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  • RV/Mobile Generator Sets

    Models:

    15/20CCO15/20CCFO15/20CCOZ

    15/20CCFOZ

    TP-5605 4/97a

    Operation andInstallation

  • Engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

    WARNINGCalifornia Proposition 65

  • TP-5605 4/97 Table of Contents

    Table of ContentsSUBJECT PAGE SUBJECT PAGESafety Precautions and Instructions I. . . . . . .

    Introduction i. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Service Assistance i. . . . . . . . . . . . . . . . . . . . . . .Routine Service Parts ii. . . . . . . . . . . . . . . . . . . .

    Section 1. Specifications 1-1. . . . . . . . . . . . . . . . .Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    General Specifications 1-1. . . . . . . . . . . . . . . . . .Engine 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Models 15/20 kW 1-4. . . . . . . . . . . . .

    Section 2. Operation 2-1. . . . . . . . . . . . . . . . . . . . .Prestart Checklist 2-1. . . . . . . . . . . . . . . . . . . . . . . . .

    Exercising the Generator 2-1. . . . . . . . . . . . . . . .Controller (Single-Phase) 2-2. . . . . . . . . . . . . . . . . . .Controller (Three-Phase) 2-3. . . . . . . . . . . . . . . . . . .Preheat Feature 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . .Starting Procedure 2-4. . . . . . . . . . . . . . . . . . . . . . . .Stopping Procedure 2-4. . . . . . . . . . . . . . . . . . . . . . .Fault Shutdowns 2-4. . . . . . . . . . . . . . . . . . . . . . . . . .

    Low Oil PressureShutdown Switch 2-4. . . . . . . . . . . . . . . . . . . . .

    High Water TemperatureShutdown Switch 2-5. . . . . . . . . . . . . . . . . . . . .

    Circuit Protection 2-5. . . . . . . . . . . . . . . . . . . . . . . . . .

    Section 3. Scheduled Maintenance 3-1. . . . . . . .General 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication System 3-3. . . . . . . . . . . . . . . . . . . . . . . .

    Oil Selection 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Check 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Change 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Filter 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel System 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Specification 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Filter 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bleeding the Fuel System 3-7. . . . . . . . . . . . . . .Fuel Solenoid 3-8. . . . . . . . . . . . . . . . . . . . . . . . . .

    Air Cleaner Service 3-8. . . . . . . . . . . . . . . . . . . . . . . .Governor 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling System 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . .Belt Tension 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Charging 3-12. . . . . . . . . . . . . . . . . . . . . . . . . .Battery 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cleaning 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Checking Electrolyte Level 3-14. . . . . . . . . . . . . . .Checking Specific Gravity 3-14. . . . . . . . . . . . . . .

    Gauge Connections for Single-Phase Models 3-15.Wattage Requirements 3-16. . . . . . . . . . . . . . . . . . . . .Generator Service 3-17. . . . . . . . . . . . . . . . . . . . . . . . .

    General 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Storage Procedure 3-17. . . . . . . . . . . . . . . . . . . . . . . .

    Section 4. Troubleshooting 4-1. . . . . . . . . . . . . . .Engine 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical System 4-4. . . . . . . . . . . . . . . . . . . . . . . .Generator 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Section 5. Wiring Diagrams 5-1. . . . . . . . . . . . . . .Voltage Reconnection 5-1. . . . . . . . . . . . . . . . . . . . . .

    Voltage Reconnection Procedure 5-2. . . . . . . . . . .12-Lead (Three-Phase) Generator Sets 5-3. . . . .

    Section 6. Installation 6-1. . . . . . . . . . . . . . . . . . . .Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Features 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Generator Selection And

    Wattage Requirements 6-2. . . . . . . . . . . . . . . . . . .Installation Factors 6-2. . . . . . . . . . . . . . . . . . . . .Electrical Load 6-2. . . . . . . . . . . . . . . . . . . . . . . . .Lighting Load 6-2. . . . . . . . . . . . . . . . . . . . . . . . . .Motor Loads 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . .Appliance Loads 6-4. . . . . . . . . . . . . . . . . . . . . . . .Kilowatt Derating 6-4. . . . . . . . . . . . . . . . . . . . . . .Compartment Size 6-4. . . . . . . . . . . . . . . . . . . . . .Air Requirements 6-6. . . . . . . . . . . . . . . . . . . . . . .Remote Radiator Cooling System 6-9. . . . . . . . .

    Fuel System 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Lines 6-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Exhaust Systems 6-15. . . . . . . . . . . . . . . . . . . . . . . . . .Electrical Systems 6-17. . . . . . . . . . . . . . . . . . . . . . . . .

    Battery And Connections 6-17. . . . . . . . . . . . . . . .AC Load Lead Connections 6-19. . . . . . . . . . . . . .Remote Switch Connection

    (Single-Phase Models Only) 6-20. . . . . . . . . . . .

    Section 7. Installation Drawings 7-1. . . . . . . . . . .

    Appendix A. Glossary of Abbreviations A-1. . . .

    Appendix B. Operating Hour Service Log B-1. .

  • TP-5605 4/97 Safety Precautions and Instructions I

    Safety Precautions and InstructionsA generator set, like any other electromechanicaldevice, can pose potential dangers to life and limb ifimproperly maintained or operated. The best way toprevent accidents is to be aware of potential dangersand act safely. Please read and follow the safetyprecautions and instructions below to prevent harm toyourself and others. This manual contains several typesof safety precautions and instructions which areexplained below. SAVE THESE INSTRUCTIONS.

    DANGER

    Danger indicates the presence of a hazard that willcause severe personal injury, death, or substantialproperty damage.

    WARNING

    Warning indicates the presence of a hazard that cancause severe personal injury, death, or substantialproperty damage.

    CAUTION

    Caution indicates the presence of a hazard that will orcan cause minor personal injury or property damage.

    NOTICENotice communicates installation, operation, ormaintenance information that is important but nothazard related.

    Safety decals affixed to the generator set in prominentplaces advise the operator or service technician ofpotential hazards and how to act safely. The decals arereproduced in this publication to improve operatorrecognition. Replace missing or damaged decals.

    Accidental Starting

    Accidental starting.Can cause severe injury or death.

    Disconnect battery cables before working ongenerator set (disconnect negative lead first andreconnect it last).

    WARNING

    Disabling generator set. Accidental starting cancause severe injury or death. Disconnect batterycables (remove negative lead first and reconnect it last)to disable generator set before working on the generatorset or connected equipment. The generator set can bestarted by the remote start/stop switch unless thisprecaution is followed.

    Battery

    Sulfuric acid in batteries.Can cause severe injury or death.

    Use protective goggles and clothes. Battery acid cancause permanent damage to eyes, burn skin, and eatholes in clothing.

    WARNING

    Battery acid. Sulfuric acid in batteries can causesevere injury or death. Sulfuric acid in battery cancause permanent damage to eyes, burn skin, and eatholes in clothing. Always wear splash-proof safetygoggles when working near the battery. If battery acid issplashed in the eyes or on skin, immediately flush theaffected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case ofeye contact. Never add acid to a battery after placing thebattery in service, as this may result in hazardousspattering of battery acid.

  • II Safety Precautions and Instructions TP-5605 4/97

    Battery gases. Explosion can cause severe injuryor death. Battery gases can cause an explosion. Donot smoke or permit flame or spark to occur near abattery at any time, particularly when it is charging.Avoid touching terminals with tools, etc., to preventburns and sparks that could cause an explosion.Remove wristwatch, rings, and any other jewelry beforehandling battery. Never connect negative (--) batterycable to positive (+) connection terminal of startersolenoid. Do not test battery condition by shortingterminals together. Sparks could ignite battery gases orfuel vapors. Ventilate any compartment containingbatteries to prevent accumulation of explosive gases.To avoid sparks, do not disturb battery chargerconnections while battery is being charged. Always turnbattery charger off before disconnecting batteryconnections. Remove negative lead first and reconnectit last when disconnecting battery.

    Engine Backfire/Flash FireWARNING

    Fire.Can cause severe injury or death.

    Do not smoke or permit flame or spark to occurnear fuel or fuel system.

    Servicing fuel system. A flash fire can cause severeinjury or death. Do not smoke or permit flame or sparkto occur near carburetor, fuel line, fuel filter, fuel pump,or other potential sources of spilled fuel or fuel vapors.Catch all fuel in a suitable container when removing fuelline or carburetor.

    Servicing air cleaner. A sudden backfire can causesevere injury or death. Do not operate with air cleanerremoved.

    Exhaust SystemWARNING

    Carbon monoxide.Can cause severe nausea, fainting, or death.

    The exhaust system must be leakproof androutinely inspected.

    Generator set operation. Carbon monoxide cancause severe nausea, fainting, or death. Neveroperate the generator set inside a building unless theexhaust gas is piped safely outside. Never operate inany area where exhaust gas could accumulate andseep back inside a potentially occupied building orvehicle. Be careful when parking your vehicle to avoidobstructing the exhaust outlet. The exhaust gases mustdischarge freely to prevent carbon monoxide fromdeflecting into the vehicle. Avoid breathing exhaustfumes when working on or near the generator set.Carbon monoxide is particularly dangerous because it isan odorless, colorless, tasteless, nonirritating gas thatcan cause death if inhaled for even a short period oftime.

