Kohler 10ERG Operation Manual
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Kohler 10ERG Operation Manual

Commercial mobile generator set
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Operation
Commercial Mobile Generator Sets
Model:
10ERG
13ERG
15ERG
TP-6334
9/04

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Summary of Contents for Kohler 10ERG

  • Page 1 Operation Commercial Mobile Generator Sets Model: 10ERG 13ERG 15ERG TP-6334 9/04...
  • Page 2 California Proposition 65 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. Engine Identification Record the product identification numbers in the spaces Record the product identification information from the below immediately after unpacking the products so that engine nameplate.

  • Page 3: Table Of Contents

    Table of Contents Product Information ............Inside front cover Safety Precautions and Instructions .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can Carbon monoxide symptoms. cause severe injury or death. Carbon monoxide can cause severe can cause severe injury or death. Generator set engine fuels and fuel nausea, fainting, or death. Carbon Short circuits can cause bodily injury vapors are flammable and explosive.
  • Page 7 Fuel System LP gas fuel leaks. Explosive fuel WARNING vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas fuel WARNING system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square Hazardous voltage.
  • Page 8 Welding the generator set. Hot Parts Combustible materials. Fire can cause severe electrical equipment cause severe injury or death. A hot damage. Before welding the generator generator set can ignite debris in the WARNING set perform the following steps: compartment. Keep the compartment (1) Remove battery cables,...
  • Page 9 Tightening the hardware. Flying NOTICE projectiles can cause severe injury Canadian installations only. or death. Loose hardware can cause standby service connect the output of the hardware or pulley to release from the generator set to a suitably rated the generator set engine and can cause transfer switch in accordance with personal injury.
  • Page 10 Notes VI Safety Precautions and Instructions TP-6334 9/04...

  • Page 11: Introduction

    Obtain service from authorized service at the time of print. Kohler Co. reserves the right to distributor/dealer to keep equipment in top condition. change this publication and the products represented without notice and without any obligation or liability whatsoever. Before installing a mobile generator set, obtain the...

  • Page 12: Maintenance And Service Parts/Related Literature

    Maintenance and Service Parts/Related Literature Maintenance and Service Parts List of Related Literature Figure 1 identifies maintenance and service parts for Figure 2 identifies related literature available for the your generator set. Obtain a complete list of generator sets covered in this manual. Only trained and maintenance and service parts from your authorized qualified personnel should install or service the generator distributor/dealer.

  • Page 13: Section 1 Service Views

    Section 1 Service Views ADV6816-A- SERVICE-SIDE VIEW SERVICE-SIDE VIEW (Gasoline Models) (LP Models) 1. Advanced Digital Control (ADC 2100) 14. Fuel solenoid (LP models only) 2. Runtime hour display 15. Lube oil filter 3. Nameplate 16. Oil drain valve 4. Electronic Control Module (ECM) 17.
  • Page 14 Notes 2 Service Views TP-6334 9/04...

  • Page 15: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist Visually inspect for exhaust leaks (blowby). Check for carbon or soot residue on exhaust components. To ensure continued satisfactory operation perform the Carbon and soot residue indicates an exhaust leak. Seal leaks as needed. following checks or inspections before or at each startup, as designated, and at the intervals specified in Ensure that the carbon monoxide detector is (1) in the...

  • Page 16: Advanced Digital Control Operation

    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 system configuration adjustment instructions.

  • Page 17: Starting The Generator Set

    2.4.2 Starting the Generator Set 2.4.3 Stopping the Generator Set The following procedures describe the actions required The following procedures describe the actions required to start the generator set. to stop the generator set. Step Step Action Action Local Stopping Fuel shut-off valve.
  • Page 18 Code Fault Description Check Auxiliary fault Input from a customer-supplied switch that closes Check the cause of the auxiliary fault. input shutdown when the fault is active. Shutdown occurs 0.3 seconds after the fault is detected and will not start when the fault is active (input is grounded).

  • Page 19: Resetting The Controller After A Fault Shutdown

    If you do not plan to use your Part Fuse Label Number Location generator set for a long period of time, Kohler recommends moving the master switch to the Auxiliary Winding 358337 Lead 55 OFF/RESET position (0 mA draw). Relay Interface...
  • Page 20 Notes 8 Operation TP-6334 9/04...

  • Page 21: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General Maintenance WARNING WARNING Rotating parts. Can cause severe injury or death. Accidental starting. Operate the generator set only when Can cause severe injury or death. all guards, screens, and covers are in place. Disconnect the battery cables before working on the generator set.

