entering the advanced configuration mode Go to Figure 8 7 Note Shaded boxes show which number in the controller display changes when the up or down arrow key is pressed x denotes any number from 0 to 9
14. Two Dip Tubes in Fuel Tank Note Supply the fuel using a two dip tube arrangement if the generator shares the vehicle engine fuel tank Consult an authorized Kohler service distributor dealer for further fuel system installation information Fuel System 9 5 1 1 Fuel Lines Note Keep fuel lines away from the exhaust system Routing fuel lines Take care when routing the fuel line from the fuel tank to the generator set Keep the fuel lines as short as possible but maintain adequate clearance from the exhaust system Route the fuel lines along the frame or undercarriage never route the fuel lines inside the habitable area of the vehicle Locate the fuel lines with the entry point near the fuel pump See Section 5 4 for the fuel pump lift Sizing fuel inlet and return lines Size the fuel line to handle the flow of fuel and to withstand road shock and year round climate conditions Use steel tubing as the codes require Use 8 mm 0 31 in ID tubing with a 230 mm 8 in minimum flexible section to allow free movement of the generator set Flexible hose sections If a metal fuel line draws fuel from the fuel tank install a flexible hose section to connect the metal line to the fuel pump The flexible section allows generator set vibrational motion during operation See Section 7 for the fuel inlet and the fuel return connection points Note Gasoline fueled engines require a type A1 hose 5 2 Fuel Filters or Strainers Gasol
15. are mechanically attached Leads 11 12 are for different phases never connect them LO Neutral LO 2 gt GRD Ground gt gt 1 Load Side O Single Pole Circuit Breaker 4 3 2 1 Stator Leads 60 Hz LO L1 100 120 Volt LO L2 100 120 Volt Figure 8 2 100 120 Volt 2 Wire Configuration LO Neutral LO Ground gt GRD gt L2 gt 1 Load Side O O Factory Two Pole Line Circuit Side Breaker 100 120 200 240 Volt 1 3 Wire 4 3 2 Stator Leads 60 Hz LO L1 100 120 Volt LO L2 100 120 Volt L1 L2 200 240 Volt Figure 8 3 100 120 200 240 Volt 3 Wire Configuration TP 6335 9 04 200 240 Volt Configurations The 200 240 volt configuration does not use a jumper lead If the unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 8 1 for location LO Neutral LO OGound gt GRD Ground gt 11 Load Side O Line Single Pole Side Circuit Breaker Tape to insulate from ground ao 200 220 240 Volt Stator Leads 2 Wire 60 Hz LO L1 200 240 Volt Figure 8 4 200 220 240 Volt 2 Wire Configuration for Models with ADC 2100 TP 6335 9 04 Reconnection Adjustments 27 8 2 Advanced Digital Control ADC 2100 The model 10 13 15ERG generator sets use the ADC 2100 The ADC 2100 uses password protected menus for generator ou
16. breaker LCD liquid crystal display Id shd load shed LED light emitting diode Lph liters per hour Lpm 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 108 when used with SI units male m3 cubic meter m3 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 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 between overhauls mtg mounting TP 6335 9 04 MW mw ur N norm NA nat gas NBS NC NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns oc OD OEM OF opt OS OSHA OV oz p pp PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi pt PT PTO PVC qt qty rad RAM RDO ref rem RFI RH RHM rly megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrica
17. or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Safety Precautions and Instructions Ill Welding the generator set Can cause severe electrical equipment damage Before weldingthe 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 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 or 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 injury 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 opened Backfeed conn
18. poisonous gas present in exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e 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 not sit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air TP 6335 9 04 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 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 Consult the coach builder or dealer for approved detector location and installation Inspect the detector before each generator set use In addition to routine exhaust system inspection test the carbon monoxide detector per the manuf
19. setting to Cn01 if the optional Remote Digital Gauge is used Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position TP 6335 9 04 Parameter Definition Unit s system voltage and frequency Single phase 60 Hz 120 240 VAC Unit configuration Mobile generator set Engine type 10 13 15ERG Engine data input types All digital inputs No magnetic pick up Digital Low coolant level and low oil pressure Analog Low coolant temperature Digital Low coolant level and low coolant temperature Analog Low oil pressure Digital Low coolant level Analog Low coolant temperature and low oil pressure Digital Low coolant temperature and low oil pressure Analog Low coolant level Digital Low oil pressure Analog Low coolant level and low coolant temperature Digital Low coolant temperature Analog Low coolant level and low oil pressure All analog inputs Battery voltage Battery voltage 12 VDC Communications No CAN communications SAE J1939 Used for ADC remote digital gauge Figure 8 8 Controller Parameters TP 6335 9 04 Future CANbus Reconnection Adjustments 33 Controller Configuration Mode Use with Figure 8 8 Controller Parameters Hold the Select button Display Move the generator set master switch to the
