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Summary of Contents for Kohler 10EORDB
- Page 1 Installation Commercial/Recreational Mobile Generator Sets Models: 10EORDB/EORZDB 15EORDB/EORZDB 20EORDB/EORZDB 30EORZDB 40EORZDB 9EFORDB/EFORZDB 12.5EFORDB/EFORZDB 16.5EFORDB/EFORZDB 25EFORZDB 33EFORZDB TP-6552 2/10a...
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Page 3: Table Of Contents
Table of Contents Safety Precautions and Instructions ............Section 1 Introduction . - Page 4 Table of Contents, continued 9.3.1 Configuration Mode Time Out ........9.3.2 Controller Software Version Number .
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Page 5: Safety Precautions And Instructions
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting Engine Backfire/Flash Electromechanical equipment, Fire including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose WARNING life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. - Page 6 Exhaust System Installing the exhaust tail pipe. Draining the fuel system. Explosive Carbon monoxide can cause severe fuel vapors can cause severe injury nausea, fainting, or death. Install the or death. Spilled fuel can cause an WARNING exhaust system tail pipe to prevent the explosion.
- Page 7 Welding on the generator set. Can Hot Parts WARNING cause severe electrical equipment damage. Before welding on the WARNING generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnect all engine electronic control module Hazardous voltage.
- Page 8 NOTICE Canadian installations only. standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. NOTICE Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces.
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Page 9: Section 1 Introduction
Section 1 Introduction Information in this publication represents data available 1.2 Generator Set Specifications at the time of print. Kohler Co. reserves the right to change this publication and the products represented Refer to the model’s specification sheet for details. Use... - Page 10 Notes Section 1 Introduction TP-6552 2/10...
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Page 11: Section 2 Location And Mounting
Section 2 Location and Mounting 2.1 General Considerations 2.2.1 Generator Set Compartment Location Kohler Co. ships this generator set as a unit except for exhaust- radiator-system components. Consider the following factors when installing a Assemble the exhaust system after installing the generator set in a compartment. -
Page 12: Mounting
2.3 Mounting Install vibration isolators beneath the unit. Securely fasten the generator set to avoid unwanted movement from vibration and road shock. Units with mounting trays. If the unit includes a mounting tray, angle iron usually supports the tray. Use the same number of bolts as mounting holes in the tray to secure the tray to the support structure. -
Page 13: Section 3 Cooling System
Use the following procedures/data to design and install differences from the factory test configuration, perform a the generator set cooling system to ensure a safe, qualification test following temperature effective installation. constraints listed in Figure 3-1. 10EORDB/ 9EFORDB/ 15EORDB/ 12.5EFORDB/ 20EORDB/ 16.5EFORDB EORZDB EFORZDB EORZDB... -
Page 14: Air Requirements
See the generator set specification sheet that shipped with the generator set for air requirements. The air intake silencer/cleaner provides combustion air to the engine. Engine-End View Do not compromise the recommended minimum clearance of 38 mm (1.5 in.) between a duct opening and enclosure wall. -
Page 15: Compartment Air Inlet/Outlet Openings
3.3.2 Compartment Air Inlet/Outlet 30/40EORZDB and 25/33EFORZDB Models: Openings Remote Radiator 10/15/20EOR(Z)DB and mm (in.) 9/12.5/16.5EFOR(Z)DB Models: Required Inlet Inlet Inlets Inlet Forced Remote Radiator Ventilation mm (in.) 1400 cfm Length: Required Diameter: (9.8) (24.0) (16.9) Inlet Inlets Outlet Forced Section (14.2) Height:... - Page 16 Radiator Generator Note: Dimensions are shown in millimeters with inch equivalents in brackets. Figure 3-8 Compartment Inlet/Outlet Openings (10/15/20EOR(Z)DB and 9/12.5/16.5EFOR(Z)DB) Radiator Generator Note: Dimensions are shown in millimeters with inch equivalents in brackets. Figure 3-9 Compartment Inlet/Outlet Openings (30/40EORZDB and 25/33EFORZDB) Section 3 Cooling System TP-6552 2/10...
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Page 17: Overall Free Air Inlet And Outlet Openings
3.3.3 Overall Free Air Inlet and Outlet 3.4 Radiator Installation Openings Kohler Co. offers radiator assemblies which meet the requirements to adequately cool the generator. See Total Air Total Air Figure 3-11 for radiator minimum specifications. Inlet, Outlet, sq. cm. -
Page 18: Radiator Location
Note: Install the coolant lines with minimal bends. separate from the engine, design the cooling system to Excessive bends in the routing of the coolant comply with engine combustion air and heat rejection lines will cause cooling system air locks. 10EORDB/ 9EFORDB/ 15EORDB/ 12.5EFORDB/ 20EORDB/ 16.5EFORDB... -
Page 19: Compartment Fabrication
3.5 Compartment Fabrication Length Width Height mm (in.) mm (in.) mm (in.) Model The dimensions shown are the compartment’s Remote Radiator (No Tray) minimum inside measurements. The compartment 30EORZDB must allow 38 mm (1.5 in.) clearance on all sides of the 1260 (49.6) 635 (25) 831 (32.7) - Page 20 Top View Maintain tight Discharge chute seal around radiator through compartment floor Inlet Air Flow Generator Cooled by Suction Fan Figure 3-14 Typical Cooling System Installation for Remote Radiator Mounted in the Generator Compartment To Radiator Inlet From Radiator Outlet 5605612 1.
