Kohler 10ERG, 15ERG, 13ERG User Manual
Installation
Commercial Mobile Generator Sets
Model:
10ERG
13ERG
15ERG
TP-6335 9/04
Table of Contents
Safety Precautions and Instructions I.........................................................
Section 1 Introduction 1.....................................................................
1.1 Installation Standards 1..................................................
1.2 Generator Set Specifications 1............................................
1.3 Generator Set Operation 1...............................................
Section 2 Location and Mounting 3...........................................................
2.1 General Considerations 3................................................
2.2 Location 3.............................................................
2.3 Vehicle-Floor Mounting 3.................................................
Section 3 Cooling System 5..................................................................
3.1 Air Requirements 5......................................................
3.2 Block Heaters 5.........................................................
3.3 High Water Temperature Switch 5.........................................
3.4 Unit-Mounted Radiator Cooling 5..........................................
3.4.1 System Features 5..............................................
Section 4 Exhaust System 7.................................................................
4.1 Planning 8.............................................................
4.2 Clearance Requirements 8...............................................
4.3 Exhaust Piping, If Used 8................................................
Section 5 Fuel System 9.....................................................................
5.1 Gasoline 9.............................................................
5.1.1 Fuel Lines 10....................................................
5.2 Fuel Filters or Strainers 10.................................................
5.3 LP Gas 10..............................................................
5.4 Fuel Pump Lift and Fuel Consumption 11....................................
Section 6 Electrical System 13................................................................
6.1 Electrical Connections 13.................................................
6.2 AC Load Lead Connections 13.............................................
6.3 Circuit Protection 15......................................................
6.3.1 Circuit Breaker Considerations 15..................................
6.3.2 Circuit Breaker Installation 16......................................
6.4 ADC 2100 Continuous Power Mode Jumper 17...............................
6.5 Battery and Connections 18...............................................
6.6 Remote Connection 19...................................................
Section 7 Installation Drawing 21..............................................................
Section 8 Reconnection/Adjustments 25.......................................................
8.1 Four-Lead Reconnection 26...............................................
8.2 Advanced Digital Control (ADC 2100) 28....................................
8.2.1 Configuration Mode Time Out 28...................................
8.2.2 Controller Software Version Number 28..............................
8.2.3 Adjusting the Voltage, Gain, and Volts/Hz 29.........................
8.2.4 Voltage Adjustment 29............................................
8.2.5 Controller Configuration 32........................................
Appendix A Generator Selection and Wattage Requirements A-1.................................
Appendix B Abbreviations A-2................................................................
Notes
Safety Precautions and Instructions
IMPORTANT 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. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manualhas several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death,or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
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.
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, orengine start command from a
remote computer.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, asthis mayresult in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames orsparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove alljewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
TP-6335 9/04
Safety Precautions and Instructions I
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
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
WARNING
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide
poisoning symptoms include but are
not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improvewithin minutes of breathing
fresh air.
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
Generator set operation. Carbon
monoxide cancause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gasthat can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building unless the exhaust gas is
piped safely outside. Never operate
the generator set where exhaust gas
could accumulate and seep backinside
a potentially occupied building or
vehicle. Do not obstruct the exhaust
outlet when parking your vehicle. The
exhaust gasesmust discharge freely to
prevent carbon monoxide from
deflecting into the vehicle.
Installing the exhaust tail pipe.
Carbon monoxide can 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. Do not use flexible tail
piping because it could crack and allow
lethal exhaust f umes to enter the
vehicle.
Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the
safety of thevehicle’s occupants, install
a carbon monoxide detector. Consult
the coach builder or dealer for
approved detector location and
installation. Inspect the detector before
each generator set use. In addition to
routine exhaustsystem inspection, test
the carbon monoxide detector per the
manufacturer’s instructions and keep
the detector operational at all times.
II Safety Precautions and Instructions
TP-6335 9/04
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Explosive fuel vapors can cause
severe injury or death. Tak e
additional precautions when using the
following fuels:
Gasoline—Store gasoline only in
approved red containers clearly
marked GASOLINE.
Propane (LP)—Adequate ventilation
is mandatory. Because propane is
heavier than air, install propane gas
detectors low in a room. Inspect the
detectors per the manufacturer’s
instructions.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.
LP gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check theLP vapor gas fuel
system forleakage by using a soap and
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 because
both prevent bubble formation. A
successful test depends on the ability
of the solution to bubble.
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure tonoise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Electrical Shock
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Hazardous voltage.
Backfeed to the utility system can
cause severe injury, death, or
property damage.
Connect the generator set to the
building’s electrical system only
through an approved deviceand after
the building’s main switch is opened.
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Open the main circuit
breakers of all power sources before
servicing theequipment. Configure the
installation to electrically ground the
generator set, transfer switch, and
related equipment and electrical
circuits to comply with applicablecodes
and standards. Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
TP-6335 9/04
Safety Precautions and Instructions III
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 batterycharging 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 alljewelry 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 unauthorizedconnection to the
utility electrical system. Install a
transfer switch to prevent
interconnection of the generator set
power and other sources of power.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and followthe instructionsof the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approvedelectrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
system to operate automatically.
(600 volts and under)
Hot Parts
WARNING
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.
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 capwith 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 thecoolant 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
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
Moving rotor.
IV Safety Precautions and Instructions
TP-6335 9/04
WARNING
Airborne particles.
Can cause severe injury or
blindness.
Notice
NOTICE
This generator set has been
rewired fromits nameplate voltage
to
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
Tightening the hardware. Flying
projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator setengine andcan cause
personal injury. Retorque all
crankshaft and rotor hardware after
servicing. Do not loosen thecrankshaft
hardware or rotor thrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise can loosen the
hardware.