20. the battery used to start the generator is not the same as the vehicle TP 6335 9 04 Using a Separate Battery for the Generator Set Batter Vehicle Frame Positive View B Ground Strap Vehicle Frame Using the Same Battery as the Vehicle Engine Battery Positive Battery Negative to Vehicle Frame Figure 6 6 Battery Connection Details TP 6335 9 04 6 6 Remote Connection Kohler Co offers several remote panels for connection to the generator set Contact your local Kohler distributor dealer for detailed descriptions See Figure 6 7 for the location of the remote interface connection to the generator set junction box Kohler Co also offers wiring harnesses in various lengths with a connector keyed to the junction box connector A pigtail harness is also offered which includes the appropriate connector on one end and has pigtails that the installer can use to connect to a customer supplied start stop switch or separate lights and hourmeter Consult wiring diagrams ADVs and instruction sheets for connection information details These models use a 12 pin connector for the remote interface connection See Figure 6 7 for the connector s location See Figure 6 8 for the correct customer supplied plug and pin part numbers Non Service Side View GM34867C 1 Remote interf
21. the generator set master switch 7 Reconnect the J15 and J16 connectors 8 Reconnect the engine wiring harness connector P1 plug 35 pin to the controller 9 Reinstall the controller in the generator set 10 Reconnect the generator set engine starting battery negative lead last 11 Reconnect power to the battery charger if equipped 12 Place the generator set master switch in the AUTO position Electrical System 17 6 5 Battery and Connections A WARNING Sulfuric acid in batteries Can cause severe injury or death Use protective goggles and clothes Battery acid can cause permanent damage to eyes burn skin and eat holes in clothing Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batterie
22. voltage stability gain in smaller increments To enter volts Hz adjustment mode To raise or lower the volts Hz 00 low 09 high i 9 Continued on Figure 8 7 669 Shaded boxes show which character in the controller display changes for each adjustment x in the examples above denotes any number from 0 to 9 The actual values may vary from model to model Figure 8 6 Output Voltage Adjustments 30 Reconnection Adjustments TP 6335 9 04 Continued from Figure 8 6 Display To enter SAVE mode SAVE Note Be sure to save your settings before exiting the configuration mode The controller reverts to the last saved settings when the master switch is moved to the OFF RESET position There are 3 options when the display says SAVE SA Press To return to the first parameter coarse voltage adjustment to check or change settings before saving See Figure 8 6 Or To save changes or To discard changes without saving Yes or no flashes when the up or down arrow is pressed and then the controller exits the configuration mode The display returns to the runtime hours Now move the master switch to OFF RESET x in the examples above denotes any number from O to 9 The actual values may vary from model to model
23. 4 Unit configuration Uc This parameter sets the generator set type marine standby or mobile The setting for the 10 13 15ERG is Uc02 mobile 32 Reconnection Adjustments Note The engine type EC and the engine data input type ED are factory set and should only be changed by an authorized Kohler dealer distributor Incorrect settings will make your unit non functional Engine configuration Ec The engine configuration must match the generator set engine type The engine configuration setting for the 10 13 15ERG is Ec03 Advanced configuration mode Adnc The data input types battery voltage and communications setting can be changed in the advanced configuration mode Press the up arrow button when Adnc is displayed to enter the advanced configuration mode Engine data input types Ed This setting defines the type of senders used on the generator set engine Setting the Ec parameter automatically sets the Ed parameter The remote digital gauge requires the optional analog oil pressure sender Install the optional sender and change the Ed parameter to Ed02 Battery voltage Bt This setting toggles between 12 and 24 VDC for the engine starting battery voltage The 10 13 15ERG models use a 12 volt battery Bt12 Communications setting Cn This setting allows the user to set the controller for communication with optional meters The 10 13 15ERG models are factory set for no CAN communications Cn00 Change this
24. Adjust the voltage stability gain parameter 2P to minimize light flicker 5 Readjust the voltage if necessary 6 Readjust the voltage stability gain parameter 2P if necessary 7 Readjust the voltage parameter 1P if necessary 8 Stop the generator set Reconnection Adjustments 29 Output Voltage Adjustment Mode Display Move the generator set master switch to the RUN position The generator set Xxx x engine starts and the controller display shows the engine runtime hours Hold Wait about 5 seconds until the display changes from runtime hours x to the program version number Press the down arrow key and then the up arrow key 3 times to enter the adjustment mode This is the controller password The controller is now in the voltage coarse adjustment mode Press pe To raise or lower the voltage in large increments approximately 5 7 volts per step To enter fine voltage adjustment mode To raise or lower the voltage in smaller increments approximately 0 5 0 7 volts per step To enter coarse voltage stability gain adjustment mode To raise or lower the voltage stability gain in large increments To enter fine voltage stability gain adjustment mode To raise or lower the
