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Kohler 15ERG manual

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Table of contents for the manual

  • Page 1

    Commercial Mobile Generator Sets Model: 10ERG 13ERG 15ERG TP-6335 9/04 Installation[...]

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    [...]

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    T able of Conte nts Safet y Pr ecauti ons and I nstr uct ions I ......................................................... Secti on 1 Int r oducti on 1 ..................................................................... 1.1 Inst all ati on Standar ds 1 .................................................. 1.2 Gener ator Set Speci fi cati ons 1 ......[...]

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    Notes[...]

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    Safety Precautions and Instructions I TP-6335 9/04 Safety Precautions and Instructions IMPORT ANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear , and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. T o prevent accident[...]

  • Page 6

    II Safety Precautions and Instructions TP-6335 9/04 Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove t[...]

  • Page 7

    Safety Precautions and Instructions III TP-6335 9/04 Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuels.[...]

  • Page 8

    IV Safety Precautions and Instructions TP-6335 9/04 Welding the generator set. Can cause severe electrical equipment damage. Before welding the generator set perform the following steps: (1) Remove the battery cables, negative ( - - ) lead first. (2) Disconnect all engine electronic control module (ECM) connectors. (3) Disconnect all generator set [...]

  • Page 9

    Safety Precautions and Instructions V TP-6335 9/04 Airborne particles. Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air . W ARNING Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release fr[...]

  • Page 10

    VI Safety Precautions and Instructions TP-6335 9/04 Notes[...]

  • Page 11

    1 Introduction TP-6335 9/04 Section 1 Introduction All information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this literature and the products represented without incurring obligation. The safe and successful operation of a mobile power system depends primarily on the installation. Us[...]

  • Page 12

    2 Introduction TP-6335 9/04 Notes[...]

  • Page 13

    TP-6335 9/04 Location and Mounting 3 Section 2 Location and Mounting 2.1 General Considerations Consider the following items concerning the generator set and Section 2.2 for the proposed location. 1. Select a generator set having adequate capacity to handle the electrical load. 2. Design the fuel system to prevent fuel starvation of the main or gen[...]

  • Page 14

    4 Location and Mounting TP-6335 9/04 Notes[...]

  • Page 15

    TP-6335 9/04 Cooling System 5 Section 3 Cooling System 3.1 Air Requirements Air flow around the generator set is necessary for adequate cooling. See the current generator set specification sheet for air requirements. The air intake silencer/cleaner provides combustion air to the engine. See Figure 3-1 for allowable intake restriction. The engine/ge[...]

  • Page 16

    6 Cooling System TP-6335 9/04 Notes[...]

  • Page 17

    7 TP- 6335 9/04 Ex haust S ys tem 7 Secti on 4 E xhau st System Carbon m onoxide. Can cause severe nausea, f ainti ng, or death. The exhaust system must be leakpr oof and routi nely inspected. W ARNING Gener ator set oper ation. Carbon monoxi de can cause severe nausea, fai nting, or deat h. Carbon m onoxide is an odorl ess, color less, t astel ess[...]

  • Page 18

    TP- 6335 9/04 8 Ex haus t Sy st em 4.1 P lanni ng Caref ully plan t he gener ator exhaust syst em to ensure a sa fe, q uie t i ns tal l ati o n. V e ri fy th at the in sta ll ati on complies wit h all stat e and local requirement s and applicable artic les of the codes list ed at t he beginning of this m anual. 4.2 Clear ance Requi rem ents Kohler [...]

  • Page 19

    TP-6335 9/04 Fuel System 9 Section 5 Fuel System Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. W ARNING The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in [...]

  • Page 20

    TP-6335 9/04 10 Fuel System 5.1.1 Fuel Lines Note: Keep fuel lines away from the exhaust system. Routing fuel lines. T ake care when routing the fuel line from the fuel tank to the generator set. Keep the fuel lines as short as possible but maintain adequate clearance from the exhaust system. Route the fuel lines along the frame or undercarriage—[...]