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Page 21: Section 4 Enclosures
Cooling air exits through a third bottom passage in the front of the generator set. Published cooling capability The Kohler 12.5--40 kW enclosed mobile generator sets based on the maximum allowable ambient temperature are self-contained units with an internal exhaust silencer... -
Page 22: Clearance Requirements
As a worst case, the Kohler enclosed mobile generator set was qualified assuming that it was completely exposed (on all sides) to rainwater. Under... -
Page 23: Section 5 Exhaust System
Section 5 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 24 Kohler Co. recommends a min. clearance of 51 mm (2 in.) between exhaust system parts and fuel system, electrical system, and all combustible components.
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Page 25: Section 6 Fuel System
Fuel system design. Design the generator set diesel 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 Explosive fuel vapors. -
Page 26: Fuel Lines
Incoming fuel cools the injectors and the generator achieves maximum engine efficiency when fuel is cool. Note: Fuel Return Dip Tube. Kohler Co. recommends utilizing a fuel return dip tube located below the fuel supply tube. This will prevent air from... -
Page 27: Section 7 Electrical System
Section 7 Electrical System 7.2 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 28: Circuit Protection
7.3 Circuit Protection AC Vehicle Circuit 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 Ground Fault authorized distributor/dealer. -
Page 29: Circuit Breaker Installation
Electrical backfeed to the utility. Hazardous backfeed WARNING voltage can cause severe injury or death. Connect the generator set to the building/campground electrical system only through approved device after building/campground main switch is turned off. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near the work area. - Page 30 7. Four reconnection systems using circuit breakers Generator-End View follow. Make recommended connections. 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).
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Page 31: Battery And Connections
7.4 Battery and Connections View A Using Separate Battery Starting battery. Kohler Co. recommends a separate for Generator Set 12-volt battery 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. -
Page 32: Remote Connection
Figure 7-7 for the location of the remote interface Interface Seal GM29507 connection to the generator set junction box. Kohler Co. Cavity Plug GM28769 also offers wiring harnesses in various lengths with a Figure 7-8 Connector Components connector keyed to the junction box connector. -
Page 33: Section 8 Installation Drawings
Section 8 Installation Drawings Dimensions are in mm [in.] ADV-7389A-A Figure 8-1 Dimension Drawing (Sheet 1 of 3), 10EOR(Z)DB and 9EFOR(Z)DB TP-6552 2/10 Section 8 Installation Drawings... - Page 34 ADV-7389B-A Dimensions are in mm [in.] Figure 8-2 Dimension Drawing (Sheet 2 of 3), 10EOR(Z)DB and 9EFOR(Z)DB Section 8 Installation Drawings TP-6552 2/10...
- Page 35 Dimensions are in mm [in.] ADV-7389C-A Figure 8-3 Dimension Drawing (Sheet 3 of 3), 10EOR(Z)DB and 9EFOR(Z)DB TP-6552 2/10 Section 8 Installation Drawings...
- Page 36 Dimensions are in mm [in.] ADV-7391A-A Figure 8-4 Dimension Drawing (Sheet 1 of 3), 15--20EOR(Z)DB and 12.5--16.5EFOR(Z)DB Section 8 Installation Drawings TP-6552 2/10...
- Page 37 Dimensions are in mm [in.] ADV-7391B-A Figure 8-5 Dimension Drawing (Sheet 2 of 3), 15--20EOR(Z)DB and 12.5--16.5EFOR(Z)DB TP-6552 2/10 Section 8 Installation Drawings...
- Page 38 ADV-7391C-A Dimensions are in mm [in.] Figure 8-6 Dimension Drawing (Sheet 3 of 3), 15--20EOR(Z)DB and 12.5--16.5EFOR(Z)DB Section 8 Installation Drawings TP-6552 2/10...
- Page 39 ADV-7394-B Dimensions are in mm [in.] Figure 8-7 Dimension Drawing, 15/20EOR(Z)DB & 12.5/16.5EFOR(Z)DB Enclosed Unit with Unit-Mounted Radiator TP-6552 2/10 Section 8 Installation Drawings...
- Page 40 Dimensions are in mm [in.] ADV-7392A-A Figure 8-8 Dimension Drawing (Sheet 1 of 4), 30EORZDB and 25EFORZDB Section 8 Installation Drawings TP-6552 2/10...
- Page 41 ADV-7392B-A Dimensions are in mm [in.] Figure 8-9 Dimension Drawing (Sheet 2 of 4), 30EORZDB and 25EFORZDB TP-6552 2/10 Section 8 Installation Drawings...