25. Note Circuit breaker ampere rating and availability are subject to change 6 3 1 Circuit Breaker Considerations Mounting location Mount the circuit breaker in the generator set s junction box Sizing Use the generator set voltage frequency configuration to determine the circuit breaker amperage If the circuit breaker was sized for one voltage configuration and later the generator set is reconnected to a different voltage change the circuit breaker accordingly to provide optimum protection Have a qualified electrician or technician install circuit breakers and reconnect the generator set Comply with all governing standards and codes WARNING bao Qe LO x 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 TP 6335 9 04 Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe 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
26. ace connector Figure 6 7 Remote Interface Connector Kohler Part No 229998 241618 GM29252 GM29507 GM28769 Component Amp Part No Plug 350735 1 Pin 350218 6 Cable Seal 794280 1 Interface Seal 794279 1 770377 1 Cavity Plug Figure 6 8 Connector Components Note Gauge senders Gauge senders are available for most generator sets If using customer supplied gauges be sure they are compatible with generator set senders Contact an authorized Kohler service distributor dealer Gauges and senders are available as service items from an authorized Kohler service distributor dealer Electrical System 19 Notes 20 Electrical System TP 6335 9 04 Section 7 Installation Drawing 67941 699 ABILIVO lt a 0 61 822 8 021 826 NO 193NNO9 3JAILV9IN WALSAS Tans 3INNMOSYOI 943 61 01 LER III ADV 6816A A 943 SI CL vy 9 11 1303 Ip LE 67066 831113 110 INIYA NIYYA 110 17811 697 1303 6 L 202 201 434V388 LIV 2812 1VNO LdO
27. acturer s instructions and keep the detector operational at all times WARNING m4 5 NE wara 5 Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 or 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 Exhaust System 7 4 1 Planning Carefully planthe generator exhaust systemto ensure a safe quiet installation Verify that the installation complies with all state and local requirements and applicable articles of the codes listed at the beginning of this manual 4 2 Clearance Requirements Kohler Co recommends a minimum clearance of 38 mm 1 1 2 in between the exhaust system parts and the fuel system the electrical system and all combustible components to protect the generator set components and to avoid igniting adjacent combustible materials 8 Exhaust System 4 3 Exhaust Piping If Used Route the exhaust piping to maintain minimum clearances and to minimize exhaust piping bends Use a tail pipe as short as possible with as few bends as possible to reduce back pressure Design the exhaust piping to prevent excessive back pressure of the unit mounted mu
28. and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
29. and successful operation of a mobile power system depends primarily on the installation Use this manual as a guide for installing the mobile generator set Refer to the operation manual for operating instructions 1 1 Mobile generator set installations must comply with the Kohler detailed installation instructions following and state and local requirements Installation Standards The installer is responsible for improper installations resulting in penalties from noncompliance with California Air Resources Board CARB or Environmental Protection Agency EPA emission standards as well as state and local requirements 1 2 Generator Set Specifications Refer to the model s specification sheet for details Use the spec sheet as a guide for planning the installation Use the current dimension drawing and wiring diagrams TP 6335 9 04 Section 1 Introduction 1 3 Generator Set Operation After the installer attaches the generator set to the vehicle s frame and makes connections do the following to make the generator set operational e Attach the exhaust system e Add radiator coolant e Add oil to the engine crankcase until the dipstick indicates full e Connect the fuel inlet and fuel return lines for gasoline models or fuel inlet line for LP models e Connect the remote switch if equipped e Connect the load leads e Connect the battery terminals Introduction 1 Notes 2 Introduction TP 6335 9 04 2 1 General Co
30. ards and electrical enclosures are in place WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers arein place TP 6335 9 04 WARNING G Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when using power tools hand tools or compressed air Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware 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 6335 9 04 Notice NOTICE This generator set has been rewired from its nameplate voltage to NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the na
31. attery WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seekimmediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permit flames or sparks to occur near a ba
32. attery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas 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 TP 6335 9 04 WARNING Hazardous voltage Moving rotor 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 Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water oron wet ground because these conditions increase the risk of electrocution Reconnection Adjustments 25 8 1 Four Lead Reconnection The following drawings illustrate the reconnection of four lead ge
33. d 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 containerto catch fuelwhen draining the fuel system Wipe up spilled fuel after draining the system TP 6335 9 04 Section 5 Fuel System 5 1 Gasoline Fuel system design Design the generator set gasoline fuel system to operate independently of the vehicle engine fuel system if the operator may operate both engines simultaneously Kohler Co recommends using separate fuel tanks if possible however using separate fuel tanks is usually impractical because of space restrictions In most installations both engines operate off a common tank with a separate dip tube arrangement as shown in Figure 5 1 The dip tube arrangement prevents the larger engine from starving the smaller engine of fuel The generator set dip tube is generally shorter than the vehicle dip tube to stop the generator set before the vehicle engine runs out of fuel With the dip tube arrangement the generator may not get fuel during a low fuel supply situation Tee arrangement Do not use the tee arrangement Do not tee into the fuel supply or return line of fuel injected systems 5605613 1 Fuel line to the generator set 2 Fuel line to the vehicle engine Figure 5 1