    Carbon monoxide symptoms. Carbon monoxidecan cause severe nausea, fainting, or death. Carbonmonoxide is a poisonous gas which is present inexhaust gases. Carbon monoxide poisoning symptomsinclude but are not limited to the following:

    D Light-headedness, dizzinessD Physical fatigue, weakness in joints and musclesD Sleepiness, mental fatigue, inability to concentrate

    or speak clearly, blurred visionD Stomachache, vomiting, nausea

    If experiencing any of these symptoms and carbonmonoxide poisoning is possible, affected personsshould seek fresh air immediately. They should remainactive. They should not sit, lie down, or fall asleep. Alertothers to the possibility of carbon monoxide poisoning.If the condition of affected persons does not improvewithin minutes of breathing fresh air, they should seekmedical attention.

    Copper tubing exhaust systems. Carbon monoxidecan cause severe nausea, fainting, or death. Do notuse copper tubing in diesel exhaust systems. Sulfur indiesel exhaust causes rapid deterioration of coppertubing exhaust systems resulting in exhaust leakage.

  • TP-5605 4/97 Safety Precautions and Instructions III

    Installing exhaust tail pipe. Carbon monoxide cancause severe nausea, fainting, or death. Installexhaust system tail pipe so discharged exhaust gaseswill not be drawn into vehicle interior through windows,doors, air conditioners, etc. Do not use flexible tailpiping because it could crack and allow lethal exhaustfumes to enter the vehicle.

    Inspecting exhaust system. Carbon monoxide cancause severe nausea, fainting, or death. In additionto routine exhaust system inspection, install a carbonmonoxide detector. Consult your coach builder ordealer for approved detector installation. Inspect yourdetector before each generator set use.

    Fuel System

    Explosive fuel vapors.Can cause severe injury or death.

    Use extreme care when handling, storing,and using fuels.

    WARNING

    Fuel system. Explosive fuel vapors can causesevere injury or death. All fuels are highly explosive ina vapor state. Use extreme care when handling andstoring fuels. Store fuel in a well-ventilated area awayfrom spark-producing equipment and out of the reach ofchildren. Never add fuel to the tank while the engine isrunning since spilled fuel may ignite on contact with hotparts or from ignition spark. Do not smoke or permitflame or spark to occur near sources of spilled fuel orfuel vapors. Keep fuel lines and connections tight and ingood condition. Do not replace flexible fuel lines withrigid lines. Use flexible sections to avoid breakagecaused by vibration. Do not operate generator set in thepresence of fuel leaks, fuel accumulation, or sparks.Repair systems before resuming generator setoperation

    Draining fuel system. Explosive fuel vapors cancause severe injury or death. Spilled fuel can causean explosion. Use a container to catch fuel whendraining fuel system. Wipe up all spilled fuel afterdraining system.

    Hazardous Noise

    Hazardous noise.Can cause loss of hearing.

    Never operate generator set without a muffler orwith a faulty exhaust system.

    CAUTION

    Hazardous Voltage/Electrical Shock

    WARNING

    Hazardous voltage. Moving rotor.

    Can cause severe injury or death.

    Operate generator set only with all guards andelectrical enclosures in place.

    WARNING

    Hazardous voltage.Backfeed to utility system can cause severeinjury, death, or property damage.

    Connect generator set to building electrical systemonly through an approved device and after buildingmain switch is open.

    Grounding generator set. Hazardous voltage cancause severe injury or death. Electrocution ispossible whenever electricity is present. Open maincircuit breakers of all power sources before servicingequipment. Configure the installation to electricallyground the generator set and electrical circuits when inuse. Never contact electrical leads or appliances whenstanding in water or on wet ground, as the chance ofelectrocution is increased under such conditions.

  • IV Safety Precautions and Instructions TP-5605 4/97

    Short circuits. Hazardous voltage can cause severeinjury or death. Short circuits can cause bodily injuryand/or equipment damage. Do not contact electricalconnections with tools or jewelry while adjustments aremade. Remove wristwatch, rings, and jewelry beforeservicing equipment.

    Engine block heater. Hazardous voltage can causesevere injury or death. Engine block heater can causeelectrical shock. Remove engine block heater plug fromelectrical outlet before working on block heater electricalconnections.

    Electrical backfeed to utility. Hazardous backfeedvoltage can cause severe injury or death. Connectgenerator set to building/campground electrical systemonly through an approved device and afterbuilding/campground main switch is open. Backfeedconnections can cause serious injury or death to utilitypersonnel working on power lines and/or personnel inthe vicinity of the work area. Unauthorized connection toutility electrical system may be unlawful in some statesand/or localities. Install a transfer switch to preventinterconnection of generator set power and othersources of power.

    Heavy Equipment

    Unbalanced weight.Improper lift can cause severe injury or deathand/or equipment damage.

    Do not use lifting eyes.Use slings under skid to balance and lift generatorset.

    WARNING

    Hot PartsWARNING

    Hot coolant and steam.Can cause severe injury or death.

    Before removing pressure cap, stop generator setand allow it to cool. Then loosen pressure cap torelieve pressure.

    WARNING

    Hot engine and exhaust system.Can cause severe injury or death.

    Do not work on generator set until it is allowed tocool.

    Checking coolant level. Hot coolant can causesevere injury or death. Allow engine to cool. Releasepressure from cooling system before opening pressurecap. To release pressure, cover the pressure cap with athick cloth; then slowly turn it counterclockwise to thefirst stop. Remove cap after pressure has beencompletely released and the engine has cooled. Checkcoolant level at tank if generator set is equipped with acoolant recovery tank.

    Servicing exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts.An engine becomes hot while running and exhaustsystem components become extremely hot.

    Combustible materials. Fire can cause severeinjury or death. Hot exhaust system can igniteadjacent combustible materials. Do not locate electricalwiring, fuel lines, or combustible material above theexhaust muffler. Exercise caution when parking yourvehicle to prevent exhaust system and hot exhaustgases from starting grass fires.

  • TP-5605 4/97 Safety Precautions and Instructions V

    Combustible materials. Fire can cause severeinjury or death. Hot generator set can ignite debris incompartment. Keep the compartment and generatorset clean and free of debris and combustible materials tominimize possibility of fire. Do not block fuel/oil drainopening in generator set mounting tray. Cut acorresponding hole in the subfloor for drain opening ifsubfloor is used.

    Moving PartsWARNING

    Hazardous voltage. Moving rotor.

    Can cause severe injury or death.

    Operate generator set only with all guards andelectrical enclosures in place.

    WARNING

    Rotating parts.Can cause severe injury or death.

    Do not operate generator set without all guards,screens, and covers in place.

    Tightening hardware. Flying projectiles can causesevere injury or death. Retorque all crankshaft androtor hardware after servicing. Do not loosen crankshafthardware or rotor thrubolt when making adjustments orservicing generator set. Rotate crankshaft manually in aclockwise direction only. Turning crankshaft bolt or rotorthrubolt counterclockwise can loosen hardware. Loosehardware can cause hardware or pulley to release fromengine of generator set and can cause personal injury.

    Servicing generator set when operating. Exposedmoving parts can cause severe injury or death.Keep hands, feet, hair, clothing, and test leads awayfrom belts and pulleys when generator set is running.Replace guards, screens, and covers before operatinggenerator set.

    NoticeNOTICE

    This generator set has been rewired from itsnameplate voltage to:

    246242

    NOTICEVoltage reconnection! Affix notice to generator setafter reconnecting to a voltage different than thenameplate. Order voltage reconnection decal 246242from authorized service distributors/dealers.

    NOTICEHardware damage! Engine and generator set may useboth American Standard and metric hardware. Use thecorrect size tools to prevent rounding of bolt heads andnuts.

    NOTICEWhen replacing hardware, do not substitute withinferior grade hardware. Screws and nuts areavailable in different hardness ratings. AmericanStandard hardware uses a series of markings andmetric hardware uses a numeric system to indicatehardness. Check markings on bolt head and nuts foridentification.

    NOTICECanadian installations only:For standby service connect output of generator set to asuitably rated transfer switch in accordance withCanadian Electrical Code, Part 1.

    NOTICEThis generator set does not comply with UnitedStates Coast Guard (U.S.C.G.) requirements andmust not be used for marine applications. Use onlygenerator sets specified for marine use in marineinstallations. U.S.C.G. Regulation 33CFR183 requiresa generator set to be ignition protected when used in agasoline-fueled environment.

  • VI Safety Precautions and Instructions TP-5605 4/97

    Notes

  • TP-5605 4/97 Introduction i

    IntroductionAll information in this publication represents dataavailable at time of printing. Kohler Co. reserves theright to change this literature and the productsrepresented without incurring obligation.

    Read through this manual and carefully follow allprocedures and safety precautions to ensure properequipment operation and to avoid bodily injury. Readand follow the Safety Precautions and Instructionssection at the beginning of this manual. Keep this

    manual with equipment for future reference.

    Equipment service requirements are minimal but arevery important to safe and efficient operation; therefore,inspect parts often and perform required service at theprescribed intervals. An authorized servicedistributor/dealer should perform required service tokeep equipment in top condition.

    Service AssistanceFor sales and service in the U.S.A. and Canada checkthe yellow pages of the telephone directory under theheading GENERATORS ELECTRIC for an authorizedservice distributor/dealer or call 1-800-544-2444.

    For sales and service outside the U.S.A. and Canada,contact your local distributor.

