Kohler 20EORZ Operation
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Kohler 20EORZ Operation

Kohler 20EORZ Operation

Mobile generator sets
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Operation
Mobile Generator Sets
Model:
20EORZ
(Marathon Coach)
TP-5964 7/01c

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Summary of Contents for Kohler 20EORZ

  • Page 1 Operation Mobile Generator Sets Model: 20EORZ (Marathon Coach) TP-5964 7/01c...

  • Page 2: Product Identification Information

    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 Identification 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 Exhaust System Copper tubing exhaust systems. Carbon monoxide can cause severe can cause severe injury or death. nausea, fainting, or death. Do not Short circuits can cause bodily injury WARNING use copper tubing in diesel exhaust and/or equipment damage.
  • Page 7 sparks to occur near sources of spilled Testing voltage regulator. WARNING fuel or fuel vapors. Keep the fuel lines Hazardous voltage cause and connections tight and in good severe injury or death. High voltage condition. Do not replace flexible fuel is present at the voltage regulator heat lines with rigid lines.
  • Page 8 Moving Parts Notice WARNING NOTICE WARNING This generator set has been rewired from its nameplate voltage Hot engine and exhaust system. Can cause severe injury or death. Hazardous voltage. Moving rotor. Do not work on the generator set until Can cause severe injury or death. it cools.

  • Page 9: Introduction

    Information in this publication represents data available at the time of print. Kohler Co. reserves the right to Before installing a mobile generator set, obtain the change this publication and the products represented...

  • Page 10: Service Assistance

    Fax: (91) 80-2284286 Consult the Yellow Pages under the heading Japan Generators—Electric Japan Regional Office Visit the Kohler Co. Generator Division web site at Tokyo, Japan www.kohlergenerators.com Phone: (813) 3440-4515 Inside the U.S.A. and Canada, call 1-800-544-2444 Fax: (813) 3440-2727 Outside the U.S.A.

  • Page 11: Section 1 Service Views

    Section 1 Service Views 11 10 Spec: PA-135332 Spec: PA-135333 ADV-6346-D A-226911-D 1. Air cleaner 15. Cooling air inlet 2. Pressure cap (at surge tank) 16. AC main circuit breaker (80-amp) 3. Overflow tube 17. Remote start connector (rear) 4. Surge tank 18.
  • Page 12 Notes Section 1 Service Views TP-5964 7/01...

  • Page 13: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist Check the exhaust gas color. If the exhaust is blue or black, contact your local distributor/dealer. To ensure continued satisfactory operation perform the Visually inspect for exhaust leaks (blowby). Check following checks or inspections before or at each for carbon or soot residue on exhaust components.

  • Page 14: Starting And Stopping Procedure

    If the unit fails to start after three attempts, Preheat/cold weather starts contact an authorized Kohler distributor/dealer During cold weather starts,* place the controller for repair. Failure to follow these guidelines may start/stop switch in the STOP/PREHEAT position for result in starter motor burnout.

  • Page 15: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General Maintenance 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 WARNING and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

  • Page 16: Service Schedule

    3.2 Service Schedule Every Every Every Every Every 50 Hrs. 100 Hrs. 150 Hrs. 300 Hrs. Perform Service at Intervals Reference Before 500 Hrs. or 1 or 3 or 3 or 6 Indicated (X) Section Starting or Year Month Months Months Months FUEL SYSTEM...
  • Page 17 Service Schedule, Continued Every Every Every Every Every 50 Hrs. 100 Hrs. 150 Hrs. 300 Hrs. Perform Service at Intervals 500 Hrs. Reference Before or 1 or 3 or 3 or 6 or Yearly Indicated (X) Section Starting Month Months Months Months INTAKE/EXHAUST SYSTEM...

  • Page 18: Lubrication System

    3.3 Lubrication System 3.3.2 Oil Check Check the oil level in the crankcase daily or before each See the Scheduled Maintenance section for oil change startup to ensure that the level is in the safe range. To and oil filter replacement intervals. See the Service check the oil level, remove the dipstick and wipe the end Views section for the oil drain, oil check, oil fill, and oil clean, reinsert as far as possible into the tube and...

  • Page 19: Oil Change Procedure

    Model L (Qt.) 20EORZ 5.8 (6.1) b. Apply a light coat of clean oil to the rubber seal of the new oil filter. Figure 3-3 Oil Capacity c. Install the new oil filter following the instructions provided with the filter.