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replaceguards, screens,and
covers before operating the generator
set.
246242
NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
NOTICE
Hardware damage. The engine and
generator 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
hardware. Screws and nuts are
available in different hardness ratings.
To indicate hardness, American
Standard hardware uses a series of
markings, and metric hardware uses a
numeric system. Check the markings
on the bolt heads and nuts for
identification.
TP-6335 9/04
NOTICE
Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
NOTICE
This generator set does not comply
with United States Coast Guard
(USCG) requirements and must not
be used for marine applications. For
marine installations use only generator
sets specified for marine use. USCG
Regulation 33CFR183 requires that a
generator set must be ignition
protected when used in a
gasoline-fueled environment.
Safety Precautions and Instructions V
Notes
VI Safety Precautions and Instructions
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. Use this
manual as a guide for installing the mobile generator set.
Refer to the operation manual for operating instructions.
1.1 Installation Standards
Mobile generator set installations must comply with the
Kohler detailed installation instructions following and
state and local requirements.
The installer is responsible for improper installations
resulting in penalties from noncompliance with California
Air Resources Board (CARB) or Environmental
Protection Agency (EPA) emission standards as well as
state and local requirements.
1.2 Generator Set Specifications
1.3 Generator Set Operation
After the installer attaches the generator set to the
vehicle’s frame and makes connections, do the following
to make the generator set operational:
D Attach the exhaust system
D Add radiator coolant
D Add oil to the engine crankcase until the dipstick
indicates full
D Connect the fuel inlet and fuel return lines (for
gasoline models) or fuel inlet line (for LP models)
D Connect the remote switch, if equipped
D Connect the load leads
D Connect the battery terminals
Refer to the model’s specification sheet for details. Use
the spec sheet as a guide for planning the installation.
Use the current dimension drawing and wiring diagrams.
IntroductionTP-6335 9/04
1
Notes
2
Introduction TP-6335 9/04
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 generator set engine.
3. Ensure that the exhaust system meets all safety
requirements after installation.
4. Ensure compatibility of all electrical systems
(battery, load, and remote switch) with the vehicle’s
electrical systems.
2.2 Location
Note: This generator set is not designed for installation
in a compartment or enclosure.
Before making final plans for locating the generator set,
ensure the following:
2.3 Vehicle-Floor Mounting
Install the Kohler mobile generator set on an open
vehicle’s floor or truck bed. Follow the guidelines below.
Contact an authorized Kohler service distributor/dealer
with your specific application questions.
Minimum clearance. Allow clearance for vibration and
cooling during operation. Minimum clearance for
vibration (top, front, rear, and sides) is 38 mm (1 1/2 in.).
Keep the radiator end unobstructed for proper air flow.
Additional clearance. Generator set service requires
more clearance than 38 mm (1 1/2 in.). Design the
mounting location to allow for sufficient room to easily
remove the generator set to perform major service.
Securely fasten the generator set to avoid unwanted
movement from vibration and road shock. Attach the
generator set vibromounts directly to the vehicle’s
frame. See Figure 2-1 for vibromount installation.
1. The location has sufficient room to maintain
required minimum clearances.
2. The location provides enough air flow to allow
required cooling and combustion.
3. The location can support the generator set weight.
4. The location provides ample room for routine
service of the generator set’s engine, controller,
cooling system, and fuel system components.
See the current generator set specification sheet or
Section 7 of this manual for generator set dimensions
and weights.
For angular operating limits, consult the operation
manual.
Vibromount
Top V i ew
Color Mounting Location
Purple (2) Engine end
White (2) Generator end
1. Lock nut
2. Flat washer (7/16 x 1)
3. Generator set frame
4. Vibromount
5. Vehicle frame
6. Flat washer (13/32 x 2)
7. Screw (3/8--16 x 2--1/4)
Vibromount
Side View
123
4
5
6
7
ADV6816-
Figure 2-1 Vibromount Installation
TP-6335 9/04 Location and Mounting 3
Notes
4 Location and Mounting TP-6335 9/04
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/generator performance will be adversely
affected if these guidelines are neglected. Follow these
guidelines to optimize generator set performance.
Model Normal Intake Restriction
10/13/15ERG 0.06 psi (0.50 in. H2O)
Figure 3-1 Intake Restriction
3.2 Block Heaters
Block heaters are available as installed accessories on
these generator sets. Use block heaters in applications
where the generator set is subject to temperatures
below 16_C(60_F). Connect the block heater to a
power source that is energized when the generator set
is not running.
3.3 High Water Temperature Switch
Each generator set includes a high water temperature
shutdown switch that automatically shuts down the set if
operating temperatures climb too high. Follow the
guidelines described in Section 3.1 to prevent
shutdowns.
3.4 Unit-Mounted Radiator Cooling
The generator set is equipped with a unit-mounted
radiator common cooling system.
3.4.1 System Features
The system’s major components include an
engine-driven fan and circulating water pump, a
radiator, and a thermostat. The pump circulates water
through the engine until it reaches operating
temperature. Then, the engine thermostat opens,
allowing water circulation through the radiator. The
thermostat restricts water flow as necessary to prevent
overcooling. The fan blows air from the engine side of
the radiator across the cooling surface.
Note: Block heater damage. The block heater will fail if
the energized heater element is not immersed in
coolant. Fill the cooling system before turning on
the block heater. Run the engine until it is warm
and refill the radiator to purge the air from the
system before energizing the block heater.
TP-6335 9/04 Cooling System 5
Notes
6 Cooling System TP-6335 9/04
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