    For further information or questions, contact thecompany directly at the following address or number:

    KOHLER CO., Kohler, Wisconsin 53044 U.S.A.Phone: 414-565-3381Fax: 414-459-1646 (U.S.A. Sales)

    414-459-1614 (International)

    To ensure supply of correct parts or information, makenote of the following identification numbers in thespaces provided:

    GENERATOR SET

    Model No.

    Specification No.

    Serial No.

    MODEL, SPEC, and SERIAL numbers are found on thenameplate attached to the generator set.

    Accessory Nos.

    GENERATOR SET ACCESSORIES

    An alternate nameplate inside the junction boxidentifies factory-installed generator set accessories.

    ENGINE

    Engine Serial No.

    The engine serial number is found on the enginenameplate.

  • ii Introduction TP-5605 4/97

    Routine Service PartsKohler generator distributor/dealers have a completelisting of parts for each generator set. Contact the localKohler generator distributor/dealer for service.

    Part Decsription Kohler Part No.Air cleaner element 258646Oil filter 229841Fuel filter 225010Alternator V-belt 225626Black spray paint 221292

  • TP-5605 4/97 Specifications 1-1

    Section 1. Specifications

    IntroductionYour vehicle is equipped with a dependable Kohleralternating-current RV/Mobile Generator Set. Servicerequirements of the generator set are minimal, but it isimportant that the required services be performed at theprescribed intervals. Please take a few moments toread through this manual; then carefully follow allservice recommendations to keep your set in topcondition. In the space provided, record the MODEL,SPECIFICATION, SERIAL and ENGINE SPEC.numbers as found on the nameplate attached to the belt

    guard of the engine for remote-radiator models and onthe radiator bracket for in-line radiator models (seeSection 8 Service Ordering Instructions). Thisinformation will enable your Kohler Generator ServiceDealer/Distributor to supply the correct part or data foryour particular version. Keep this manual in your vehiclefor future reference. The illustrations in this manual arerepresentative of most units. Your generator set maydiffer slightly from those shown.

    General Specifications15 kW (60Hz) 20 kW (60Hz)

    Dimensions L x W x H in. (mm):Remote Radiator (Single Phase) 39.57 x 20.89 x 25.61 39.57 x 20.89 x 27.25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (1005 x 531 x 650) (1005 x 531 x 692)Remote Radiator (Single Phase) Airbag Mounted 39.57 x 22.00 x 25.61 39.57 x 22.00 x 28.51. . . . . . . . . . . . . . . . . . . .

    (1005 x 559 x 650) (1005 x 559 x 724)In-line Radiator (Single Phase) 45.02 x 20.99 x 28.00 45.02 x 20.99 x 28.00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (1144 x 533 x 711) (1144 x 533 x 711)In-line Radiator (Three Phase) 46.62 x 20.99 x 28.00 46.62 x 20.99 x 28.00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (1184 x 533 x 711) (1184 x 533 x 711)Weight dry, lbs. (kg):

    Remote Radiator (Single Phase) 684 (310) 695 (315). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote Radiator (Single Phase) Airbag Mounted N/A N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line Radiator (Single Phase) 719 (326) 730 (331). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line Radiator (Three Phase) 719 (326) 730 (331). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Air Requirements CFM (M3/min):Combustion. 70 (2) 70 (2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling 1930 (55) 1930 (55). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel Inlet Size in. (mm) 1/4-18 N.P.S.F 1/4-18 N.P.S.F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Return Size in. (mm) 1/4-18 N.P.S.F 1/4-18 N.P.S.F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Fuel Consumption gph (Lph):Load 25% 50% 75% 100%15 kW 0.6 (2.3) 0.8 (3.0) 1.1 (4.2) 1.4 (5.3)20 kW 0.9 (3.4) 1.2 (4.5) 1.5 (5.7) 1.9 (7.2)

    DERATION: All units are rated 1.0 power factor. The kilowatts of the generator set will decrease 3.5% for each 1,000 feet (305 meters) above500 feet (152 meters) above sea level and 1% for each 10_F (5.5_C) above 85_F (30_C).

  • TP-5605 4/971-2 Specifications

    EngineSome general engine specifications are listed below.Refer to the appropriate service section and the engineservice manual for specific service details.

    15 kW 20 kWManufacturer Yanmar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Model 4TN84E-RK 4TN84TE-TK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Type Water-cooled, 4-cycle diesel engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Number Cylinders 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Firing Order 1-3-4-2 1-3-4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Compression Ratio 17.79:1 16.99:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Displacement cu. in. (cm3) 116 (1910). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rated Horsepower (60 Hz) 27.4 36.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RPM (60 Hz) 1800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bore in. (mm) 3.307 (84). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stroke in. (mm) 3.386 (86). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Combustion System Direct Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valve Clearance in. (mm)

    Intake 0.0079 (0.2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust 0.0079 (0.2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cylinder Block Material Cast Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder Head Tightening Torque ft. lbs (Nm)

    Step 1: 25.23--31.1 (3.5--4.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Step 2: 54.23--61.46 (7.5--8.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Cylinder Head Material Cast Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Rod Forged Carbon Steel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston Rings 2 Compression/1 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main Bearings, Number and Type 4, Replaceable Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Governor Mechanical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication System Full Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Capacity (with filter) qts. (L) 6.1 (5.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Type (API) CC or CD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Pressure psi (kPa) 42.66--56.88 (294--392). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Recommendation Diesel ASTM D975 No. 2-D (Cetane No. > 45). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Aspiration Natural Aspiration Turbocharged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Injection Pump Yanmar YPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Voltage 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Ground Negative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery Recommendation (min.) 625 Cold Cranking Amps 100 Amp Hr.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter Motor Bendix Automotive Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling System Capacity qts. (L)

    Remote Radiator (Engine Water Jacket) 2.85 (2.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line Radiator 4 qts. 16 oz. (4.26). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Timing 16_ 1_ 12_ 1_. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air Cleaner Dry Paper Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

  • TP-5605 4/97 Specifications 1-3

    GeneratorModels 15CCO/CCFO/CCOZ/CCFOZ

    Model Voltage Amps/Series Code Voltage Wire Pole kW PH60 Hz Models:15CCO 61 120/240 3 62.5 15.0 115CCO 101 100/200 3 75.0 15.0 115CCOZ 01 120/240 4 45.1 15.0 315CCOZ 51 139/240 4 45.1 15.0 315CCOZ 51 127/220 4 49.2 15.0 315CCOZ 71 227/480 4 22.6 15.0 315CCOZ 71 240/416 4 26.0 15.0 315CCOZ 81 120/208 4 52.0 15.0 3

    50 Hz Models:15CCFO 101 120/240 3 52.1 12.5 115CCFO 61 110/220 3 56.8 12.5 115CCFO 11 100/200 3 62.5 12.5 115CCFO 41 220 2 56.8 12.5 115CCFOZ 51 110/190 4 47.5 12.5 315CCFOZ 51 115/200 4 45.1 12.5 315CCFOZ 71 220/380 4 23.7 12.5 315CCFOZ 71 230/400 4 22.6 12.5 315CCFOZ 71 240/416 4 21.7 12.5 315CCFOZ 81 120/208 4 43.4 12.5 315CCFOZ 81 110/220 4 41.0 12.5 3

    Models 20CCO/CCFO/CCOZ/CCFOZModel Voltage Amps/Series Code Voltage Wire Pole kW PH60 Hz Models:20CCO 61 120/240 3 83.3 20.0 120CCO 101 100/200 3 100.0 20.0 120CCOZ 01 120/240 4 60.1 20.0 320CCOZ 51 139/240 4 60.1 20.0 320CCOZ 51 127/220 4 65.6 20.0 320CCOZ 71 227/480 4 30.1 20.0 320CCOZ 71 240/416 4 34.7 20.0 320CCOZ 81 120/208 4 69.4 20.0 3

    50 Hz Models:20CCFO 101 120/240 3 69.4 16.5 120CCFO 61 110/220 3 75.8 16.5 120CCFO 11 100/200 3 83.3 16.5 120CCFO 41 220 2 75.8 16.5 120CCFOZ 51 110/190 4 63.3 16.5 320CCFOZ 51 115/200 4 60.1 16.5 320CCFOZ 71 220/380 4 31.7 16.5 320CCFOZ 71 230/400 4 30.1 16.5 320CCFOZ 71 240/416 4 28.9 16.5 320CCFOZ 81 120/208 4 57.8 16.5 320CCFOZ 81 110/220 4 54.7 16.5 3

  • TP-5605 4/971-4 Specifications

    Generator Models 15/20 kWSingle-Phase Models Three-Phase Models

    RPM (60-Hz Models) 1800 1800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RPM (50-Hz Models) 1500 1500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    15 kW:Stator Resistance (ohms)** Leads:

    1-2, 3-4, 33-44 0.07 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-33 1.3 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1-B2 0.06 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Rotor Resistance (ohms) 3.0 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    20 kW:Stator Resistance (ohms)** Leads:

    1-2, 3-4, 33-44 0.07 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55-33 1.3 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1-B2 0.06 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Rotor Resistance (ohms) 3.0 N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Excitation Method Static Excited Rotating Exciter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overbolt Torque 25 ft. lbs. (300 in. lbs.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage Regulator Type PowerBoost IIIE PowerBoost V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insulation (Rotor and Stator) Class 155, Epoxy Varnish, Vacuum Impregnated. . . . . . . . . . . . . . . . . . . . . . . . . . .Winding Material Copper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Bearing (Number and Type) 1, Replaceable Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Circuit Protection:

    Controller 10-Amp Fuse 10-Amp Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optional AC Output Manual-Reset Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage Regulator 10-Amp Fuse N/A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Solenoid 10-Amp Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    ** Most ohmmeters will not give accurate readings when measuring less than 1 ohm. The stator can be consideredgood if a low resistance reading (continuity) is obtained and there is no evidence of shorted windings(discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.

