Page 3 - Table of Contents
Table of Contents Safety Precautions and Instructions I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 Introduction 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 4 - Notes
Page 5 - Safety Precautions and Instructions; DANGER; Accidental Starting; Battery; WARNING
Safety Precautions and Instructions I TP-6335 9/04 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanicalequipment, including generator sets,transfer switches, switchgear, andaccessories, can cause bodily harmand pose life-threatening danger whenimproperly installed, op...
Page 6 - Exhaust System
II Safety Precautions and Instructions TP-6335 9/04 Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injuryand/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equi...
Page 7 - Fuel System; Hazardous Noise; CAUTION
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. WARNING The fuel system. Explosive fuel vapors can cause severe injury ordeath. Vaporized fuels are highly explosive. Use ...
Page 8 - Hot Parts; Moving Parts
IV Safety Precautions and Instructions TP-6335 9/04 Welding the generator set. Can cause severe electrical equipmentdamage. Before welding the generator set perform the following steps: (1) Remove the battery cables, negative (--) lead first. (2) Disconnectall engine electronic control module(ECM) c...
Page 9 - Notice; NOTICE
Safety Precautions and Instructions V TP-6335 9/04 Airborne particles.Can cause severe injury or blindness. Wear protective goggles and clothingwhen using power tools, hand tools,or compressed air. WARNING Tightening the hardware. Flying projectiles can cause severe injuryor death. Loose hardware ca...
Page 11 - Section 1 Introduction; Installation Standards
1 Introduction TP-6335 9/04 Section 1 Introduction All information in this publication represents dataavailable at the time of print. Kohler Co. reserves the rightto change this literature and the products representedwithout incurring obligation. The safe and successful operation of a mobile powersy...
Page 13 - Section 2 Location and Mounting; General Considerations; Additional clearance.
TP-6335 9/04 Location and Mounting 3 Section 2 Location and Mounting 2.1 General Considerations Consider the following items concerning the generatorset 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 sys...
Page 15 - Section 3 Cooling System; High Water Temperature Switch; System Features
TP-6335 9/04 Cooling System 5 Section 3 Cooling System 3.1 Air Requirements Air flow around the generator set is necessary foradequate cooling. See the current generator set specification sheet for air requirements. The air intakesilencer/cleaner provides combustion air to the engine.See Figure 3-1 ...
Page 17 - Section 4 Exhaust System
7 TP-6335 9/04 Exhaust System 7 Section 4 Exhaust System Carbon monoxide.Can cause severe nausea, fainting,or death. The exhaust system must be leakproof and routinely inspected. WARNING Generator set operation. Carbon monoxide can causesevere nausea, fainting, or death. Carbon monoxide is an odorle...
Page 18 - Planning; Verify that the installation; Clearance Requirements; Adding exhaust-pipe extensions; Allowable Exhaust Back Pressure
TP-6335 9/04 8 Exhaust System 4.1 Planning Carefully plan the generator exhaust system to ensure asafe, quiet installation. Verify that the installation complies with all state and local requirements andapplicable articles of the codes listed at the beginning ofthis manual. 4.2 Clearance Requirement...
Page 19 - Section 5 Fuel System
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. WARNING The fuel system. Explosive fuel vapors can cause severeinjury or death. Vaporized fuels are highly explosive. Use extreme care whe...
Page 20 - Fuel Lines; Sizing fuel inlet and return lines.; Fuel Filters or Strainers; Testing the fuel system.
TP-6335 9/04 10 Fuel System 5.1.1 Fuel Lines Note: Keep fuel lines away from the exhaust system. Routing fuel lines. Take care when routing the fuel line from the fuel tank to the generator set. Keep the fuellines as short as possible but maintain adequateclearance from the exhaust system. Route the...
Page 21 - Fuel Pump Lift and Fuel; Fines
TP-6335 9/04 Fuel System 11 5.4 Fuel Pump Lift and Fuel Consumption See Figure 5-3 for the fuel pump lift capability. Consultthe current generator set specification sheet for thegenerator set fuel consumption rates. Do not exceed3 1/2 psi fuel pump pressure to the carburetor. Note: Fuel system alter...
Page 23 - Section 6 Electrical System; Electrical Connections
TP-6335 9/04 Electrical System 13 Section 6 Electrical System Hazardous voltage.Can cause severe injury or death. Operate the generator set only whenall guards and electrical enclosuresare in place. Moving rotor. WARNING Electrical backfeed to the utility. Hazardous backfeedvoltage can cause severe ...
Page 24 - Protect the AC load
14 Electrical System TP-6335 9/04 Note: Transfer switch. Use a triple-pole, double-throw transfer switch rated for the calculated load of thevehicle to transfer the load from one source to theother. Install a ground-fault circuit interrupter inthe wiring system to protect all branch circuits. Note: ...
Page 25 - Circuit Protection; Circuit Breaker Considerations
TP-6335 9/04 Electrical System 15 6.3 Circuit Protection The AC circuit breaker protects the generator set fromextreme overload. The AC circuit breaker trips when itdetects a fault in the output circuit. For application and selection information contact anauthorized distributor/dealer. After correct...
Page 26 - Circuit Breaker Installation; circuit
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, conductorterminals and splices, and overcurrent protection(c...
Page 27 - Mode Jumper
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 controllercauses the controller to remain powered at all times.Controllers are shipped from the factory with the jumperconnected. Disconnecting the jumper causes the controller to ...