34. ections 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 IV Safety Precautions and Instructions Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under Hot Parts 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 WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to c
35. es 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 cm square centimeter sq in square inch ss 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 universal US undersize underspeed UV ultraviolet undervoltage V volt VAC volts alternating current VAR voltampere reactive VDC volts direct current VFD vacuum fluorescent display VGA video graphics adapter VHF very high frequency w watt WCR withstand and closing rating w with w o without wt weight xfmr transformer Appendix A 3 TP 6335 9 04 2004 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US
36. et for air requirements The air intake silencer cleaner provides combustion air to the engine See Figure 3 1 for allowable intake restriction The engine generator performance will be adversely affected ifthese guidelines are neglected Follow these guidelines to optimize generator set performance Model Normal Intake Restriction 10 13 15ERG 0 06 psi 0 50 in H20 Figure 3 1 Intake Restriction 3 2 Block Heaters Block heaters are available as installed accessories on these generator sets Use block heaters in applications where the generator set is subject to temperatures below 16 C 60 F Connect the block heater to a power source that is energized when the generator set is not running Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fillthe cooling system before turning on 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 TP 6335 9 04 Section 3 Cooling System 3 3 High Water Temperature Switch Each generator set includes a high water temperature shutdown switch that automatically shuts down the set if operating temperatures climb too high Follow the guidelines described in Section 3 1 to prevent shutdowns 3 4 Unit Mounted Radiator Cooling The generator set is equipped with a unit mounted radiator common cooling system 3 4 1 System Features
37. ffler if equipped See Figure 4 1 for the allowable exhaust back pressure Do not apply weight or pressure to the unit mounted muffler otherwise premature exhaust system damage will occur Adding exhaust pipe extensions to the unit mounted muffler may cause excessive vibration and noise transmitted to the vehicle For generator sets without a unit mounted muffler install a muffler made of aluminized steel or other corrosion resistant material of welded or crimped construction Allowable Exhaust Back Pressure lt 10 2 kPa 3 0 in Hg Model 10 13 15ERG Figure 4 1 Allowable Exhaust Back Pressure TP 6335 9 04 WARNING gt b Explosive fuel vapors 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 notreplace flexible fuellines with rigidlines Use flexible sections to avoid fuel line breakage cause
38. heaters Except for the resistance type loads such as the water heater the requirements for appliances are usually low Do not overlook such loads when figuring the total requirements Allow a reserve capacity for anticipated appliance loads to avoid overloading a generator set Lighting Load To calculate the lighting load add the wattage of each generator set operated lamp Note that not all of the lights or lamps are on the generator set AC circuit some are DC powered by a 12 volt battery Ensure that the calculated total wattage includes only lights actually on the generator set AC circuit Air Conditioners The starting characteristics of air conditioners vary greatly for example one 12 000 Btu unit has lower starting requirements than a 10 000 Btu unit of another variety When using only one unit there is usually no starting problem provided thatthe lighting and appliance load is not too high when starting the generator set Simultaneous starting of two air conditioning units however can present problems if the generator set capacity is marginal Because ofthe variation in starting characteristics among air conditioners this publication makes no statements regarding multiple motor starting capabilities of the generator set covered Consider delayed starting or the use of easy starting devices on air conditioner units whenever simultaneously starting more than one motor See Figure 2 for typical air conditioner requiremen
39. ine model generator sets are shipped with a fuel filter No additional fuel filter or strainer is required ADV 6450 E 1 Fuel filter Figure 5 2 Fuel Filter Location Gasoline Models 10 Fuel System 5 3 LP Gas LP fuel hose Use a flexible fuel hose designated for use with LP fuel between the generator set and the main fuel tank See Section 7 for the fuel inlet connection point Take care when routing the fuel line Maintain a 51 mm 2 in clearance between the fuel line and any bare exhaust component Do nottie any electrical wiring to the fuel line If the flexible fuel line passes through sheet metal install grommets or clamps to prevent hose abrasion The LP fuel system shall conform to Section 3 6 4 of NFPA58 Storage and Handling of Liquified Petroleum Gases For an LP gas system use UL classified pipe joint sealing compound to prevent dangerous fuel leaks Use a sealing compound approved for use with LP gas Apply UL classified sealing compound at all fuel line pipe joints Use flexible fuel lines in areas where vibration and or movement of connected components is likely such as the main fuel line to the generator set Use seamless steel tubing wherever long main fuel lines are required Testing the fuel system After all of the LP connections have been completed pressure test the enti