  • TP-5605 4/97 Specifications 1-5

    1-933

    1

    2

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    45 6 7

    89

    10 11 12 13 1415

    1617

    18

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    22232425262728

    29

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    3132

    33

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    1. Optional AC circuit breaker2. Voltage regulator fuse3. Start-stop/preheat switch4. Fuel solenoid fuse5. Controller fuse6. Hourmeter7. Controller8. Remote connection (at rear of controller)9. Air cleaner

    10. Lifting eye11. Intake heater12. Fuel solenoid13. Oil fill14. Lifting eye15. High water temperature shutdown16. Coolant inlet17. Oil fill18. Generator nameplate

    19. Mechanical governor20. Oil filter21. Fuel filter22. Ground connection23. Oil drain24. Fuel pump25. Fuel inlet connection point26. Fuel return connection point27. Oil check28. Heater coil relay29. Low oil pressure shutdown30. Voltage regulator

    (inside junction/circuit breaker box)31. Coolant outlet32. Exhaust outlet33. Battery charging alternator (behind guard)34. Starter

    Figure 1-1. Service View of 20CCO RV with Remote Radiator (Typical)

  • TP-5605 4/971-6 Specifications

    1-933

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    2

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    5 6 7 8 9

    10 1112

    13 1415 16

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    232425262728293031

    32

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    34

    35

    1. Optional AC circuit breaker2. Voltage regulator fuse3. Start-stop/preheat switch4. Fuel solenoid fuse5. Controller fuse6. Hourmeter7. Controller8. Remote connection (at rear of controller)9. Air cleaner

    10. Lifting eye11. Intake heater12. Fuel solenoid13. Oil fill14. Lifting eye15. High water temperature shutdown16. Pressure cap/initial coolant fill17. Generator nameplate18. Oil fill19. In-line radiator

    20. Mechanical governor21. Oil filter22. Coolant drain23. Ground connection24. Oil drain25. Fuel inlet connection point26. Fuel pump27. Fuel return connection point28. Oil check29. Fuel filter30. Heater coil relay31. Low oil pressure shutdown32. Voltage regulator

    (inside junction/circuit breaker box)33. Exhaust outlet34. Battery charging alternator (behind guard on non-service side of

    unit)35. Starter (on non-service side of unit)

    Figure 1-2. Service View of 20CCO RV In-line Radiator (Typical)

  • TP-5605 4/97 Operation 2-1

    Section 2. OperationTo ensure continued satisfactory operation, check thefollowing items before each startup and at regularintervals.

    Prestart ChecklistAir Cleaner. Keep air cleaner element clean. Installelement to keep unfiltered air from entering engine.

    Air Shrouding. Keep tight and in position.

    Air Inlets. Keep clean and unobstructed.

    Battery. Ensure tight battery connections. Maintain fullbattery electrolyte level.

    Coolant Level. For cooling systems equipped with acoolant recovery tank, check coolant level at tank afterthe engine has cooled.

    Maintain coolant level just below the filler neck,approximately 3/4 to 1 1/2 in. (19 to 33 mm).

    A coolant solution of 50% ethylene glycol providesfreezing protection of --34F (--37C) and overheatingprotection to 265F (129C). A coolant solution with lessthan 50% ethylene glycol may not provide adequatefreezing and overheating protection. A coolant solutionwith more than 50% ethylene glycol can cause engine orcomponent damage. Do not use alcohol or methanolantifreeze or mix them with the specified coolant.Consult the engine manufacturers operation manual forengine coolant specifications.

    Do not add coolant to a hot engine. Wait until engine hascooled. Adding coolant to a hot engine can cause thecylinder block or cylinder head to crack.

    NOTEDo not energize block heater before filling coolingsystem. Before energizing block heater, run engine untilit is warm and refill radiator to purge air from the system.Immerse heater element in coolant to prevent blockheater failure.

    Drive Belts. Check belt condition and tension ofradiator fan, water pump, and battery chargingalternator belt(s).

    Exhaust System. Keep exhaust outlet clear. Keepmuffler and piping tight and in good condition.

    Fuel Level. Keep tank(s) full to ensure adequate fuelsupply.

    Oil Level. Maintain oil level at or near full mark ondipstick but not over. Keep the oil level in the mechanicalgovernor (if equipped) at or near the full level.

    Operating Area. Check for obstructions that couldblock the flow of cooling air. Keep the air intake areaclean. Do not leave rags, tools, or debris on or near thegenerator set.

    Exercising the GeneratorRun the generator set under load once each week forone hour with an operator present.

    Operator should perform all prestart checks beforestarting the exercise procedure. While the generator setis running, listen for a smooth-running engine andvisually inspect the generator set to ensure there are nofluid or exhaust leaks.

    Start the generator set according to the startingprocedure in the controller section of this manual.

  • TP-5605 4/972-2 Operation

    Controller (Single-Phase)Depending on application, the Kohler relay controllermay be located at the set or at a location remote from thegenerator. Remote harnesses for the controller areavailable in 7.5- and 15-foot (2.3- and 4.6-meter)lengths. If the generator set has automatically stoppedbecause of high water temperature (230_F/110_C) orlow oil pressure (6.8 psi/46.9 kPa or less), correct thecause before restarting the set.

    Refer to Figure 2-1 or Figure 2-2 and the followingdescriptions to identify controller components.

    Generator Start and Stop/Preheat Switch. Switchserves the dual function of generator operation andgenerator preheat. When pressed to the preheatposition, the preheat switch aids in cold weatherstarting. Refer to Start/Stop and Preheating proceduresfollowing.

    Fuel Solenoid Fuse. 10-amp fuse protects fuelsolenoid circuitry.

    Controller Fuse. 10-amp fuse protects controllercircuitry against damage if a short develops in theengine wiring system or the wiring to the remotestart/stop switch.

    Remote Switch Connection (located at rear ofcontroller). Connect the remote start/stop switch tooperate the generator set at a location remote from theset. Controller connections are made through the plugconnector at the rear of the unit.

    Hourmeter. Meter records total generator set operatinghours for reference in maintenance schedule.

    DC Circuit Breaker. Circuit breaker shuts down thegenerator set automatically after fault. See CircuitProtection following.

    AC Circuit Breaker (optional). Circuit breaker tripswhen a fault is detected in the output circuit. Used todisconnect generator set during maintenance onvehicle wiring. To close circuit breaker(s), place breakerin ON position.

    1-932

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    1. Generator start and stop/preheat switch2. Fuel solenoid fuse3. Controller fuse4. Remote switch connection5. Hourmeter

    Figure 2-1. Single-Phase Controller

    1

    2 3 4

    A-229301-L

    5

    1. Generator start and stop/preheat switch2. Hourmeter3. DC circuit breaker4. Remote switch connection5. AC circuit breaker

    Figure 2-2. Single-Phase Controller(spec PA-135322)

  • TP-5605 4/97 Operation 2-3

    Controller (Three-Phase)For identification of three-phase controller, seeFigure 2-3.

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    2 3 4 5

    1. Generator start and stop preheat switch2. DC circuit breaker3. Hourmeter4. AC circuit breaker5. Fuel solenoid fuse

    Figure 2-3. Three-Phase Controller

    Generator Start and Stop Preheat Switch serves thedual function of generator operation and generatorpreheat. When pressed to the preheat position, thepreheat switch aids in cold weather starting. Refer toStart/Stop and Preheating procedures following.

    DC Circuit Breaker trips when a fault is detected in theDC circuitry. The generator set shuts downautomatically after fault. See Circuit Protectionfollowing.

    Hourmeter records total generator set operating hoursfor reference in maintenance schedule.

    AC Circuit Breaker (optional) trips when a fault isdetected in the output circuit. Used to disconnectgenerator set during maintenance of vehicle wiring. Toclose circuit breaker(s), place in ON position.

    Fuel Solenoid Fuse (located inside the controller).10-amp fuse protects fuel solenoid circuitry.

  • TP-5605 4/972-4 Operation

    Preheat FeatureDuring cold weather starts (below 23_F [--5_C]), placecontroller start switch in STOP/PREHEAT position for15 to 20 seconds before attempting to start thegenerator set. This provides energizing of the air heatercoil. Do not energize preheat feature for more than30 seconds or damage may occur.

    Starting ProcedureMove the START-STOP/PREHEAT switch to theSTART position and hold in this position until the engineis running, then release. Do not crank enginecontinuously for more than 10 seconds at a time. If theengine does not start, allow a 60-second cooldownperiod between cranking attempts. If the unit fails tostart after three attempts, contact an authorized servicedealer/distributor for repair. Failure to follow theseguidelines may result in burnout of the starter motor.

    NOTEIf the engine starts and then stops, allow the engine tocome to a complete stop before making a restartattempt. If the flywheel ring gear is still rotating when thestarter pinion gear is engaged, the pinion gear will clashwhich may damage the ring gear teeth.

