Kohler 13ERG Installation Manual
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Kohler 13ERG Installation Manual

Kohler 13ERG Installation Manual

Commercial mobile generator sets
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Installation
Commercial Mobile Generator Sets
Model:
10ERG
13ERG
15ERG
TP-6335
9/04

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Summary of Contents for Kohler 13ERG

  • Page 1 Installation Commercial Mobile Generator Sets Model: 10ERG 13ERG 15ERG TP-6335 9/04...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Section 1 Introduction .
  • Page 4 Notes...

  • 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. Testing live electrical circuits. Servicing the exhaust system. Hot cause severe electrical equipment Hazardous voltage or current can parts can cause severe injury or damage. Before welding the generator cause severe injury or death. Have death. Do not touch hot engine parts. set perform the following steps: trained and qualified personnel take The engine and exhaust system...
  • Page 9 Notice WARNING NOTICE This generator set has been rewired from its nameplate voltage Airborne particles. cause severe injury blindness. Wear protective goggles and clothing 246242 when using power tools, hand tools, or compressed air. NOTICE Tightening the hardware. Flying Voltage reconnection. Affix a notice projectiles can cause severe injury to the generator set after reconnecting or death.
  • Page 10 Notes VI Safety Precautions and Instructions TP-6335 9/04...

  • Page 11: Section 1 Introduction

    Section 1 Introduction All information in this publication represents data 1.3 Generator Set Operation available at the time of print. Kohler Co. reserves the right After the installer attaches the generator set to the to change this literature and the products represented vehicle’s frame and makes connections, do the following...
  • Page 12 Notes 2 Introduction TP-6335 9/04...

  • Page 13: Section 2 Location And Mounting

    2.1 General Considerations 2.3 Vehicle-Floor Mounting Consider the following items concerning the generator Install the Kohler mobile generator set on an open set and Section 2.2 for the proposed location. vehicle’s floor or truck bed. Follow the guidelines below. Contact an authorized Kohler service distributor/dealer 1.
  • Page 14 Notes 4 Location and Mounting TP-6335 9/04...

  • Page 15: Section 3 Cooling System

    Section 3 Cooling System 3.1 Air Requirements 3.3 High Water Temperature Switch Air flow around the generator set is necessary for Each generator set includes a high water temperature adequate cooling. See the current generator set shutdown switch that automatically shuts down the set if specification sheet for air requirements.
  • Page 16 Notes 6 Cooling System TP-6335 9/04...

  • Page 17: Section 4 Exhaust System

    Section 4 Exhaust System Installing the exhaust tail pipe. Carbon monoxide can WARNING 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.

  • Page 18: Planning

    Do not apply 4.2 Clearance Requirements weight or pressure to the unit-mounted muffler, otherwise premature exhaust-system damage will Kohler Co. recommends a minimum clearance of occur. Adding exhaust-pipe extensions to the 38 mm (1 1/2 in.) between the exhaust system parts...

  • Page 19: Section 5 Fuel System

    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 Explosive fuel vapors. separate fuel tanks is usually impractical because of Can cause severe injury or death.

  • Page 20: Fuel Lines

    5.1.1 Fuel Lines 5.3 LP Gas Note: Keep fuel lines away from the exhaust system. LP fuel hose. Use a flexible fuel hose designated for use with LP fuel between the generator set and the main Routing fuel lines. Take care when routing the fuel line fuel tank.

  • Page 21: Fuel Pump Lift And Fuel Consumption

    5.4 Fuel Pump Lift and Fuel Note: Fuel system alterations may adversely affect emissions levels. Fines resulting from Consumption higher-than-allowable emissions levels are the responsibility of the user. See Figure 5-3 for the fuel pump lift capability. Consult the current generator set specification sheet for the Fuel Pump Lift generator set fuel consumption rates.
  • Page 22 Notes 12 Fuel System TP-6335 9/04...

  • Page 23: Section 6 Electrical System

    Section 6 Electrical System 6.2 AC Load Lead Connections WARNING Routing. Each generator set has four color-coded load leads. The black leads (L1 and L2) are hot, the white lead (L0) is neutral, and the green lead is the hazard ground.
  • Page 24 Note: Transfer switch. Use a triple-pole, double-throw transfer switch rated for the calculated load of the 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.

  • Page 25: Circuit Protection

    6.3 Circuit Protection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator The AC circuit breaker protects the generator set from set as follows: (1) Move the generator set master switch to the extreme overload.

  • Page 26: Circuit Breaker Installation

    6.3.2 Circuit Breaker Installation lead (see Section 8). Attach stator leads 2 and 3 to Note: Wire material. Use stranded copper for all wiring. Use wire gauges and insulation, Single-pole circuit breaker with conductor temperature ratings, sheath stripping, single-voltage system (example: 240 volt, conductor support and protection, conductor 2 wire).