  • Page 22: Service Schedule

    Engine Service. Perform generator set engine service the runtime hours shown on the ADC2100 to determine at the intervals specified by the engine operation when to schedule routine maintenance. Service more manual. frequently generator sets that are subject to extreme weather or dusty or dirty conditions.
  • Page 23 Service Schedule, continued After Every Every Every 50 Hrs 100 Hrs 300 Hrs 500 Hrs Reference Before Perform Service at Intervals Indicated (X) Section Starting 1 Month 3 Months 6 Months Yearly INTAKE/EXHAUST SYSTEM Inspect the exhaust system components * Check the exhaust gas condition (during operation)

  • Page 24: Lubrication System

    3.3 Lubrication System 3.3.1 Oil Specifications Use oil that displays the American Petroleum Institute (API) “Starburst” certification mark for gasoline engines on the container. Using unsuitable oil or neglecting an oil change may result in engine damage that is not TP-5586-3 1.

  • Page 25: Oil Filter Change

    Do not use gasoline left over from the previous safe, approved manner. season. Kohler Co. recommends unleaded fuel because it 3.3.5 Oil Filter Change leaves fewer combustion chamber deposits. Never mix oil with fuel.

  • Page 26: Gaseous Fuel System

    3.5 Gaseous Fuel System 3.6 Air Cleaner The gaseous fuel system utilizes a fuel valve (with At the interval specified in the service schedule, inspect, solenoid) to control the fuel flow to the fuel regulator. clean, or replace the air cleaner element. Clean the generator-mounted regulator reduces...

  • Page 27: Exhaust System

    3.7 Exhaust System 3.8 Cooling System WARNING WARNING Hot coolant and steam. Carbon monoxide. Can cause severe injury or death. cause severe nausea, fainting, or death. Before removing the pressure cap, stop the generator set and allow it to exhaust system must cool.

  • Page 28: Draining The Cooling System

    3.8.2 Draining the Cooling System 5. Stop the engine and allow it to cool. The radiator contains a coolant drain valve to drain the 6. Remove the radiator’s pressure cap. cooling system. When draining the coolant, remove the 7. Add coolant to the radiator to just below the radiator’s pressure cap: this will allow the entire system overflow tube on the filler neck.

  • Page 29: Ignition System

    3.9 Ignition System 3. Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling Service spark plugs at the interval specified in the into the combustion chamber. service schedule using the following procedure. 4.
  • Page 30 5. Clean spark plugs by wiping them with a rag. File the center electrode to keep it parallel to the side electrode. Note: Do not sandblast, wire brush, scrape, or otherwise service spark plug in poor condition. Obtain a new plug for best results.

  • Page 31: Battery

    3.10 Battery 3.11 Belt Check Consult battery manufacturer’s instructions Check the belt tension at the intervals specified in the regarding battery care and maintenance. service schedule. If the tension is not within specification, adjust as necessary using the following procedure. WARNING Adjust the tension of the alternator/fan belt so that the belt can be depressed about 12.7 mm (0.5 in.) when...

  • Page 32: Generator Storage Procedure

    3.12 Generator Storage Procedure 6. Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs. Follow the procedure below when storing your 7. Clean the exterior of the generator set and spread generator set for a long period (3 months or more). a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion.

  • Page 33: Section 4 Troubleshooting

    Section 4 Troubleshooting This section contains generator set troubleshooting, Corrective action and testing often require knowledge of diagnostic, and repair information. electrical and electronic circuits. To avoid additional problems caused by incorrect repairs, have an Use the following chart as a quick troubleshooting authorized service distributor/dealer perform service.
  • Page 34 TP-6334 9/04 Section 4 Troubleshooting...
  • Page 35 TP-6334 9/04 Section 4 Troubleshooting...
  • Page 36 TP-6334 9/04 Section 4 Troubleshooting...

  • Page 37: Section 5 Wiring Diagrams

    Section 5 Wiring Diagrams WARNING WARNING Hazardous voltage. Moving rotor. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working on the generator set.
  • Page 38 GM28747A-C Figure 5-1 Wiring Diagram (Sheet 1 of 2) Section 5 Wiring Diagrams TP-6334 9/04...
  • Page 39 GM28747B-C Figure 5-2 Wiring Diagram (Sheet 2 of 2) TP-6334 9/04 Section 5 Wiring Diagrams...
  • Page 40 ADV6846A-A Figure 5-3 Schematic Diagram (Sheet 1 of 2) Section 5 Wiring Diagrams TP-6334 9/04...
  • Page 41 ADV6846B-A Figure 5-4 Schematic Diagram (Sheet 2 of 2) TP-6334 9/04 Section 5 Wiring Diagrams...
  • Page 42 GM33846-A Figure 5-5 Accessory Wiring Diagram Section 5 Wiring Diagrams TP-6334 9/04...

  • Page 43: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 44 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter µF microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.

  • Page 45: Appendix B Operating Hour Service Log

    Appendix B 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 HOURS TOTAL...
  • Page 48 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-6334 9/04 7 Jurong Pier Road Singapore 619159 E 2004 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

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