    NOTEIf ambient temperature is below 23_F (--5_C), seePreheat Feature.

    Stopping ProcedureWhenever possible, allow a brief cooling period byrunning the set at low or no load for a few minutes justprior to shutdown. To stop, move the switch to the STOPposition and hold until the set comes to a complete halt.If the generator set shuts down automatically, identifyand correct the problem before attempting to restart.

    NOTEDo not place Start-Stop/Preheat switch in Stop/Preheatposition for more than 30 seconds or damage to thepreheat feature may occur.

    Fault ShutdownsLow Oil PressureShutdown Switch

    The low oil pressure (LOP) shutdown feature protectsthe engine against internal damage if the oil pressuredrops below 6.8 psi (46.9 kPa) because of an oil pumpfault or other engine malfunction. The LOP shutdowndoes not protect the set from damage due to operatingwith the oil level below the safe range IT IS NOT ALOW OIL LEVEL SHUTDOWN. Check the oil levelregularly and add oil as needed to prevent running out ofoil. Location of the LOP shutdown switch is shown inFigure 2-4.

    NOTEThis is not a low oil level shutdown. Maintain proper oillevel to enable low oil pressure shutdown switch tofunction.

    1-933

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    1. Low oil pressure switchFigure 2-4. Low Oil Pressure Shutdown Switch

  • TP-5605 4/97 Operation 2-5

    High Water TemperatureShutdown Switch

    The generator set is also equipped with a high watertemperature (HWT) shutdown switch. See Figure 2-5.The unit will automatically shut down when the enginecoolant temperature exceeds 230_F (110_C). Correctthe cause of the shutdown before restarting thegenerator.

    NOTEThe high water temperature (HWT) shutdown switch isnot a low coolant level switch. Maintain proper coolantlevel to enable HWT switch to function.

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    1. High water temperature switchFigure 2-5. High Water Temperature

    Shutdown Switch

    Circuit ProtectionRefer to Figure 2-6 and the following descriptions toidentify controller components.

    10-Amp Fuel Solenoid Fuse. A replaceable 10-ampfuse protects the fuel solenoid. (On three-phase modelsthe in-line fuse is mounted inside the controller.) If thisfuse is blown, the generator shuts down. If the fuse isreplaced and then blows again, have the generator setexamined by an authorized Kohler servicedistributor/dealer.

    10-Amp Controller-Input Fuse (Single-Phase) orCircuit Breaker (Three-Phase). A replaceable10-amp fuse or circuit breaker protects the controllercircuitry. If the generator will not crank and the batteryand/or connections are intact, the controllerfuse/breaker may be blown or tripped. Contact anauthorized Kohler service distributor/dealer iffuse/breaker blows/trips repeatedly.

    10-Amp PBIIIE Voltage Regulator Fuse(Single-Phase Models Only). A replaceable 10-ampfuse protects the voltage regulator circuitry. If this fuse isblown, the generator set shuts down. If this fuse isreplaced and then blows again, have the generator setexamined by an authorized Kohler servicedistributor/dealer.

    Optional AC Circuit Breaker(s) trips when a fault isdetected in the AC output circuit. See Section4 Troubleshooting to determine cause of fault. Afterfault is corrected, reset AC circuit breaker by placing inON position.

    DC Circuit Breaker will trip when a fault occurs in thecontroller circuit. See Section 4 Troubleshooting todetermine cause of fault. After fault is corrected, resetDC circuit breaker by depressing center button.

  • TP-5605 4/972-6 Operation

    1-933Single-Phase

    Controller

    Three-PhaseController

    1 2

    34

    1 2 4

    54

    Spec PA-135322

    1. 10-amp fuel solenoid fuse2. 10-amp controller-input fuse or circuit breaker3. 10-amp PBIIIE voltage regulator fuse

    4. Optional AC circuit breaker5. DC circuit breaker

    Figure 2-6. Circuit Protection

  • TP-5605 4/97 Scheduled Maintenance 3-1

    Section 3. Scheduled MaintenanceGeneral

    Schedule routine maintenance using the MaintenanceSchedule following and the hourmeter located on thegenerator controller. If the generator will be subject toextreme operating conditions, service the unit morefrequently. Instructions to perform most of thescheduled services are provided in the following pages.Items in the maintenance schedule marked with anasterisk (*) should be performed more often if thegenerator set is operated in dirty, dusty conditions.Items identified with asterisks (**) should be performedonly by an authorized Kohler service dealer/distributor.Tools and instruments required for these additionalsteps are usually not available to the generator setowner. For this reason, return the set periodically to anauthorized service distributor/dealer for completeservicing and tune-up. Such service improvesperformance and continuous satisfactory operationduring a long trouble-free service life.

    NOTEPerform the items listed in the maintenance schedule atthe designated intervals for the life of the generator. Forexample, an item serviced every 100 hours or 3 monthsmust also be serviced after 200 hours or 6 months, 300hours or 9 months, etc. The generator will eventuallyaccumulate enough hours to warrant a completeoverhaul. The exact time at which extensive service willbe necessary cannot be predicted. However, roughoperation, lack of power, and excessive oil use indicateserious generator set problems. As part of a preventivemaintenance program, service the engine (cleancylinder head, inspect valves, check compression, etc.)and generator (replace bearing, inspect wiring, removedebris, etc.) at the earliest indication that a seriousproblem exists.

  • TP-5605 4/973-2 Scheduled Maintenance

    FUEL SYSTEMCheck the fuel level X. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fill fuel tank X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remove sediment from fuel tank X. . . . . . . . . . . . . . . . . .Replace the fuel filter element X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (Break-in Period)Check the injection timing** X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check governor operation and adjust

    as necessary** X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check the injection spray condition** X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    LUBRICATION SYSTEMCheck the oil level in crankcase X. . . . . . . . . . . . . . . . . .Replace the oil in crankcase* X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (Break-in Period)Replace the lube oil filter element* X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (Break-in Period)COOLING SYSTEM

    Check coolant level X. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust the tension of water pump V-belt X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (Break-in Period)Change coolant X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clean radiator fins, inspect hoses X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    AIR CLEANERReplace the air cleaner element* X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clean the breather pipe* X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    ELECTRICAL SYSTEMVerify proper operation of gauges, if equipped X. . . . . .Check the electrolyte level in the battery X. . . . . . . . . . .Check the electrical connections X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Check the battery specific gravity X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust battery charging alternator V-belt X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (Break-in Period)CYLINDER HEAD

    Check for leakage of water and oil X X. . . . . . . . . . . . . . . . . . . . . . . . . .Retighten all major nuts and bolts X X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    (Break-in Period)Check mounting bolts and vibromounts

    for tightness X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Retighten the cylinder head bolts** X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust intake and exhaust valve clearance** X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    GENERATORBlow dust out of generator* X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clean slip rings and inspect brushes (Single-phase units only)** X. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Perform Service at Intervals Indicated (X)

    BeforeEach

    Startup

    Every 50Hours or1 Month

    Every 100Hours or3 Months

    Every 500Hours or

    Yearly

    Every 300Hours or6 Months

    * Service more frequently if operated in dusty areas.** Should be performed by an authorized Kohler Service Dealer/Distributor.

  • TP-5605 4/97 Scheduled Maintenance 3-3

    Lubrication SystemOil Selection

    The selection of engine oil is very important to a dieselengine. If an unsuitable oil is used or an oil change isneglected, damage and a shorter engine life may result.Oil must meet the American Petroleum Institute (API)classification of CC or CD. Avoid mixing different brandsof oils and lubricants; oils of different manufacturers maybe incompatible and deteriorate when mixed.Recommended SAE viscosity designations for giventemperature ranges in which the generator set will beoperated are listed in Figure 3-1.

    NOTEFailure to observe these standards may causeinadequate oil pressure and cold-starting difficulties.

    S.A.E. ServiceGrade

    C

    F

    --30 --20 --10 0 10 20 30 40

    0 20 40 60 80 100Operating Temperature

    Recommended Value

    Usable Limit

    5W

    10W

    20W

    SAE 20

    SAE 30

    SAE 40

    C

    F

    5W

    10W

    20W

    20

    30

    40

    5W20

    10W30

    20W40

    Figure 3-1. Engine Oil Selection.

    Oil CheckCheck crankcase oil level daily or before each start toensure that the level is in the safe range. To check oillevel, remove oil dipstick and wipe dipstick clean (seeFigure 3-2). Reposition dipstick in crankcase and pushit all the way down into the tube. Remove dipstick andcheck the level. Oil level should read between MIN andMAX marks on dipstick. Do not operate set if oil levelexceeds the MAX mark or registers below the MIN markon dipstick.

    1-933

    1 2

    1. MAX level2. MIN level

    Figure 3-2. Oil Level Check

    NOTEDo not check oil level when the set is in operation. Theengine must be stopped and on a level surface whenchecking oil. Obtain the most accurate oil reading byshutting down the generator and waiting severalminutes before checking oil.

  • TP-5605 4/973-4 Scheduled Maintenance

    Oil ChangeOn a new engine, change the oil after the first 50 hours ofoperation and thereafter at 100-hour intervals or3 months, whichever occurs first. Change oil morefrequently under dirty, dusty conditions. Change oilwhile the engine is still warm.

