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Kohler 10EORD Operation

Kohler 10EORD Operation

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Commercial/Recreational Mobile
9EFORD/EFORZD
12.5EFORD/EFORZD
16.5EFORD/EFORZD
Operation
Generator Sets
10EORD/EORZD
15EORD/EORZD
20EORD/EORZD
30EORZD
40EORZD
25EFORZD
33EFORZD
Models:
TP-6385 9/06a

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Summary of Contents for Kohler 10EORD

  • Page 1 Operation Commercial/Recreational Mobile Generator Sets Models: 10EORD/EORZD 15EORD/EORZD 20EORD/EORZD 30EORZD 40EORZD 9EFORD/EFORZD 12.5EFORD/EFORZD 16.5EFORD/EFORZD 25EFORZD 33EFORZD TP-6385 9/06a...

  • 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 ............. Safety Precautions and Instructions .
  • Page 4 TP-6385 9/06...

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Battery electrolyte is a diluted Electromechanical equipment, sulfuric acid. Battery acid can cause including generator sets, transfer severe injury or death. Battery acid WARNING switches, switchgear, and accessories, can cause blindness and burn skin. can cause bodily harm and pose Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can WARNING can cause severe injury or death. cause severe injury or death. Short circuits can cause bodily injury Generator set engine fuels and fuel and/or equipment damage. vapors are flammable and explosive. Disconnect battery before...
  • Page 7 Exhaust System Copper tubing exhaust systems. WARNING Carbon monoxide can cause severe nausea, fainting, or death. Do not WARNING use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in Avoid high pressure fluids.
  • Page 8 Hazardous Noise Engine block heater. Hazardous CAUTION voltage can cause severe injury or death. The engine block heater can CAUTION cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections. Welding the generator set.
  • Page 9 Moving Parts Servicing the generator set when it WARNING is operating. Exposed moving parts can cause severe injury or death. WARNING Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.
  • Page 10 NOTICE Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground.

  • Page 11: Introduction

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

  • Page 12: Maintenance And Service Parts/Related Literature

    Maintenance and Service Parts/Related Literature Maintenance and Service Parts Figure 1 identifies maintenance and service parts for your generator set. Obtain a complete list of maintenance and service parts from your authorized generator distributor/dealer. Models 10EORD 15EORD 20EORD 10EORZD 15EORZD 20EORZD 9EFORD 12.5EFORD 16.5EFORD...

  • Page 13: Section 1 Service Views

    Section 1 Service Views Service-Side View Engine-End View (With Radiator Removed) ADV7031-A 1. Fuses (F1, F2, and F3) 16. Oil fill (front gear cover) 2. Advanced Digital Control (ADC 2100) 17. Radiator 3. Alternator cooling air inlet 18. V-belt 4. Run-Off/Reset-Auto switch 19.
  • Page 14 Notes Section 1 Service Views TP-6385 9/06...

  • Page 15: Section 2 Operation

    Inspect the exhaust system components for cracks and corrosion (exhaust manifold, exhaust line, exhaust 2.3 Load Profile clamps, and muffler). Whenever operating the generator set, Kohler Co. Check for corroded or broken metal parts and replace recommends maintaining the minimum load profile them as needed.

  • Page 16: Advanced Digital Control Operation

    If the Digital Control (ADC 2100). generator set is reconnected to a different voltage Note: Have setup and adjustments of the ADC 2100 and/or frequency, refer to an authorized Kohler performed only by an authorized Kohler distributor/dealer system configuration distributor/dealer.

  • Page 17: Starting The Generator Set

    Move the generator set master switch to the RUN of time, Kohler recommends moving the master position. The ADC 2100 attempts to start the generator switch to the OFF/RESET position (0 mA draw).
  • 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

    2.4.6 Resetting the Controller after a 2.5 Circuit Protection Fault Shutdown If the generator set circuit breaker trips or the fuses blow Always identify and correct the cause of a fault repeatedly, see Section 4, Troubleshooting, for possible shutdown before resetting the controller. Use the causes.
  • Page 20 Notes Section 2 Operation TP-6385 9/06...

  • Page 21: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General Maintenance NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct WARNING size tools to prevent rounding of the bolt heads and nuts. See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set.

  • Page 22: Service Schedule

    3.2 Service Schedule Every Every Every Every 50 Hrs. 250 Hrs. 500 Hrs. Perform Service at Intervals Reference 1000 Hrs. or 1 or 3 or 6 Indicated (X) Section Daily or Yearly Month Months Months FUEL SYSTEM Check the fuel level and fill as necessary (Before operation) Check for any unusual noise [...
  • Page 23 Service Schedule, continued Every Every Every Every 50 Hrs. 250 Hrs. 500 Hrs. 1000 Hrs. or 1 or 3 or 6 Perform Service at Intervals Reference or Yearly Daily Month Months Months Indicated (X) Section INTAKE/EXHAUST SYSTEM Inspect the exhaust system components [ (Before operation) Check the exhaust gas condition.

  • Page 24: 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 Section 1 for the check the oil level, remove the dipstick and wipe the end oil drain, oil check, oil fill, and oil filter locations.

