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IV Safety Precautions and Instructions

TP-6334

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 controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery-
charging

alternator

connections.

(5) Attach the weld ground connection
close to the weld location.

Short

circuits.

Hazardous

voltage/current can cause severe
injury or death.

Short circuits can

cause bodily injury and/or equipment
damage

.

Do not contact electrical

connections with tools or jewelry while
making

adjustments

or

repairs.

Remove all jewelry before servicing the
equipment.

Engine block heater.

Hazardous

voltage can cause severe injury or
death.

The engine block heater can

cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.

Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause

severe

injury

or

death.

Connect the generator set to the
building/campground electrical system
only through an approved device and
after the building/campground main
switch

is

opened.

Backfeed

connections can cause severe injury or
death to utility personnel working on
power lines and/or personnel near the
work area. Some states and localities
prohibit unauthorized connection to the
utility electrical system.

Install a

transfer

switch

to

prevent

interconnection of the generator set
power and other sources of power.

Hot Parts

Hot coolant and steam.
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

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 cause severe injury or
death.

Allow the engine to cool.

Release pressure from the cooling
system before removing the pressure
cap. To release pressure, cover the
pressure cap with a thick cloth and then
slowly turn the cap counterclockwise to
the first stop. Remove the cap after
pressure

has

been

completely

released and the engine has cooled.
Check the coolant level at the tank if the
generator set has a coolant recovery
tank.

Servicing the exhaust system. Hot
parts can cause severe injury or
death.

Do not touch hot engine parts.

The

engine

and

exhaust

system

components become extremely hot
during operation.

Combustible materials.

Fire can

cause severe injury or death.

A hot

exhaust system can ignite adjacent
combustible materials. Do not locate
electrical

wiring,

fuel

lines,

or

combustible

materials

above

the

exhaust muffler.

Exercise caution

when parking your vehicle to prevent
the exhaust system and hot exhaust
gases from starting grass fires.

Combustible materials.

Fire can

cause severe injury or death.

A hot

generator set can ignite debris in the
compartment. Keep the compartment
and generator set clean and free of
debris and combustible materials to
minimize the possibility of fire. Do not
block the fuel/oil drain opening in the
generator set mounting tray.

Cut a

corresponding hole in the subfloor, if
used, for the drain opening.

Moving Parts

Hazardous voltage.
Can cause severe injury or death.

Operate the generator set only when
all guards and electrical enclosures
are in place.

Moving rotor.

WARNING

Rotating parts.
Can cause severe injury or death.

Operate the generator set only when
all guards, screens, and covers are in
place.

WARNING

Airborne particles.
Can

cause

severe

injury

or

blindness.

Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.

WARNING

Содержание 10ERG

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

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 46: ......

Страница 47: ......

Страница 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...

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