    1. Place a container below the oil drain hole andremove oil drain plug. Allow sufficient time for theold oil to drain completely. Replace oil drain plug.Dispose of used engine oil in an environmentallysafe manner. Take used oil to a suitable collectionfacility in your area. DO NOT POUR USED OIL ONTHE GROUND, DOWN SEWERS, OR INTOSTREAMS OR OTHER BODIES OF WATER.

    2. Remove oil fill cap. One is located on therocker-arm cover and one is located near the fuelinjector pump. See Figure 3-4.

    3. Fill crankcase with proper amount and type of oil;see Figure 3-3 and Oil Selection.

    4. If replacing engine oil filter, see Oil Filter following.

    5. Start the generator set and check for oil leaks.6. Stop the generator set. Remove the dipstick and

    wipe clean, reinsert as far as possible, and removeto check oil level. Add oil, as necessary, to bringlevel up to MAX mark.

    OIL CAPACITY(with Filter)

    qts. (L)

    15 kW 6.1 (5.8). . . . . . . . . . . . . . . . . . . . . . . . . . . .20 kW 6.1 (5.8). . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Figure 3-3.

    NOTEToo high an oil level causes high oil consumption andcarbonizing of the engine. Low oil level will causeengine damage.

    1-933

    1

    1. Oil fillFigure 3-4. Oil Fill Locations

  • TP-5605 4/97 Scheduled Maintenance 3-5

    Oil FilterReplace the oil filter for the first time after 50 hours or1 month of operation and then every 100 hours or3 months. Change more frequently if operating in dirty,dusty conditions. See Figure 3-5 and refer to thefollowing procedure.

    1-933

    1

    1. Oil filterFigure 3-5. Oil Filter Location

    1. Loosen oil filter by turning with a filter wrench in acounterclockwise direction. Use rags to clean upspilled oil. Remove and discard.

    2. Clean contact surface on oil filter adapter.

    3. Lightly lubricate the gasket surface of the new oilfilter with the fresh engine oil. Thread oil filter toadapter until gasket makes contact, hand tightenan additional one-half turn.

    4. Start the generator set and check for oil leaks.

    5. Stop the generator set. Remove dipstick and wipeclean. Reinsert as far as possible, then remove tocheck oil level. Add oil, as necessary, to bring levelup to MAX level.

  • TP-5605 4/973-6 Scheduled Maintenance

    Fuel SystemSpecification

    Use a clean, good quality No. 2-D (DIN 51 601) dieselfuel oil. The fuel must meet the requirements of theAmerican Society of Testing and Materials (ASTM)diesel fuel classification D975 (Federal SpecificationW-F-800a). Cleanliness of the fuel is especiallyimportant on diesel engines which have easily cloggedprecision fuel injectors and pumps. See chart below.

    United States ASTM/D975 No. 2-D Diesel

    United Kingdom BS2869 Class A1 or Class A2

    Other Considerations:Sulfur Content Less than 0.5%. . . . . . . . . . . . . . . . . . .Sediment/Water Content Not to exceed 0.1%. . . . . . .Cetane Number 45 minimum. . . . . . . . . . . . . . . . . . . . .Pour point At least 10_F (5.6_C). . . . . . . . . . . . . . . . . .

    Below the lowest outsideair temperature

    NOTENever store diesel fuel in galvanized containers; dieselfuel and the galvanized coating react chemically toproduce flaking which quickly clogs filters or causesfailure of the fuel pump or injectors. Do not run thegenerator set out of fuel; air will be drawn into the fuellines and the entire system will have to be bled beforethe unit can be restarted.

    NOTEAvoid storing fuel over long periods of time. Take specialprecautions to keep all dirt, water, and othercontaminants out of the fuel. Storage tanks containingdiesel fuel contaminated with water may cause thegrowth of microbes. The presence of microbes will forma slime which will clog fuel filters and lines.

    Fuel FilterThe fuel filter serves to remove water and dirt containedin the fuel. The fuel filter element is paper and noattempt should be made to clean it. Its useful life will bedetermined largely by the quality and condition of thefuel used. Under normal conditions, replace the fuelfilter element for the first time after 50 hours or onemonth and then every 300 hours or six months. SeeFigure 3-6 for location and use the following procedureto service the fuel filter.

    1. Loosen the fuel filter by turning in acounterclockwise direction. Use rags to clean upspilled fuel oil. Remove and discard filter.

    2. Clean contact surface on the fuel filter adapter.

    3. Lightly lubricate the gasket surface of the new fuelfilter with fresh fuel oil. Thread the fuel filter to theadapter until the gasket makes contact, handtighten an additional one-half turn.

    See Bleeding section following.

    1-933

    1

    1. Fuel filterFigure 3-6. Fuel Filter Location

  • TP-5605 4/97 Scheduled Maintenance 3-7

    Bleeding the Fuel SystemIf the generator set engine runs out of fuel, air leaksdevelop in the suction side of the fuel system, or the fuelfilter is replaced, bleed the entire system to preventstarting failures and/or erratic operation. See Figure 3-7and refer to the following procedure.

    1. Disconnect lead 71A from the starter relay todisable cranking during the bleeding procedure.

    2. Fill the fuel tank.

    3. Loosen the line connection at the fuel filter.4. Crank the engine until fuel (free from bubbles)

    flows from the loosened connection. Tighten thefuel line connection.

    5. Loosen the small vent screw (with Phillips head) onthe fuel filter.

    6. Crank the engine until fuel (free from bubbles)flows from this point. Tighten vent screw.

    7. Loosen the line connection (bleed point) at the fuelinjection pump inlet.

    8. Crank the engine to operate the fuel pump until fuel(free from bubbles) flows from this loosenedconnection. Tighten line connection.

    9. Reconnect lead 71A to the starter relay.

    WARNING

    Explosive fuel vapors.Can cause severe injury or death.

    Use extreme care when handling, storing,and using fuels.

    Draining fuel system. Explosive fuel vapors cancause severe injury or death. Spilled fuel can causean explosion. Use a container to catch fuel whendraining fuel system. Wipe up all spilled fuel afterdraining system.

    1-933

    1 2 3 4

    561. Line connection (bleed point)2. Vent screw3. Line connection (bleed point)4. Fuel injection pump5. Electric fuel pump6. Fuel filter

    Figure 3-7. Bleeding the Fuel System

  • TP-5605 4/973-8 Scheduled Maintenance

    Fuel SolenoidThe fuel solenoid (Figure 3-8) stops fuel flow throughthe fuel injection pump when the start-stop/preheatswitch is placed in the STOP position. If the fuelsolenoid is removed or the setting is believed incorrect,readjust according to the following procedure. Do notmodify the solenoid linkage during reconnection.

    1. With the fuel solenoid mounted to the engine block,compress the plunger and adjust the fuel-solenoidlinkage so that the linkage connects to the fuelcontrol lever 1/16 in (1.6 mm) before the levercontacts internal full-open stop.

    2. Attach the balljoint to the fuel-solenoid linkage.

    1-933

    1

    1. Fuel solenoidFigure 3-8. Fuel Solenoid Location

    Air Cleaner ServiceReplace the paper element at 300-hour or 6-monthintervals; change more frequently if operating underdirty, dusty conditions. Operating the set with a dirty aircleaner element may cause engine damage andincreased fuel consumption. At the time of service,clean the air cleaner breather pipe and remove all dustand foreign matter from the air cleaner housing. SeeFigure 3-9 and refer to the following procedure.

    1-932

    1 2

    3456

    1. Eyebolt/clamp2. Base3. Cover4. Element5. Threaded rod6. Wing nut

    Figure 3-9. Air Cleaner Components

    1. Loosen eyebolt and clamp to remove the aircleaner cover.

    2. Remove wing nut and slide air cleaner elementfrom the threaded rod.

    3. Clean dry element by tapping edges on a hardsurface. Replace if damaged or very dirty.

    NOTEDo not attempt to clean dry-type element in anyliquid or with compressed air as this will damagepaper filter material.

    4. Wipe dirt or dust accumulation from cover andbase. Check that all clamps are tight on inlet/outletconnections.

    5. Install air cleaner element on threaded rod.Tighten wing nut making sure parts fit properly.

    6. Position cover with arrow up; place clamp overbase and cover, and tighten eyebolt.

  • TP-5605 4/97 Scheduled Maintenance 3-9

    GovernorThe centrifugal, mechanical-type governor keeps theengine speed constant by automatically adjusting theamount of fuel supplied to the engine according tochanges in the load. No regular service is required onthe unit. The governor is adjusted during run-in at thefactory, and further adjustment is not necessary unlessencountering greatly varying load conditions or poorgovernor control develops after extended usage.

    60-Hz generator sets are designed to operate at60--63 Hz, 1800 rpm under full load and 1890 rpm underno load.

    50-Hz generator sets are designed to operate at50-52.5 Hz, 1500 rpm under full load and 1575 rpmunder no load.

    To check speed, use a hand-held tachometer orfrequency meter. See Figure 3-10. Loosen the lockingnut on the speed-adjusting screw. Turn the screw in acounterclockwise direction to increase speed and

    frequency or in a clockwise direction to decrease speed.Tighten the lock nut to secure at new setting.

    1-933

    1

    1. Locking nutFigure 3-10. Governor

  • TP-5605 4/973-10 Scheduled Maintenance

    Cooling System

    WARNING

    Hot coolant and steam.Can cause severe injury or death.