  • Page 25: Oil Change

    4. Check for leaks. capacities. a. Check that the generator set master switch is in the OFF position. Model L (Qts.) 10EORD/EORZD b. Reconnect the generator set engine starting 3.6 (3.8) 9EFORD/EFORZD battery, negative (--) lead last. 15EORD/EORZD 4.7 (5.0) 12.5EFORD/EFORZD...

  • Page 26: Fuel Filter

    3.4.2 Fuel Filter Fuel/Water Separator Draining Procedure At the interval specified in the service schedule, drain The quality and condition of the fuel largely determine the water from the fuel/water separator. Hold a suitable the filter’s useful life. Replace the fuel filter element as container beneath the fuel/water separator and push up listed in the service schedule.

  • Page 27: Bleeding The Fuel System

    3.4.4 Bleeding the Fuel System Bleed air from the fuel system to prevent starting failures and/or erratic operation. One or more of the following causes air to collect in the fuel system: Operating the generator set until it runs out of fuel. Developing air leaks in the plumbing between the fuel tank and the engine-mounted fuel pump.

  • Page 28: Air Cleaner

    3.5 Air Cleaner 6. Install the air cleaner element on the threaded rod. Tighten the wing nut. At the interval specified in the service schedule, inspect, 7. Position the cover with the arrow up; place the clean, or replace the air cleaner element. Clean the clamp over the base and cover and tighten the element more frequently if the generator operates in eyebolt.

  • Page 29: Exhaust System

    3.6 Exhaust System Inspection Points Check for exhaust leaks and blockages. Check the WARNING muffler and piping condition and check for tight exhaust system connections. Inspect the exhaust system components for cracks and corrosion (exhaust manifold, exhaust line, exhaust clamps, and muffler). Carbon monoxide.

  • Page 30: Cooling System

    Pressure Cap Rating block or cylinder head to crack. Wait until engine 97 kPa has cooled. 10EORD/EORZD and 9EFORD/EFORZD (14 psi) 3. Fill the radiator with the recommended coolant 15EORD/EORZD and 12.5EFORD/EFORZD 83--110 kPa mixture of 50% ethylene glycol and 50% clean, 20EORD/EORZD and 16.5EFORD/EFORZD...

  • Page 31: Flushing And Cleaning

    Note: A coolant solution of 50% ethylene glycol 3.7.5 Pressure Cap provides freezing protection to --37°C (--34°F) The cooling system utilizes a pressure cap to raise the and overheating protection to 129°C (265°F). A boiling point of the coolant, enabling higher operating coolant solution with less than 50% ethylene temperatures.

  • Page 32: Battery

    3.9 Battery 2. Add or replace coolant as necessary to ensure adequate freezing protection. Use the guidelines Consult battery manufacturer’s instructions included in the engine operation manual. regarding battery care and maintenance. 3. Run the generator set for 30 minutes to redistribute added coolant.

  • Page 33: Section 4 Troubleshooting

    Section 4 Troubleshooting This section contains generator set troubleshooting, 4.1 Fault Codes diagnostic, and repair information. The Advanced Digital Control displays fault codes to aid Use the following charts as a quick troubleshooting in troubleshooting. Fault codes, descriptions, and reference. The table groups generator set faults and recommended actions are listed in Figure 2-5.
  • Page 34 TP-6385 9/06 Section 4 Troubleshooting...
  • Page 35 TP-6385 9/06 Section 4 Troubleshooting...
  • Page 36 TP-6385 9/06 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 GM39874-F Figure 5-1 Wiring Diagram (10--20EORD/EORZD and 9--16.5EFORD/EFORZD) Section 5 Wiring Diagrams TP-6385 9/06...
  • Page 39 ADV7030A-D Figure 5-2 Wiring Diagram, Schematic (10--20EORD/EORZD and 9--16.5EFORD/EFORZD) TP-6385 9/06 Section 5 Wiring Diagrams...
  • Page 40 ADV7030B-D Figure 5-3 Wiring Diagram, Schematic (10--20EORD/EORZD and 9--16.5EFORD/EFORZD) Section 5 Wiring Diagrams TP-6385 9/06...
  • Page 41 GM40822-B Figure 5-4 Wiring Diagram (30/40EORZD and 25/33EFORZD) TP-6385 9/06 Section 5 Wiring Diagrams...
  • Page 42 ADV7246A-A Figure 5-5 Wiring Diagram, Schematic (30/40EORZD and 25/33EFORZD) Section 5 Wiring Diagrams TP-6385 9/06...
  • Page 43 ADV7246B-A Figure 5-6 Wiring Diagram, Schematic (30/40EORZD and 25/33EFORZD) TP-6385 9/06 Section 5 Wiring Diagrams...
  • Page 44 Notes Section 5 Wiring Diagrams TP-6385 9/06...

  • Page 45: 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 46 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 47: 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 TP-6385 9/06...
  • Page 49 TP-6385 9/06...
  • Page 50 TP-6385 9/06...
  • Page 51 TP-6385 9/06...
  • Page 52 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-6385 9/06a 7 Jurong Pier Road Singapore 619159 E 2005 and 2006 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...

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