  • Page 21

    TP-6335 9/04 Fuel System 1 1 5.4 Fuel Pump Lift and Fuel Consumption See Figure 5-3 for the fuel pump lift capability . Consult the current generator set specification sheet for the generator set fuel consumption rates. Do not exceed 3 1/2 psi fuel pump pressure to the carburetor . Note: Fuel system alterations may adversely affect emissions levels[...]

  • Page 22

    TP-6335 9/04 12 Fuel System Notes[...]

  • Page 23

    TP-6335 9/04 Electrical System 13 Section 6 Electrical System Hazardous voltage. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures a r ei np l a c e . Moving rotor . W ARNING Electrical backfeed to the utility . Hazardous backfeed voltage can cause severe injury or death. Connect the generato[...]

  • Page 24

    14 Electrical System TP-6335 9/04 Note: T ransfer switch. Use a triple-pole, double-throw transfer switch rated for the calculated load of the 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. Protect the AC lo[...]

  • Page 25

    TP-6335 9/04 Electrical System 15 6.3 Circuit Protection 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 authorized distributor/dealer . After correcting the fault, reset the AC circuit breaker by[...]

  • Page 26

    16 Electrical System TP-6335 9/04 6.3.2 Circuit Breaker Installation Note: Wire material. Use stranded copper for all wiring. Use wire gauges and insulation, conductor temperature ratings, sheath stripping, conductor support and protection, conductor terminals and splices, and overcurrent protection (circuit breakers, fuses) that conform to standar[...]

  • Page 27

    TP-6335 9/04 Electrical System 17 6.4 ADC 2100 Continuous Power Mode Jumper A jumper on connector P7 on the back of the controller causes the controller to remain powered at all times. Controllers are shipped from the factory with the jumper connected. Disconnecting the jumper causes the controller to automatically power down 48 hours after the gen[...]

  • Page 28

    18 Electrical System TP-6335 9/04 6.5 Battery and Connections Sulfuric acid in batteries. Can cause severe injury or death. Use protective goggles and clothes. Battery acid can cause permanent damage to eyes, burn skin, and eat holes in clothing. W ARNING Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosio[...]

  • Page 29

    TP-6335 9/04 Electrical System 19 -- + Battery Positive V ehicle Frame 12-V olt Battery Using the Same Battery as the V ehicle Engine N Battery Negative to V ehicle Frame Ground Strap V ehicle Frame -- + Battery Positive V ehicle Frame 12-V olt Battery Using a Separate Battery for the Generator Set N View A View B Figure 6-6 Battery Connection Deta[...]

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    20 Electrical System TP-6335 9/04 Notes[...]

  • Page 31

    Ins tallation D rawing 21 TP- 6335 9/04 Sec t ion 7 Inst a llat ion D ra wing ADV-6816A-A Figure 7- 1 Dimens ion Drawing, G asoline F uel Sy st em[...]

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    TP- 6335 9/04 22 Ins tallat ion Draw ing ADV-6816B-A Figure 7- 2 Dimens ion Drawing, LP F uel Sy st em[...]

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    Ins tallation D rawing 23 TP- 6335 9/04 ADV-6816C-A Figure 7- 3 Dimens ion Drawing, F loor T emplat e[...]

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    TP- 6335 9/04 24 Ins tallat ion Draw ing Notes[...]

  • Page 35

    TP-6335 9/04 Reconnection/Adjustments 25 Section 8 Reconnection/Adjustments Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative ( - - ) lead first when disconnecting the battery . Reconnect the negative ( - - ) lead last when reconnecting the battery . W ARNIN[...]

  • Page 36

    26 Reconnection/Adjustments TP-6335 9/04 8.1 Four-Lead Reconnection The following drawings illustrate the reconnection of four-lead generator sets. In all cases, conform to the National Electrical Code (NEC). NOTICE V oltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the n[...]