    Before removing pressure cap, stop generator setand allow it to cool. Then loosen pressure cap torelieve pressure.

    Checking coolant level. Hot coolant can causesevere injury or death. Allow engine to cool. Releasepressure from cooling system before opening pressurecap. To release pressure, cover the pressure cap with athick cloth; then slowly turn it counterclockwise to thefirst stop. Remove cap after pressure has beencompletely released and the engine has cooled. Checkcoolant level at tank if generator set is equipped with acoolant recovery tank.

    To prevent the generator set from shutting down orbecoming damaged because of overheating, keep thecooling air inlets clean and unobstructed at all times.Inspect the exterior of the radiator for obstructions;remove all dirt and foreign material with a soft brush orcloth to avoid damaging radiator fins. Check all hosesand connections for leaks and replace any hoses thatare cracked, frayed, or spongy. When making coolantlevel checks, check condition of the radiator cap rubberseal; replace if cracked or deteriorating. Remove dirtand other debris from the radiator cap and filler neck.

    Coolant capacity for the 15/20 kW in-line radiator modelis 4 qts. 16 oz. (4.26 L). Consult the coach manufacturer

    for remote radiator cooling system capacity. Drainpetcocks are provided on the bottom tank of the radiatorand another in the engine block to drain the system.When draining the coolant, remove the radiator cap andopen the block drain located near the flywheel housing;this will allow the entire system to drain and prevent airpockets from forming and restricting coolant passage inthe block. To refill the cooling system, close the drainpetcock and fill the radiator to the proper level with therecommended coolant mixture. See Figure 3-12 forcoolant fill location. Replace the radiator cap andoperate the engine until the thermostat opens and theradiator upper hose becomes hot. Stop the engine andallow to cool. Add coolant to the radiator to just belowthe overflow tube on the filler neck. Replace the radiatorcap.

    A coolant solution of 50% ethylene glycol and 50%clean, softened water is required to inhibit corrosion,prevent freezing to -34_F (-37_C), and to improvecooling. The antifreeze should contain a rust inhibitorand be changed every two years. Do not use alcohol ormethanol antifreeze or mix them with the coolant. Donot add coolant to an overheated engine until the enginehas cooled. Adding coolant to an extremely hot enginecan cause a cracked block or cylinder head.

    Check coolant level frequently and add antifreezesolution as needed to maintain level just below theoverflow tube and at the min level in the coolant recoverytank when cold (max when hot).

    NOTEGive special attention when checking for proper coolantlevel. After a radiator has been drained, some time isnormally required before complete refill of all air cavitiestakes place.

  • TP-5605 4/97 Scheduled Maintenance 3-11

    1

    2

    ADV-5834-B

    1. Coolant outlet 2. Coolant inletFigure 3-11. Coolant Fill and Coolant Drain Connections (Remote Radiator Model)

    1

    ADV-5834-

    2

    1. Initial coolant fill 2. Coolant drainFigure 3-12. Initial Coolant Fill and Coolant Drain Locations (In-line Radiator Model)

  • TP-5605 4/973-12 Scheduled Maintenance

    Belt TensionAdjust the tension of the alternator/fan belt so that it canbe depressed about 0.4-0.6 in. (10-15 mm) whenapplying finger pressure. See Figure 3-13. Use thefollowing procedure to adjust the belt.

    1

    2

    34

    5605313

    1. Adjusting screw2. Battery charging alternator pulley3. Alternator pivot screw4. Check alternator belt tension here

    Figure 3-13. Belt Tension

    1. Disconnect battery, negative lead first.2. Loosen pivot and adjusting screws.

    3. While prying battery-charging alternator outward,tighten adjusting screw.

    4. Tighten pivot screw.

    5. Recheck and adjust as necessary.6. Reconnect battery, negative lead last.

    NOTEAlso, check fan belt for cracks or tears and replaceif necessary.

    WARNING

    Rotating parts.Can cause severe injury or death.

    Do not operate generator set without all guards,screens, and covers in place.

    Exposed moving parts can cause severe injury ordeath. Keep hands, feet, hair, and clothing away frombelts and pulleys when unit is running. Replace guards,covers, and screens before operating generator set.

    Battery ChargingYour generator is equipped with a 40-amp, belt-drivenbattery charging alternator. See Figure 3-14. It isattached to the engine block by a bracket and keeps thebattery constantly charged. Be sure to observe batterypolarity when connecting the battery to the generatorset. The alternator requires no maintenance other thanmaintaining belt tension. To adjust the alternator belttension, see Belt Tension.

    1-933

    1

    1. Battery charging alternatorFigure 3-14. Battery Charging Alternator

  • TP-5605 4/97 Scheduled Maintenance 3-13

    BatteryUse a 12-volt battery with a rating of at least 625 coldcranking amps. When using a Maintenance-Freebattery, it is not necessary to check the specific gravity orelectrolyte level. Otherwise perform these proceduresat the intervals specified in the Maintenance Schedule.A negative ground system is used. Battery connectionsare shown on the wiring diagrams. Make sure that thebattery is properly connected and the terminals are tight.

    NOTEThe generator set will not start if the battery connectionsare made in reverse.

    Sulfuric acid in batteries.Can cause severe injury or death.

    Use protective goggles and clothes. Battery acid cancause permanent damage to eyes, burn skin, and eatholes in clothing.

    WARNING

    Battery acid. Sulfuric acid in batteries can causesevere injury or death. Sulfuric acid in battery cancause permanent damage to eyes, burn skin, and eatholes in clothing. Always wear splash-proof safetygoggles when working near the battery. If battery acid issplashed in the eyes or on skin, immediately flush theaffected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case ofeye contact. Never add acid to a battery after placing thebattery in service, as this may result in hazardousspattering of battery acid.

    Battery gases. Explosion can cause severe injuryor death. Battery gases can cause an explosion. Donot smoke or permit flame or spark to occur near abattery at any time, particularly when it is charging.Avoid touching terminals with tools, etc., to preventburns and sparks that could cause an explosion.Remove wristwatch, rings, and any other jewelry beforehandling battery. Never connect negative (--) batterycable to positive (+) connection terminal of startersolenoid. Do not test battery condition by shortingterminals together. Sparks could ignite battery gases orfuel vapors. Ventilate any compartment containingbatteries to prevent accumulation of explosive gases.To avoid sparks, do not disturb battery chargerconnections while battery is being charged. Always turnbattery charger off before disconnecting batteryconnections. Remove negative lead first and reconnectit last when disconnecting battery.

    CleaningKeep battery clean by wiping it with a damp cloth. Keepall electrical connections dry and tight. If corrosion ispresent, disconnect cables from battery and removecorrosion with a wire brush. Clean battery and cableswith a solution of baking soda and water. Be careful thatcleaning solution does not enter battery cells. Whencleaning is complete, flush battery and cables with cleanwater and wipe with a dry cloth. After the battery cablesare reconnected, coat terminals with petroleum jelly orother nonconductive grease.

  • TP-5605 4/973-14 Scheduled Maintenance

    Checking Electrolyte LevelCheck the electrolyte level before each startup.Remove filler caps and check that electrolyte level is upto bottoms of filler holes. See Figure 3-15. Refill asnecessary with distilled water or clean tap water. DONOT add fresh electrolyte! Be sure filler caps are tight.

    1-046

    Figure 3-15. Battery Electrolyte Level

    Checking Specific GravityUse a battery hydrometer to check the specific gravity ofthe electrolyte in each battery cell. While holding thehydrometer vertical, read the number on the glass bulbat the top of the electrolyte level. If the hydrometer useddoes not have a correction table, use the one inFigure 3-16. Determine specific gravity and electrolytetemperature of battery cells. Locate temperature inFigure 3-16 and adjust specific gravity by amountshown. The battery is fully charged if the specific gravityis 1.260 at an electrolyte temperature of 80F (26.7C).The difference between specific gravities of each cellshould not exceed 0.01. Charge the battery if thespecific gravity is below 1.215 at an electrolytetemperature of 80F (26.7C).

    10

    20

    30

    40

    50

    60

    70

    80

    90

    100

    110

    120

    130

    140

    150

    160

    -- 12.2

    -- 6.7

    -- 1.1

    4.4

    10

    21.1

    26.7

    32.2

    37.8

    43.3

    48.9

    54.4

    60.0

    65.6

    71.1

    15.6

    + .032

    + .030

    + .028

    + .026

    + .024

    + .022

    + .020

    + .018

    + .016

    + .014

    + .012

    + .010

    + .008

    + .006

    + .004

    + .002

    0

    -- .002

    -- .004

    --. 006

    -- .008

    -- .010

    -- .012

    -- .014

    -- .016

    -- .018

    -- .020

    -- .022

    -- .024

    -- .026

    -- .028

    C F

    EXAMPLE NO. 1Temperature below 80F(26.7C)

    Hydrometer Reading 1.250

    Acid Temperature 20F(-6.7C)

    Subtract .024 Sp. GravityCorrected Sp. Gravity is1.226

    EXAMPLE NO. 2Temperature above 80F(26.7C)

    Hydrometer Reading 1.235

    Acid Temperature 100F(37.8C)

    Add .008 Sp. GravityCorrected Sp. Gravity is 1.243

    The Temperature correction amounts to about .004(4 points) of specific gravity for each 10_F (5.5_C)change in temperature.