40. l 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 6335 9 04 Accidental Starting A WARNING Pak 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 B
41. l 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 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 51 Systeme international d unit
42. ludes insulation boots Note See Figure 6 2 for electrical connections Make the recommended connections for the following three reconnection systems using circuit breakers Two pole circuit breaker with a single voltage system example 120 volt 3 wire Attach stator leads marked 2 and 4 to the side of the circuit breaker marked LINE Install the jumper lead across the LINE side of the circuit breaker terminals see Section 8 Attach stator leads 1 and 3 to LO Two pole circuit breaker with a dual voltage system example 120 240 volt 3 wire Attach stator leads marked 1 and 4 to the side ofthe circuit breaker marked LINE Do not use a jumper Electrical System 10 11 12 1 lead see Section 8 Attach stator leads 2 and 3 to LO Single pole circuit breaker with a single voltage system example 240 volt 2 wire Attach the stator lead marked 1 to the side of the circuit breaker marked LINE see Section 8 Bolt together leads 2 and 3 and tape to insulate from ground Attach the stator lead marked 4 to LO Connect the stator lead s used for neutral connection to the LO stud See Figure 6 2 Connect the side of the circuit breaker marked LOAD tto the transfer switch or vehicle Attach insulation boots to the black leads if the kit includes insulation boots With a single pole circuit breaker use one black lead L1 With a two pole circuit breaker use two black leads L1 and L2 Connect the neut
43. meplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Hardware damage 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 NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 NOTICE This generator set does not comply with United States Coast Guard USCG requirements and must 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 be ignition protected when used in a gasoline fueled environment Safety Precautions and Instructions V Notes VI Safety Precautions and Instructions TP 6335 9 04 All information in this publication represents data available atthe time of print Kohler Co reserves the right to change this literature and the products represented without incurring obligation The safe
44. nerator sets In all cases conform to the National Electrical Code NEC NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer 100 120 Volt Configurations If the installation requires a factory two pole circuit breaker do not connect the load side terminals of the circuit breaker See Figure 8 1 If the installation requires a 100 120 volt 2 wire system use a single pole circuit breaker See Figure 8 2 When connecting stator phase leads together size the output lead L1 to handle the amperage Use a jumper lead on the line side of the circuit breaker to balance the load of the generator set LO Neutral LO Ground 3 GRD gt gt L2 Load Side Two Pole Line Circuit Side Breaker Jumper Lead Figure 8 1 100 120 Volt 3 Wire Configuration 26 Reconnection Adjustments 100 120 200 240 Volt Configurations The 100 120 200 240 volt configuration does not use ajumper lead Ifthe unit was originally wired for straight 100 120 volt 3 wire remove the jumper lead see Figure 8 1 for location Select a two pole circuit breaker Application of two single pole circuit breakers does not conform to NEC requirements for supplying a 200 240 volt load even if the breakers
45. nnel 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 Electrical System 15 6 3 2 Circuit Breaker Installation Note Wire material Note Wire protection Install Use stranded copper for all wiring Use wire gauges and insulation conductor temperature ratings sheath stripping conductor support and protection conductor terminals and splices and overcurrent protection circuit breakers fuses that conform to standards and codes Use rubber grommets and cable ties as necessary to protect and secure the wiring from sharp objects the exhaust system and any moving parts Turn the generator set off and disconnect the generator set engine starting battery negative lead first Remove the screws and remove the access cover Remove the screws and nuts to remove the circuit breaker cover plate Save the mounting hardware Install the circuit breaker from the inside of the cutout panel and mount it using the existing screws Position the circuit breaker with ON in the normal upright position or to the left side Cover the cutout opening if applicable with the circuit breaker coverplate Use the existing screws and nuts See Section 8 for voltage reconnection insulation boots over the stator lead terminals if the kit inc
