Kohler 10ERG Operation Manual Download Page 3

Page: 3 / 48

TP-6334 9/04

Table of Contents

Product Information

Inside front cover

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions and Instructions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Service Parts/Related Literature

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Service Views

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Prestart Checklist

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Angular Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Exercising the Generator Set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4

Advanced Digital Control Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1

Controls and Indicators

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2

Starting the Generator Set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3

Stopping the Generator Set

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.4

Fault Shutdowns

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.5

Resetting the Controller after a Fault Shutdown

. . . . . . . . . . . . . . . . . . . .

2.4.6

Continuous Power Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Circuit Protection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1

Line Circuit Breaker

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2

Fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Scheduled Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

General Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Service Schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Lubrication System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1

Oil Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2

Oil Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3

Oil Additions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4

Oil Change

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5

Oil Filter Change

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Gasoline Fuel System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1

Fuel Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2

Fuel Filter (Gasoline)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Gaseous Fuel System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1

Carburetor (LP Vapor)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6

Air Cleaner

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7

Exhaust System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.1

Checking the Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.2

Draining the Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.3

Filling the Cooling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.4

Flushing and Cleaning

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.5

Pressure Cap

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9

Ignition System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Battery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11

Belt Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 Generator Storage Procedure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Wiring Diagrams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations

A-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Operating Hour Service Log

A-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Summary of Contents for 10ERG

Page 1: ...Commercial Mobile Generator Sets Model 10ERG 13ERG 15ERG TP 6334 9 04 Operation...

Page 2: ...ow immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Num...

Page 3: ...Breaker 7 2 5 2 Fuses 7 Section 3 Scheduled Maintenance 9 3 1 General Maintenance 9 3 2 Service Schedule 10 3 3 Lubrication System 12 3 3 1 Oil Specifications 12 3 3 2 Oil Check 12 3 3 3 Oil Additions...

Page 4: ......

Page 5: ...to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery Sulfuric acid in batteries Can cause severe in...

Page 6: ...xide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathingexhaustfumeswhenworking on or near the generator set Never operate the ge...

Page 7: ...ge by usinga soapand water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine becau...

Page 8: ...re cap to relieve pressure WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools WARNING Checking the coolant level Hot coolant can cau...

Page 9: ...or set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade...

Page 10: ...VI Safety Precautions and Instructions TP 6334 9 04 Notes...

Page 11: ...e generator set x in 001 002 a Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer D Consult t...

Page 12: ...23316 Fuse Controller F3 10 amp 223316 Oil Filter GM28351 Spark Plug GM35826 Spray Paint Black 221292 Figure 1 Maintenance and Service Parts x in 001 004 List of Related Literature Figure 2 identifies...

Page 13: ...coolant 10 Radiator 11 Oil fill on valve cover 12 Fuel filter gasoline models 13 Coolant drain 14 Fuel solenoid LP models only 15 Lube oil filter 16 Oil drain valve 17 Fuel feed pump fuel inlet gasol...

Page 14: ...TP 6334 9 04 2 Service Views Notes...

Page 15: ...needed D Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed D Check that the exhaust outlet is unobstructed D Check the exhaust gas...

Page 16: ...ction 2 4 6 The buttons on the controller keypad are used only for system configuration and adjustment The controller is factory set and should not require configuration or adjustment under normal ope...

Page 17: ...Note The ADC 2100 allows three crank cycle attempts before the overcrank shutdown occurs 2 4 3 Stopping the Generator Set The following procedures describe the actions required to stop the generator...

Page 18: ...mal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service if problem continues OU Overvoltage shutdown Shutdown occurs if the voltage exceeds 120 of the voltage...

Page 19: ...position 0 mA draw Disconnecting the jumper allows the controller to power down automatically 48 hours after the generator set shuts down if the generator set master switch is in the AUTO position A r...

Page 20: ...8 Operation TP 6334 9 04 Notes...

Page 21: ...r Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not...

Page 22: ...ed intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on 3 2 S...

Page 23: ...he battery charged and in good condition 3 10 X Check and tighten electrical connections X Clean the battery cables As required ENGINE AND MOUNTING Check for water fuel coolant and oil leakage X Retig...

Page 24: ...t level to get an accurate reading To check the oil level remove the dipstick and wipe the end clean reinsert and remove Maintain the oil level between the Full and Add marks on the dipstick as shown...

Page 25: ...rags to clean up spilled oil Dispose of the oil filter in an approved manner 2 Clean the contact surface of the oil filter adapter 3 Lightly lubricate the gasket surface of the new filter with fresh e...

Page 26: ...replace the air cleaner element Clean the element more frequently in dirty dusty conditions Check the element for accumulated oil or dirt that could cause poor performance Replace a damaged air clean...

Page 27: ...m Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure WARNING Checking the coolant level Hot...

Page 28: ...th the specified coolant Consult the engine manufacturer s operation manual for engine coolant specifications 3 Replace the radiator s pressure cap 4 Operate the engine until the thermostat opens and...

Page 29: ...Excess oil entering combustion chamber through worn rings and pistons excessive clearance between valve guides and stems or worn or loose bearings Replace the spark plug Carbon fouled spark plug Blac...

Page 30: ...lug Gap Inspection 7 Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap See Figure 3 10 Position the side electrode directly ove...

Page 31: ...ng the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a g...

Page 32: ...3 8 Note Use antifreeze capable of withstanding the lowest possible temperatures 6 Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs 7 Clean the exterior of...

Page 33: ...he generator set installation manual I M and the engine service manual Engine S M to correct the indicated problem Corrective action and testing often require knowledge of electrical and electronic ci...

Page 34: ...x Controller circuit breaker tripped Reset the controller circuit breaker Section 2 x Controller master or start stop switch inoperative Replace the controller master or start stop switch x Controller...

Page 35: ...retighten the connection Engine x x x x Air cleaner backfire flame arrestor clogged Clean or replace the filter element Section 2 x x x x x Compression weak Check the compression Eng S M x x x x x Eng...

Page 36: ...the fuel supply S S x Fuel solenoid inoperative gas only Troubleshoot the fuel solenoid S M Generator x AC output circuit breaker open Reset the breaker and check for AC voltage at the generator side...

Page 37: ...onnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Hazardou...

Page 38: ...TP 6334 9 04 26 Section 5 Wiring Diagrams GM28747A C Figure 5 1 Wiring Diagram Sheet 1 of 2...

Page 39: ...TP 6334 9 04 27 Section 5 Wiring Diagrams GM28747B C Figure 5 2 Wiring Diagram Sheet 2 of 2...

Page 40: ...TP 6334 9 04 28 Section 5 Wiring Diagrams ADV6846A A Figure 5 3 Schematic Diagram Sheet 1 of 2...

Page 41: ...TP 6334 9 04 29 Section 5 Wiring Diagrams ADV6846B A Figure 5 4 Schematic Diagram Sheet 2 of 2...

Page 42: ...TP 6334 9 04 30 Section 5 Wiring Diagrams GM33846 A Figure 5 5 Accessory Wiring Diagram...

Page 43: ...oled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO...

Page 44: ...OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase P...

Page 45: ...Log Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed Enter hours to the nearest quarter hour OPERATING HOURS SERVIC...

Page 46: ......

Page 47: ......

Page 48: ...isconsin 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...

Search results

Summary of Contents for 10ERG

Reviews:

Related manuals for 10ERG

Brands by name

Popular brands

Kohler 10ERG, Operation Manual

Search results

Summary of Contents for 10ERG

Reviews:

Related manuals for 10ERG

Brands by name

Popular brands