  • Page 20: Fuel System

    3.4 Fuel System 3.4.2 Fuel Filter The quality and condition of the fuel largely determine 3.4.1 Fuel Specifications the filter’s useful life. Do not clean the paper filter element. Replace the fuel filter according to the service Use a clean, good quality diesel fuel oil with a cetane schedule.

  • Page 21: Fuel System Bleeding

    3.4.3 Fuel System Bleeding Bleed air from the fuel system to prevent starting failures and/or erratic operation. One or more of the following causes air to collect in fuel system: Operating the generator set until the fuel supply is emptied. Developing air leaks in the suction side of the fuel system.

  • Page 22: Air Cleaner Element Cleaning Or Replacement

    3.5.2 Air Cleaner Element Cleaning or 3.6 Exhaust System Replacement WARNING A round air cleaner silences and filters the intake air. Replace a damaged or dirt-contaminated air cleaner element. See Figure 3-7 and refer to the following procedure. Carbon monoxide. Air Cleaner Element Cleaning or Replacement cause severe...

  • Page 23: Cooling System

    Then loosen the pressure cap Model L (Qt.) to relieve pressure. 20EORZ 2.7 (2.85) Checking the coolant level. Hot coolant can cause severe Figure 3-8 Coolant Capacity (Remote Radiator injury or death. Allow the engine to cool. Release pressure Model) from the cooling system before removing the pressure cap.

  • Page 24: Procedure To Drain The Cooling System

    3.7.3 Procedure to Drain the Cooling Note: Pay special attention to the coolant level. After the coolant drains, allow time for complete refill of System the water jacket. For optimum protection, drain, flush, and refill the 1. Remove the pressure caps. cooling system at the intervals listed in the service schedule.

  • Page 25: Belt Tension

    13. Replace the radiator’s pressure cap. 14. Close the valve at the top of the surge tank, if previously opened. 15. Maintain the coolant level in the coolant recovery tank between the high and low marks or approximately 1/4 full for tanks without marks. Note: Air pockets often form in the engine water jacket when the coolant system is refilled.

  • Page 26: Battery

    3.9 Battery 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, Consult battery manufacturer’s instructions particularly when it is charging. Do not dispose of a battery in a regarding battery care and maintenance.

  • Page 27: Storage Procedure

    3.10 Storage Procedure 3.10.3 Fuel System Prepare the fuel system for storage as follows: Perform the following storage procedure before taking a generator set out of service for three months or longer. Diesel-Fueled Engines Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine 1.
  • Page 28 Notes Section 3 Scheduled Maintenance TP-5964 7/01...

  • Page 29: Section 4 Troubleshooting

    Section 4 General 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 30 Notes Section 4 General Troubleshooting TP-5964 7/01...
  • Page 31 TP-5964 7/01 Section 4 Troubleshooting...
  • Page 32 TP-5964 7/01 Section 4 Troubleshooting...

  • Page 33: 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 34 226908-D Figure 5-1 Schematic Wiring Diagram, Spec: PA-135332 Section 5 Wiring Diagrams TP-5964 7/01...
  • Page 35 226908-D Figure 5-2 Point-to-Point Wiring Diagram, Spec: PA-135332 TP-5964 7/01 Section 5 Wiring Diagrams...
  • Page 36 GM10343- Figure 5-3 Schematic Wiring Diagram, Spec: PA-135333 Section 5 Wiring Diagrams TP-5964 7/01...
  • Page 37 GM10343- Figure 5-4 Point-to-Point Wiring Diagram, Spec: PA-135333 TP-5964 7/01 Section 5 Wiring Diagrams...
  • Page 38 Notes Section 5 Wiring Diagrams TP-5964 7/01...

  • Page 39: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity Fahrenheit, female ABDC after bottom dead center cubic inch displacement fglass. fiberglass alternating current centerline flat head machine (screw) analog to digital centimeter fl.
  • Page 40 kg/cm kilograms per square milliwatt rnd. round centimeter 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. gas natural gas right side kilojoule National Bureau of Standards room temperature vulcanization...

  • Page 41: 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 44 For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohlerr Power Systems Asia Pacific Headquarters TP-5964 7/01c 7 Jurong Pier Road Singapore 619159 E Kohler Co., 1998, 2000, 2001. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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