46. nsiderations Consider the following items concerning the generator set and Section 2 2 for the proposed location 1 Select a generator set having adequate capacity to handle the electrical load 2 Design the fuel system to prevent fuel starvation of the main or generator set engine 3 Ensure that the exhaust system meets all safety requirements after installation 4 Ensure compatibility of all electrical systems battery load and remote switch with the vehicle s electrical systems 2 2 Location Note This generator set is not designed for installation in a compartment or enclosure Before making final plans for locating the generator set ensure the following 1 The location has sufficient room to maintain required minimum clearances 2 The location provides enough air flow to allow required cooling and combustion 3 The location can support the generator set weight 4 The location provides ample room for routine service of the generator set s engine controller cooling system and fuel system components See the current generator set specification sheet or Section 7 of this manual for generator set dimensions and weights For angular operating limits consult the operation manual TP 6335 9 04 Section 2 Location and Mounting 2 3 Vehicle Floor Mounting Install the Kohler mobile generator set on an open vehicle s floor or truck bed Follow the guidelines below Contact an authorized Kohler
47. ntact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of allpower sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water oron wet ground because these conditions increase the risk of electrocution TP 6335 9 04 Voltage Adjustment Procedure Note Refer to Figure 8 6 and Figure 8 7 for instructions to adjust the voltage using the ADC 2100 1 With the generator set off connect a digital multimeter to the output leads or an electrical outlet on the load side of the generator set Set the meter to measure AC voltage 2 Start the generator set by moving the generator set master switch to the RUN position 3 Use the ADC controller to adjust the voltage parameter 1P until the output voltage reaches the desired value See Figure 8 5 for the approximate change in voltage per step in parameter 1P Voltage Change per Step VAC Fine Adjust Measured Voltage VAC Coarse Adjust 85 132 5 0 5 180 251 7 0 7 Figure 8 5 Voltage Adjustment 4
48. nter the configuration mode after the Select button has been pressed and held for about five seconds For example 01 00 will be displayed for software version 1 00 TP 6335 9 04 8 2 3 Adjusting the Voltage Gain and Volts Hz After setting the system voltage check the output voltage and adjust if necessary using the following procedures Follow the instructions in Figure 8 6 to adjustthe voltage gain and volts Hz while the engine is running An x in the Display column in Figure 8 6 indicates a number from O to 9 Use the up arrow to increase a setting or the down arrow to decrease the setting Note Save your settings before configuration mode exiting the Pressing the Select button when SAVE is displayed returns to the first parameter voltage adjust 1P Voltage changes are lost if they are not saved before the generator set shuts down The generator set continues to run with the new settings until it shuts down but then reverts to the previous settings at the next startup if the changes have not been saved Note A digital multimeter is required for these adjustments 8 2 4 Voltage Adjustment WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not co
49. 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 A 2 Appendix CG CID CL cm CMOS cogen Com conn cont CPVC crit CRT CSA CT Cu cu 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 El EO EMI 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 As
50. ool Release pressure from the cooling system before removing the pressure 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 ifthe generator set has a coolant recovery tank Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation 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 or 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 for the drain opening Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all gu
51. or death Do not smoke or permit flames or sparks near the carburetor 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 carburetor Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Il Safety Precautions and Instructions Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e 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 andremain 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 ofbreathing 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
52. ral white lead to the LO stud Connect the equipment ground green lead to the GRD stud See Figure 6 2 Replace the circuit breaker box access panel Reconnect the generator set engine starting battery negative lead last For voltage adjustments refer to the procedure in Section 8 2 Generator End View GM34867A A Neutral LO connection 2 Ground GRD connection Figure 6 2 Electrical Connections TP 6335 9 04 6 4 ADC 2100 Continuous Power Mode Jumper A jumper on connector P7 on the back of the controller causes the controller to remain powered at all times Controllers are shipped from the factory with the jumper connected Disconnecting the jumper causes the controller to automatically power down 48 hours after the generator set shuts down See the wiring diagram and schematic drawing in the operation manual Note Be advised that the ADC consumes 250 mA when the master switch is in the AUTO position with the jumper connected If you do not plan to use your generator set for a long period of time Kohler recommends moving the master switch to the OFF RESET position 0 mA draw Remote communications require an active powered up controller Note For most applications it is not necessary to disconnect the continuous power mode jumper Procedure to disconnect the continuous power mode jumper optional 1 Prevent the generator set from starting
53. ration Donotoperatethe generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions 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 TP 6335 9 04 LP gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble 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 noi