  • Page 27: Adc 2100 Continuous Power Mode Jumper

    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.

  • Page 28: Battery And Connections

    6.5 Battery and Connections Lengths and sizes. See Figure 6-5 for the lengths and recommended sizes of the battery cables. WARNING Distance Required (from battery to Battery Cable generator set) AWG Gauge (Minimum) 2.5 m (8.3 ft.) 5 m (16.4 ft.) Figure 6-5 Battery Cable Sizing Recommendations, Sulfuric acid in batteries.

  • Page 29: Remote Connection

    Contact your local Kohlerr distributor/dealer for detailed descriptions. 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.
  • Page 30 Notes 20 Electrical System TP-6335 9/04...

  • Page 31: Section 7 Installation Drawing

    Section 7 Installation Drawing ADV-6816A-A Figure 7-1 Dimension Drawing, Gasoline Fuel System TP-6335 9/04 Installation Drawing 21...
  • Page 32 ADV-6816B-A Figure 7-2 Dimension Drawing, LP Fuel System 22 Installation Drawing TP-6335 9/04...
  • Page 33 ADV-6816C-A Figure 7-3 Dimension Drawing, Floor Template TP-6335 9/04 Installation Drawing 23...
  • Page 34 Notes 24 Installation Drawing TP-6335 9/04...

  • Page 35: Section 8 Reconnection/Adjustments

    Section 8 Reconnection/Adjustments WARNING WARNING Moving rotor. Hazardous voltage. 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 36: Four-Lead Reconnection

    8.1 Four-Lead Reconnection 100- -120/200- -240-Volt Configurations The 100--120/200--240-volt configuration does not use The following drawings illustrate the reconnection of a jumper lead. If the unit was originally wired for straight four-lead generator sets. In all cases, conform to the 100--120 volt, 3 wire, remove the jumper lead (see National Electrical Code (NEC).
  • Page 37 200- -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). L0 (Neutral) GRD. Ground Load Side Line Single-Pole Side Circuit...

  • Page 38: Advanced Digital Control (Adc 2100)

    8.2 Advanced Digital Control 8.2.1 Configuration Mode Time Out (ADC 2100) The controller will automatically exit the configuration mode without saving any changes after about 1 minute if The model 10/13/15ERG generator sets use the no buttons are pressed. Start the configuration ADC 2100.

  • Page 39: Adjusting The Voltage, Gain, And Volts/Hz

    8.2.3 Adjusting the Voltage, Gain, and Voltage Adjustment Procedure Volts/Hz Note: Refer Figure 8-6 Figure 8-7 instructions to adjust the voltage using the After setting the system voltage, check the output ADC 2100. voltage and adjust, if necessary, using the following procedures.
  • Page 40 Output Voltage Adjustment Mode: Display :* x x x x Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours. Hold: Wait about 5 seconds until the display changes from runtime hours to the program version number.
  • Page 41 Display : * Continued from Figure 8-6: To enter SAVE mode. S A V E 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: S A V E Press:...

  • Page 42: Controller Configuration

    (ED) are factory set and should only be The controller configuration for each generator model is changed authorized Kohler set at the factory and should not normally require dealer/distributor. Incorrect settings will make changes. The controller’s configuration mode allows your unit non-functional.
  • Page 43 Parameter Setting Definition Unit’s system voltage Uu01 Single phase, 60 Hz, 120/240 VAC and frequency Unit configuration Uc02 Mobile generator set Engine type Ec03 10/13/15ERG Engine data input types Ed00 All digital inputs (No magnetic pick-up) Ed01 Digital: Low coolant level and low oil pressure Analog: Low coolant temperature Ed02 Digital: Low coolant level and low coolant temperature...
  • Page 44 Controller Configuration Mode (Use with Figure 8-8, Controller Parameters): Hold the Select button: Display: Move the generator set master switch to the RUN position. (The generator set engine will not start.) Wait about 5 seconds until the display shows the 1 0 4 program version number.
  • Page 45 Pressing the up arrow key at the Adnc display (See Figure 8-9) puts you into the Advanced Configuration Mode. Press: E d 0 x To set the engine data input type. To enter battery voltage selection mode. To toggle between 12 and 24 VDC. B t 1 2 To enter communications selection mode.
  • Page 46 Notes 36 Reconnection/Adjustments TP-6335 9/04...

  • Page 47: Appendix A Generator Selection And Wattage Requirements

    Appendix A Generator Selection and Wattage Requirements General Wattage Requirements Appliance Loads Generator sets often furnish AC for appliances such as Consider the total wattage requirements (lights, motors, TVs, stereos, and electric water heaters. Except for the appliances) when selecting a generator set, or when resistance-type loads such as the water heater, the sizing wattage usage in which available space and requirements for appliances are usually low.

  • Page 48: Appendix B Abbreviations

    Appendix B 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 49 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 52 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-6335 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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