Page 28 - Battery and Connections
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 permanentdamage to eyes, burn skin, and eatholes in clothing. WARNING Battery gases. Explosion can cause severe injury ...
Page 29 - View A; Remote Connection; Non-Service Side View
TP-6335 9/04 Electrical System 19 -- + Battery Positive Vehicle Frame 12-Volt Battery Using the Same Battery as the Vehicle Engine N Battery Negative to Vehicle Frame Ground Strap Vehicle Frame -- + Battery Positive Vehicle Frame 12-Volt Battery Using a Separate Battery for the Generator Set N View ...
Page 31 - Section 7 Installation Drawing; Dimension Drawing, Gasoline Fuel System
Installation Drawing 21 TP-6335 9/04 Section 7 Installation Drawing ADV-6816A-A Figure 7-1 Dimension Drawing, Gasoline Fuel System
Page 32 - Dimension Drawing, LP Fuel System
TP-6335 9/04 22 Installation Drawing ADV-6816B-A Figure 7-2 Dimension Drawing, LP Fuel System
Page 33 - Dimension Drawing, Floor Template
Installation Drawing 23 TP-6335 9/04 ADV-6816C-A Figure 7-3 Dimension Drawing, Floor Template
Page 35 - Section 8 Reconnection/Adjustments
TP-6335 9/04 Reconnection/Adjustments 25 Section 8 Reconnection/Adjustments Accidental starting.Can cause severe injury or death. Disconnect the battery cables beforeworking on the generator set. Remove the negative (--) lead firstwhen disconnecting the battery. Reconnect the negative (--) lead last...
Page 36 - line
26 Reconnection/Adjustments TP-6335 9/04 8.1 Four-Lead Reconnection The following drawings illustrate the reconnection offour-lead generator sets. In all cases, conform to theNational Electrical Code (NEC). NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set t...
Page 37 - If the unit was originally wired for straight
TP-6335 9/04 Reconnection/Adjustments 27 200 -- 240-Volt Configurations The 200--240-volt configuration does not use a jumperlead. If the unit was originally wired for straight 100--120 volt, 3 wire, remove the jumper lead (seeFigure 8-1 for location). 4 3 2 1 Stator Leads L0 GRD. L1 L0 (Neutral) Li...
Page 38 - Advanced Digital Control; Configuration Mode Time Out
28 Reconnection/Adjustments TP-6335 9/04 8.2 Advanced Digital Control (ADC 2100) The model 10/13/15ERG generator sets use theADC 2100. The ADC 2100 uses password-protectedmenus for generator output adjustments and controllerconfiguration. This section contains instructions for using the ADC’spasswor...
Page 39 - Voltage Adjustment; Voltage Adjustment Procedure
TP-6335 9/04 Reconnection/Adjustments 29 8.2.3 Adjusting the Voltage, Gain, andVolts/Hz After setting the system voltage, check the outputvoltage and adjust, if necessary, using the followingprocedures. Follow the instructions in Figure 8-6 to adjust the voltage, gain, and volts/Hz while the engine ...
Page 40 - The controller is now in the voltage coarse adjustment mode.; x x; Output Voltage Adjustment Mode:
30 Reconnection/Adjustments TP-6335 9/04 TP6196 Move the generator set master switch to the RUN position. The generator setengine starts and the controller display shows the engine runtime hours. Display :* or or To raise or lower the voltage in large increments(approximately 5--7 volts per step). T...
Page 41 - in the examples above denotes any number from 0 to 9.; the last; S A V E; or; x x x x; Output Voltage Adjustments, Continued
TP-6335 9/04 Reconnection/Adjustments 31 Display : * 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 To enter SAVE mode. Note: Be sure to save your settings before exiting the configuration mode. The contro...
Page 42 - Controller Configuration; Adnc
32 Reconnection/Adjustments TP-6335 9/04 8.2.5 Controller Configuration The controller configuration for each generator model isset at the factory and should not normally requirechanges. The controller’s configuration mode allowsadjustment of the system parameters listed in thissection. Use the inst...
Page 43 - Controller Parameters
TP-6335 9/04 Reconnection/Adjustments 33 Parameter Setting Definition Unit’s system voltageand frequency Uu01 Single phase, 60 Hz, 120/240 VAC 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 yp (No magnetic pick-...
Page 44 - Hold the Select button:; A d n c; Now release the Select button.; Controller Configuration Mode
34 Reconnection/Adjustments TP-6335 9/04 Wait about 5 seconds until the display shows theprogram version number. (The number may bedifferent than the one shown here.) Hold the Select button: or To set the voltage/frequency setting for 60 Hzmodels. To step to the next parameter, unit configurationUc....
Page 45 - saved
TP-6335 9/04 Reconnection/Adjustments 35 or To set the engine data input type. To enter battery voltage selection mode. or To toggle between 12 and 24 VDC. To enter communications selection mode. or To set the communications parameter. To enter SAVE mode. Go to Figure 8-11. E d 0 x Pressing the up a...
Page 47 - Appendix A Generator Selection and Wattage Requirements; General Wattage Requirements; Motor Loads; Figure 1; Appliance Loads; Figure 2
TP-6335 9/04 Appendix A-1 Appendix A Generator Selection and Wattage Requirements General Wattage Requirements Consider the total wattage requirements (lights, motors,appliances) when selecting a generator set, or whensizing wattage usage in which available space andconstruction limit the size of th...
Page 48 - Appendix B Abbreviations
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 dimension...