54. rce See Figure 6 1 Electrical System 13 Note Transfer switch Use atriple pole double throw transfer switch rated for the calculated load ofthe AC Vehicle Circuit vehicle to transfer the load from one source to the other Install a ground fault circuit interrupter in the wiring system to protect all branch circuits Note AC load circuit protection Protect the AC load circuit ofthe generator set against overloading or short circuiting with a circuit breaker s Ground Fault Circuit Protection Note For standby service connect output of the generator to a suitably rated transfer switch in accordance with the Canadian Electrical Code Part 1 120 Volt AC Vehicle Circuit Q O Bos LO Ground Fault Circuit Protection 240 Volt Figure 6 1 Transfer Switch Connections 3 Wire AC Circuit 14 Electrical System TP 6335 9 04 6 3 Circuit Protection The AC circuit breaker protects the generator set from extreme overload The AC circuit breaker trips when it detects a fault in the output circuit For application and selection information contact an authorized distributor dealer After correcting the fault resetthe AC circuit breaker by placing it in the ON position Restart the unit See an authorized service distributor dealer for AC circuit breaker ratings The units voltage configuration determines the circuit breaker selection
55. re system to 6 8 ounces 10 14 inches water column Test the connections for leakage with soapy water or bubble solution Do not use solutions that contain ammonia or chlorine since the solution will not bubble for an accurate leakage test The gas supply pressure should not exceed 6 ounces To check the inlet pressure remove the plug on the fuel inlet for the gas regulator Insert an ounce pressure gauge or manometer Adjust the operating pressure to 4 6 ounces or 7 11 inches water column adjust the inlet pressure on the primary regulator Note Fuel leakage could cause an explosion After making all LP gas connections pressure test the entire system to 6 8 ounces 10 14 inches water column Note Gas pressure above 10 ounces can result in non operation of the gas valve TP 6335 9 04 5 4 Fuel Pump Lift and Fuel Consumption See Figure 5 3 for the fuel pump lift capability Consult the current generator set specification sheet for the generator set fuel consumption rates Do not exceed 3 1 2 psi fuel pump pressure to the carburetor TP 6335 9 04 Note Fuel system alterations may adversely affect emissions levels Fines resulting from higher than allowable emissions levels are the responsibility of the user Fuel Pump Lift Model m ft 10 13 15ERG 0 9 3 Figure 5 3 Fuel Pump Lift Capability Max Gasoline Models Fuel System 11 Notes 12 Fuel System TP 6335 9 04 WARNING Hazardous
56. s to prevent accumulation of explosive gases Starting battery A separate 12 volt battery is recommended for the generator set With a separate battery the battery can be installed closer to the generator set and the cable length can be minimized to eliminate voltage drop See Figure 6 4 for the minimum cold cranking amps CCA battery recommendation Model CCA 10 13 15ERG 600 Figure 6 4 Battery Recommendation 18 Electrical System Lengths and sizes See Figure 6 5 for the lengths and recommended sizes of the battery cables Distance from battery to generator set Required Battery Cable AWG Gauge Minimum 2 5 m 8 3 ft 6 5 m 16 4 ft 2 Figure 6 5 Battery Cable Sizing Recommendations 10 15ERG Models Cable connections See Section 7 for the battery positive and negative connection points Refer to Figure 6 6 View A for cable connections Note that installers must connect a ground strap between the ground lug on the generator set and the frame of the vehicle with this arrangement For installations where the starting battery for the vehicle engine must also be used for starting the generator engine ground the negative battery terminal to the vehicle frame and connect a heavy gauge 4 ground strap to the ground lug on the generator set to the vehicle frame as illustrated in Figure 6 6 View B Note Ensure a ground connection between the generator and the vehicle frame even if
57. se can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock WARNING Hazardous voltage Moving rotor 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 opened CAUTION 2 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 Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads
58. service distributor dealer with your specific application questions Minimum clearance Allow clearance for vibration and cooling during operation Minimum clearance for Vibration top front rear and sides is 38 mm 1 1 2 in Keep the radiator end unobstructed for proper air flow Additional clearance Generator set service requires more clearance than 38 mm 1 1 2in Design the mounting location to allow for sufficient room to easily remove the generator set to perform major service Securely fasten the generator set to avoid unwanted movement from vibration and road shock Attach the generator set vibromounts directly to the vehicle s frame See Figure 2 1 for vibromount installation la Vibromount 84 9 DIA _ 2MTG HOLES Vibromount Side View 1 2 3 T Mounting Location Engine end Generator end Purple 2 White 2 ADV6816 Lock nut Flat washer 7 16 x 1 Generator set frame Vibromount Vehicle frame Flat washer 13 32 x 2 Screw 3 8 16 x 2 1 4 Figure 2 1 Vibromount Installation Location and Mounting 3 Notes 4 Location and Mounting TP 6335 9 04 3 1 Air Requirements Air flow around the generator set is necessary for adequate cooling See the current generator set specification she
59. sociation 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 e 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 forth exhaust external Fahrenheit female fglass FHM fl oz flex freq FS ft ft Ibs ft min g ga gal gen 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