  • Page 37

    TP-6335 9/04 Reconnection/Adjustments 27 200 - - 240-V olt 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). 43 2 1 Stator Leads L0 GRD. L1 L0 (Neutral) Line Side Single-Pole Circuit Breaker Groun[...]

  • Page 38

    28 Reconnection/Adjustments TP-6335 9/04 8.2 Advanced Digital Control (ADC 2100) The model 10/13/15ERG generator sets use the ADC 2100. The ADC 2100 uses password-protected menus for generator output adjustments and controller configuration. This section contains instructions for using the ADC’s password-protected menus to check and adjust the ge[...]

  • Page 39

    TP-6335 9/04 Reconnection/Adjustments 29 8.2.3 Adjusting the V oltage, Gain, and V olts/Hz After setting the system voltage, check the output voltage and adjust, if necessary , using the following procedures. Follow the instructions in Figure 8-6 to adjust the voltage, gain, and volts/Hz while the engine is running. An x in the Display column in Fi[...]

  • Page 40

    30 Reconnection/Adjustments TP-6335 9/04 TP6196 Move the generator set master switch to the RUN position. The generator set engine starts and the controller display shows the engine runtime hours. Display :* or or T o raise or lower the voltage in large increments (approximately 5 - - 7 volts per step). T o enter fine voltage adjustment mode. T o r[...]

  • Page 41

    TP-6335 9/04 Reconnection/Adjustments 31 D i s p l a y:* Continued from Figure 8 - 6: * x in the examples above denotes any number from 0 to 9. The actual values may vary from model-to-model. S A V E T o enter SA VE mode. Note: Be sure to save your settings before exiting the configuration mode. The controller reverts to the last saved settings whe[...]

  • Page 42

    32 Reconnection/Adjustments TP-6335 9/04 8.2.5 Controller Configuration The controller configuration for each generator model is set at the factory and should not normally require changes. The controller ’s configuration mode allows adjustment of the system parameters listed in this section. Use the instructions in this section to check the confi[...]

  • Page 43

    TP-6335 9/04 Reconnection/Adjustments 33 Parameter Setting Definition Unit’s system voltage and frequency Uu01 Single phase, 60 Hz, 120/240 V AC Unit configuration Uc02 Mobile generator set Engine type Ec03 10/13/15ERG Engine data input types ( N i i k ) Ed00 All digital inputs g p y p (No magnetic pick-up) Ed01 Digital: Low coolant level and low[...]

  • Page 44

    34 Reconnection/Adjustments TP-6335 9/04 W ait about 5 seconds until the display shows the program version number . (The number may be different than the one shown here.) Hold the Select button: or T o set the voltage/frequency setting for 60 Hz models. T o step to the next parameter , unit configuration Uc. or T o set the unit configuration settin[...]

  • Page 45

    TP-6335 9/04 Reconnection/Adjustments 35 or T o set the engine data input type. T o enter battery voltage selection mode. or T o toggle between 12 and 24 VDC. T o enter communications selection mode. or T o set the communications parameter . T o enter SA VE mode. Go to Figure 8 -1 1. E d 0 x Pressing the up arrow key at the Adnc display (See Figure[...]

  • Page 46

    36 Reconnection/Adjustments TP-6335 9/04 Notes[...]

  • Page 47

    TP-6335 9/04 Appendix A-1 Appendix A Generator S election and W attage Requirements General W attage Requirements Consider the total wattage requirements (lights, motors, appliances) when selecting a generator set, or when sizing wattage usage in which available space and construction limit the size of the generator set. Motor Loads When figuring g[...]

  • Page 48

    TP-6335 9/04 A-2 Appendix Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing AHWT anticipatory high water temperatur[...]

  • Page 49

    TP-6335 9/04 Appendix A-3 kg kilogram kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A kilovolt ampere kV AR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L [...]

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    E 2004 by Kohler Co. All rights reserved. TP-6335 9/04 KOHLER CO. Kohler , Wisconsin 53044 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 7 Jurong Pier Road Singapore 619159 Phone (65)6264-6422, Fax (65)6264-64[...]