- Page 42 Dimensions are in mm [in.] ADV-7392C-A Figure 8-10 Dimension Drawing (Sheet 3 of 4), 30EORZDB and 25EFORZDB Section 8 Installation Drawings TP-6552 2/10...
- Page 43 Dimensions are in mm [in.] ADV-7392D-A Figure 8-11 Dimension Drawing (Sheet 4 of 4), 30EORZDB and 25EFORZDB TP-6552 2/10 Section 8 Installation Drawings...
- Page 44 Dimensions are in mm [in.] ADV-7393A-A Figure 8-12 Dimension Drawing (Sheet 1 of 4), 40EORZDB and 33EFORZDB Section 8 Installation Drawings TP-6552 2/10...
- Page 45 ADV-7393B-A Dimensions are in mm [in.] Figure 8-13 Dimension Drawing (Sheet 2 of 4), 40EORZDB and 33EFORZDB TP-6552 2/10 Section 8 Installation Drawings...
- Page 46 ADV-7393C-A Dimensions are in mm [in.] Figure 8-14 Dimension Drawing (Sheet 3 of 4), 40EORZDB and 33EFORZDB Section 8 Installation Drawings TP-6552 2/10...
- Page 47 ADV-7393D-A Dimensions are in mm [in.] Figure 8-15 Dimension Drawing (Sheet 4 of 4), 40EORZDB and 33EFORZDB TP-6552 2/10 Section 8 Installation Drawings...
- Page 48 ADV-7362A- Dimensions are in mm [in.] Figure 8-16 Dimension Drawing, 30/40EORZDB and 25/33EFORZDB Enclosed Unit with Unit-Mounted Radiator Section 8 Installation Drawings TP-6552 2/10...
- Page 49 ADV-7362B- Dimensions are in mm [in.] Figure 8-17 Dimension Drawing, 30/40EORZDB and 25/33EFORZDB Enclosed Unit with Remote Radiator TP-6552 2/10 Section 8 Installation Drawings...
- Page 50 Notes Section 8 Installation Drawings TP-6552 2/10...
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Page 51: Section 9 Reconnection/Adjustments
Section 9 Reconnection/Adjustments 9.1 Four-Lead Reconnection 9.1.2 100- -120/200- -240-Volt Configurations The following information illustrates the reconnection of four-lead generator sets. In all cases, conform to the The 100--120/200--240-volt configuration does not use National Electrical Code (NEC). a jumper lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see NOTICE Figure 9-1 for location). -
Page 52: 200--240-Volt Configurations
9.1.3 200- -240-Volt Configurations L0 (Neutral) The 200--240-volt configuration does not use a jumper GRD. Ground lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see Figure 9-1 for location). See Figure 9-4 for models equipped with the Load Side ADC 2100. -
Page 53: Twelve-Lead Reconnection
9.2 Twelve-Lead Reconnection NOTICE Voltage reconnection. Affix a notice to the generator set after The reconnection procedure that follows details voltage reconnecting the set to a voltage different from the voltage on reconnections only. If the generator set requires the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer. -
Page 54: Adc 2100 Adjustment After Reconnection
Note: The unit configuration (UC), engine type (EC), and 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. Figure 9-6 Advanced Digital Control (ADC 2100) 9.3.3... - Page 55 110/220 V, 1 Ph, 3 W or 6 (J1939 3 (ops) w/1 hr. 120/240 V, 1 Ph, 3 W power 10EORDB/ 120 V, 1 Ph, 3 W down) ] EORZDB 120 V, 1 Ph, 2 W 220 V, 1 Ph, 2 W 12.5EFORDB/...
- Page 56 Volts, Engine Data Battery CANbus Type Inputs Voltage Comm. Market Mobile Mobile Freq Freq Model Model Voltage, Phases Voltage, Phases 220 V, 1 Ph, 2 W 115/230 V, 1 Ph, 3 W 25EFORZDB (1 Ph) 240 V, 1 Ph, 2 W 0 (No Can) 110/220 V, 1 Ph, 3 W 1 (J1939)
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Page 57: Adjusting The Voltage, Gain, And Volts/Hz, And Engine Speed
Gauge Kit Gauge Description Cn Setting Description None — Cn00 No CAN communication GM32337-KP2 w Remote Digital Gauge for Cn01 J1939 CAN communication, continuous power to ADC* Mobile and Residential/ Cn06 J1939 CAN communication, ADC power down after 1 hour for either:* Commercial a. - Page 58 Controller Configuration Mode (Use with Figure 9-7, 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 59 Pressing the up arrow key at the Adnc display (See Figure 9-10) 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 12-volt models To enter communications selection mode.
- Page 60 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.
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Page 61: 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 62: 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 63 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.
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- Page 68 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPower.com Kohler Power Systems Asia Pacific Headquarters TP-6552 2/10a 7 Jurong Pier Road Singapore 619159 E 2008 and 2010 by Kohler Co. All rights reserved. Phone (65)6264-6422, Fax (65)6264-6455...
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