60. switch remote start stop switch or engine start command from a remote computer WARNING Hazardous voltage Moving rotor 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 Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution 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 or repairs Remove all jewelry before servicing the equipment Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury 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 opened Backfeed connections can cause severe injury or death to utility personnel working on power lines and or perso
61. te the wiring directly below or near the fuel system parts or the oil fill tube The following paragraphs cover some other points to consider when making AC load connections Note At the time of installation make the wiring connections accessible for inspection and service TP 6335 9 04 Section 6 Electrical System 6 2 AC Load Lead Connections Routing Each generator set has four color coded load leads The black leads L1 and L2 are hot the white lead LO is neutral and the green lead is the hazard ground See Section 8 for the AC load lead connections Route the load leads directly from the junction box to the vehicle AC circuit or transfer switch connection Route the load leads of all installations through flexible conduit from the generator end bracket to the junction box Keep the load lead junction box accessible for service and inspection Note Keep the load lead circuit away from the generator fuel and exhaust system components Note Use field supplied wiring capable of withstanding temperatures of 75 C 167 F Connect the neutral of the AC circuit in the vehicle to lead LO white or gray Ifthe vehicle uses equipment ground type plugs and receptacles 3 pronged connect the green wire to the U shaped pin On vehicles that also have provisions for using an outside AC power source completely isolate the neutral as well as the hot black leads from the generator set when switching power to the outside sou
62. ting the battery Reconnect the negative lead last when an Train Al ti the batt N personnel on fire extinguisher Bene male ever operation and fire prevention connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together procedures Exhaust System WARNING Engine Backfire Flash Fire WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be Fire leakproof and routinely inspected Can cause severe injury or death 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 exhaustfumes 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 or 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 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
63. tput adjustments and controller configuration This section contains instructions for using the ADC s password protected menus to check and adjust the generator output and controller configuration The controller configuration and generator set output are factory set and should not require field adjustment under normal circumstances Check and adjust the configuration and or output in the following cases e Check and adjust the controller configuration and generator output after generator set reconnection to a different voltage e Check the controller configuration when troubleshooting generator set problems e Check and adjust the generator set output after installation if the voltage requires adjustment for a particular application 28 Reconnection Adjustments 8 2 1 Configuration Mode Time Out The controller will automatically exit the configuration mode without saving any changes after about 1 minute if no buttons are pressed Start the configuration procedure over again from the beginning if the controller exits the configuration mode before the settings have been saved 8 2 2 Controller Software Version Number The application software for controller operation is factory loaded onto the Advanced Digital Control At times it may be necessary to check the software version number for troubleshooting purposes The controller s application software version number is displayed on the LED screen during the key sequence to e
64. ts The requirements vary among different manufacturers Air Conditioner Size Btu 9 000 12 000 16 000 Voltage 115 230 115 230 115 230 Full load amps 9 9 5 0 11 8 6 3 16 3 8 0 Rated load amps 5 7 0 3 5 8 9 4 8 13 0 6 2 Locked rotor amps 50 0 31 0 75 0 36 0 Starting inrush watts 5750 7130 8630 8280 Running watts 1020 1100 1500 1430 Figure 2 Typical Air Conditioner Requirements 60 Hz TP 6335 9 04 Appendix A 1 Appendix B Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC 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 blk htr BMEP bps br BTDC Btu Btu min C cal CARB CB cc CCA cow CEC cfh cfm ampere after bottom dead center alternating current analog to digital analog to digital converter adjust adjustment advertising dimensional drawing anticipatory high water temperature American Iron 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
65. ttery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Safety Precautions and Instructions Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnec
66. voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury 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 opened 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 6 1 Electrical Connections Have qualified electricians make electrical connections Connections to the load leads battery and remote switch panel complete the installation To prevent unintentional starting make final connections to the battery only after making all other connections The following paragraphs provide details on each connection Refer also to the wiring diagram in the operation manual Securely support or harness all wiring to the generator set to prevent abrasion Provide additional support for the wiring to prevent exposure to the exhaust system and drippage of fuel oil or grease Allow at least a 51 mm 2 in clearance between the electrical wiring and hot exhaust parts Do not loca

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