    Correction

    Figure 3-16. Specific GravityTemperature Correction

  • TP-5605 4/97 Scheduled Maintenance 3-15

    Gauge Connections for Single-Phase ModelsThe 15/20 kW generator sets may be equipped withsending devices for optional connection to oil pressureand water temperature gauges (not provided).

    Because lead 10 (from water temperature sender) andlead 11 (from oil pressure sender) may not appear atcontroller plug J4 or P4, it may be necessary to accessthese leads in the engine harness or remote harness ifused. Leads 10 and 11 do not run the full length of the

    remote harness. Retrieve the ends of these leads fromthe harness for connection to the oil pressure and watertemperature gauges. The installer may also elect to runseparate leads from each sender directly to the gaugesand bypass the harnesses entirely. See Figure 3-17and refer to the wiring diagram in Section 5. Use insulinkor similar connectors at all spliced connections toensure reliable operation of the senders and gauges.

    OilPressureSender

    WaterTemperature

    Sender

    11

    10

    11

    10

    P4-10

    J4-10

    P4-13

    J4-13

    11

    10

    P3-6

    J3-3

    P3-3

    J3-2

    Light Blue

    Tan

    OilPressureGauge

    S +

    WaterTemperature

    Gauge

    S +

    J3-4

    P3-2

    ToController

    Violet (53)

    Violet (53)

    B+

    Figure 3-17. Oil Pressure/Water Temperature Sender Connections

  • TP-5605 4/973-16 Scheduled Maintenance

    Wattage RequirementsIf the rated capacity of your generator is exceeded, thecircuit breaker(s) located in the controller trips to protectthe generator against damage. This could be caused bya short in the AC circuit in your vehicle or simply byhaving too many appliances or tools turned onsimultaneously time resulting in an overload condition.If the circuit breaker(s) trips, the set may continuerunning but there will be no AC output to the protectedcircuit. Before resetting the circuit breaker(s), turn offsome of the appliances or tools and lights inside thevehicle to bring the load down within the rated limits ofthe set. If this is done and the circuit breaker(s) tripsagain after being reset, a short circuit is indicated. In thisevent, turn off the set and have a qualified electricianlocate and correct the cause of the short circuit.

    The average wattage requirements of some commonRV/Mobile appliances/tools and motor loads are listed inthe following charts. Use these figures to calculate thetotal load on your set to avoid having the circuit breakertrip because of overload. The lighting load is easilydetermined by adding the wattage rating of each bulb inthe circuit. Check the nameplate rating on motors andappliances in your vehicle for exact wattagerequirements.

    Electrical Appliance Rating (Watts)

    Blanket 50-250. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blender 600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Broiler 1350. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan, Air Circulating 25-100. . . . . . . . . . . . . . . . . . . . . .Fan, Furnace 270. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heater, Space 750-1500. . . . . . . . . . . . . . . . . . . . . . . . .Heater, Water 1500. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pan, Frying 1200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Percolator, Coffee 650. . . . . . . . . . . . . . . . . . . . . . . . . .Radio 50-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Television 300-750. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Toaster 750-1200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Figure 3-18. Appliance AverageWattage Ratings

    MotorStartingWatts

    Air Compressor (Small) 1500 725Air Compressor, 3/4 hp 4000+ 2000Drill, 1/4 in. 500 250Drill, 3/8 in. 600 350Drill, 1/2 in. 800 600Grinder, 1/2 hp 1500 1200Hammer, Demolition 2000 1800Hammer, HD Rotary 1500 1200Paint Sprayer (Airless) 400 240Polisher, Orbit 500 360Power Paint Roller 120 90Power Plane 600 450Router 900 700Saw, Circular 6 1/2 in. 2200 1000Saw, Circular 7 1/4 in. 2500 1200Saw, Table 10 in. 4000 1500Saw, Sabre (Worm Drive) 2500 1200Sander, Belt 1500 600Sander, Finishing 900 360Screwdriver, Power 1000 530Shear, 12 gauge 1800 720Soldering Gun 250Vacuum Cleaner, Wet/Dry 1500 1260Wrench, Impact 1/2 in. 2000 840

    RunningWattsConstruction Tools

    Figure 3-19. Construction Tool AverageWattage Ratings.

    NOTEMotor-driven equipment generally takes 2 to 3 timesmore the listed running amperage or wattage to start themotor. Always check the tool or motor nameplate to besure.

  • TP-5605 4/97 Scheduled Maintenance 3-17

    Generator ServiceGeneral

    Under normal conditions, generator service will not berequired on a regular basis. If operating under dusty and

    dirty conditions, use dry compressed air to blow dust outof the generator at frequent intervals. Do this with thegenerator set operating and direct the stream of air inthrough the cooling slots at the end of the generator.

    Storage ProcedureIf your generator set is to be out of service for aconsiderable length of time (2 months or more),complete the following steps to preserve the set beforeplacing it in storage.

    1. Drain the oil (while hot) from the crankcase thenrefill with regular grade oil. See Section 3, OilSelection in this manual.

    2. Drain the fuel from the fuel tank to preventaccumulated moisture from mixing with the fuel.

    3. Check the engine coolant protection. SeeSection 3 Cooling System for additionalinformation.

    4. Disconnect battery (negative lead first) and placein storage.

    5. Seal all openings in the engine with non-absorbentadhesive tape. Mask off all areas to be used forelectrical contact.

    6. Clean exterior surface of the generator. Spread alight film of oil over unpainted metallic surfaceswhich could rust or corrode.

  • TP-5605 4/973-18 Scheduled Maintenance

    Notes

  • TP-5605 4/97 Troubleshooting 4-1

    Section 4. TroubleshootingWhen troubles occur, do not overlook simple causes. Astarting problem, for example, could be caused byincorrect fuel or an empty fuel tank. The following chartslist some common problems. If procedures in thismanual do not explain how to correct the problem, take

    the generator set to an authorized Kohler servicedistributor/dealer. Tell the dealer exactly what happenedwhen the problem occurred and of any adjustmentsmade to the set.

    EngineProblem Possible Cause Corrective Action

    Engine hard to start orwill not start

    Weak or dead battery Recharge or replaceEngine hard to start orwill not start Battery connections made in reverse Correct

    Faulty ground Clean and retightenFuse blown ReplaceOut of fuel ReplenishIncorrect type of fuel Use correct type of fuel; consult fuel and engine

    supplier (see fuel system specification)Fault shutdown Check low oil pressure and high water

    temperature shutdown switchesClogged fuel filter Replace filter elementAir cleaner clogged Clean or replace elementDefective fuel feed pump Replace fuel feed pumpAir in fuel system Bleed air from fuel systemIncorrect type of crankcase lube oil Use correct lube oil (see oil selection)Water, dirt in fuel system Drain, flush fuel system and replace fuelDirty or faulty injectors See authorized service distributor/dealerIncorrect compression See authorized service distributor/dealerInjection pump malfunctioning See authorized service distributor/dealerIncorrect valve clearance See authorized service distributor/dealer

    Engine knocks Faulty injector See authorized service distributor/dealerEngine knocksIncorrect type of fuel Use correct type of fuel; consult fuel supplier

    (see fuel specifications)Incorrect fuel injection timing See authorized service distributor/dealerIncorrect cylinder top clearance See authorized service distributor/dealerDefective piston or piston ring See authorized service distributor/dealerDefective crankshaft bearing or piston pinbearing

    See authorized service distributor/dealer

    Incorrect valve clearance See authorized service distributor/dealerAir in injectors Bleed air in fuel system

  • TP-5605 4/974-2 Troubleshooting

    Engine (continued)Problem Possible Cause Corrective Action

    Engine runs irregularlyor stalls frequently

    Vent in fuel tank cap obstructed Clean cap in solvent; blow dryEngine runs irregularlyor stalls frequently Clogged fuel filter Replace fuel filter element

    Water, dirt, or air in fuel system Drain, flush, fill, and bleed air in fuel systemDirty or faulty injectors See authorized service distributor/dealerFaulty governor linkage See authorized service distributor/dealerDefective fuel feed pump Replace fuel feed pumpIncorrect valve clearance See authorized service distributor/dealerIncorrect compression See authorized service distributor/dealer

    Stops suddenly Out of fuel Replenish fuel supplyStops suddenlyAir intake restriction Service air cleanerFuse blown in controller Replace fuse. If fuse blows again, see

    authorized service distributor/dealerHigh water temperature (HWT) shutdown* Check engine coolant level, loose fan belt,

    radiator obstructions, etc.Low oil pressure (LOP) shutdown* Check engine lube oil levelDefective fuel pump See authorized service distributor/dealerClogged fuel filter Replace filter

    Lack of engine power Engine overload Reduce loadLack of engine powerAir intake restriction Service air cleanerClogged fuel filter Replace filter elementIncorrect valve clearance See authorized service distributor/dealerDirty or faulty injectors See authorized service distributor/dealerIncorrect fuel injection timing See authorized service distributor/dealerIncorrect engine compression See authorized service distributor/dealerVent in fuel tank cover obstructed Clean cap in solvent; blow dryOverfueling (rich) See authorized service distributor/dealer

    Engine overheats Engine overloaded Reduce loadEngine overheatsDefective cooling system Check water pumpLoose or defective water pump v-belt Adjust belt tension or replace beltCooling system needs flushing Flush cooling systemD