Kohler 15CCO Service Manual
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Kohler 15CCO Service Manual

Kohler 15CCO Service Manual

Commercial & recreational mobile generator sets
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Commercial & Recreational Mobile
Service Manual
Generator Sets
15CCO
15CCFO
15CCOZ
15CCFOZ
20CCO
20CCFO
20CCOZ
20CCFOZ
TP-5606 6/02a
Models:

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Summary of Contents for Kohler 15CCO

  • Page 1 Service Manual Commercial & Recreational Mobile Generator Sets Models: 15CCO 15CCFO 15CCOZ 15CCFOZ 20CCO 20CCFO 20CCOZ 20CCFOZ TP-5606 6/02a...

  • Page 3: Table Of Contents

    Table of Contents SUBJECT PAGE SUBJECT PAGE Safety Precautions and Instructions ..Head Bolt Torque ......3-19 Routine Service Parts .

  • Page 4: Subject Page

    SUBJECT PAGE SUBJECT PAGE Sender Tests ......7-26 Section 9. Wiring Diagrams ....Panel Tests .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Battery electrolyte is a diluted Accidental Starting INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Battery gases. Explosion can cause Engine Backfire/Flash Generator set operation. Carbon monoxide can cause severe nausea, severe injury or death. Battery gases Fire fainting, or death. Carbon monoxide can cause an explosion. Do not smoke is an odorless, colorless, tasteless, or permit flames or sparks to occur near WARNING nonirritating gas that can cause death if...
  • Page 7 Installing the exhaust tail pipe. The fuel system. Explosive fuel Hazardous Voltage/ Carbon monoxide can cause severe vapors can cause severe injury or Electrical Shock nausea, fainting, or death. Install the death. Vaporized fuels are highly exhaust system tail pipe to prevent the explosive.
  • Page 8 Grounding electrical equipment. Electrical backfeed to the utility. Hot Parts Hazardous voltage cause Hazardous backfeed voltage can severe injury or death. Electrocution cause severe injury or death. WARNING is possible whenever electricity is Connect the generator set to the present. Open the main circuit building/campground electrical system breakers of all power sources before...
  • Page 9 Combustible materials. Fire can Tightening the hardware. Flying NOTICE cause severe injury or death. A hot projectiles can cause severe injury When replacing hardware, do not generator set can ignite debris in the or death. Loose hardware can cause substitute with inferior grade...

  • Page 10: Routine Service Parts

    Routine Service Parts Your Kohler generator dealer/distributor has a complete listing of parts for your generator set. Contact him for service. Part Kohler Description Part No. Air Cleaner Element 258646 Oil Filter 229841 Fuel Filter 225010 Alternator V-belt 225626 Black spray paint...

  • Page 11: Section 1. Specifications

    Obtain service from an authorized service distributor/ Information in this publication represents data available dealer to keep equipment in top condition. at the time of print. Kohler Co. reserves the right to change this publication and the products represented x:in:001:002:a...

  • Page 12: Engine

    Engine Some general engine specifications are listed below. Refer to the appropriate service section and the engine service manual for specific service details. 15 kW Model 20 kW Model Manufacturer ............Yanmar Model .

  • Page 13: Generator

    Generator Models 15CCO/CCFO/CCOZ/CCFOZ Models 20CCO/CCFO/CCOZ/CCFOZ Model Voltage Amps/ Model Voltage Amps/ Series Code Voltage Wire Pole Series Code Voltage Wire Pole 60 Hz Models: 60 Hz Models: 15CCO 120/240 62.5 15.0 20CCO 120/240 83.3 20.0 15CCO 100/200 75.0 15.0 20CCO 100/200 100.0 20.0...
  • Page 14 Generator Models 15/20 kW (continued) 15CCO Single-Phase Models 15CCOZ Three-Phase Models (60/50 Hz) (60/50 Hz) Rotor field voltage/current readings at rated voltage (hot) No load (63 Hz) ....
  • Page 15 NOTES TP-5606 6/02 Specifications 1-5...
  • Page 16 Service View Components Remote-Radiator Model (See Figure 1-1) 1. Optional AC Circuit Breaker 18. Generator Nameplate 19. Mechanical Governor 2. Voltage Regulator Fuse 20. Oil Filter 3. Start-Stop/Preheat Switch 21. Fuel Filter 4. Fuel Solenoid Fuse 22. Ground Connection 5. Controller Fuse 23.
  • Page 17 1-933 Figure 1-1. Service View of 20CCO-RV with Remote Radiator (Typical) TP-5606 6/02 Specifications 1-7...
  • Page 18 Service View Components In-line-Radiator Model (See Figure 1-2) 1. Optional AC Circuit Breaker 19. In-line Radiator 20. Mechanical Governor 2. Voltage Regulator Fuse 21. Oil Filter 3. Start-Stop/Preheat Switch 22. Coolant Drain 4. Fuel Solenoid Fuse 23. Ground Connection 5. Controller Fuse 24.
  • Page 19 1-933 Figure 1-2. Service View of 20CCO-RV In-line Radiator (Typical) TP-5606 6/02 Specifications 1-9...
  • Page 20 1-10 Specifications TP-5606 6/02...

  • Page 21: Section 2. Operation

    Section 2. Operation To ensure continued satisfactory operation, the BATTERY: Check connections. Consult the battery following items should be checked before each start-up. manufacturer’s instructions regarding battery care and maintenance. OPERATING AREA: Make sure there are no obstructions that could block the flow of cooling air. Prestart Checklist Make sure the area is clean.

  • Page 22: Controller (Single Phase)

    Controller (Single Phase) Depending on application, the Kohler relay controller 4. Remote Switch Connection (located at rear of may be located at the set or at a location remote from the controller). Connect the remote start/stop switch to generator. Remote harnesses for the controller are operate the generator set at a location remote from available in 7.5- and 15-foot (2.3- and 4.6-meter)

  • Page 23: Preheat Feature

    Preheat Feature Stopping Procedure During cold weather starts (below 23_F [--5_C]), place Whenever possible, allow a brief cooling period by controller start switch in STOP/PREHEAT position for running the set at low or no load for a few minutes just 15 to 20 seconds before attempting to start the prior to shutdown.

  • Page 24: Fault Shutdowns

    Fault Shutdowns High Water Temperature Shutdown Switch The generator set is also equipped with a high water Low Oil Pressure temperature (HWT) shutdown switch. See Figure 2-4. Shutdown Switch The unit will automatically shut down when the engine coolant temperature exceeds 230_F (110_C). Cause of The low oil pressure (LOP) shutdown feature protects the shutdown must be corrected before the generator the engine against internal damage if the oil pressure...

  • Page 25: Circuit Protection

    If the fuse is replaced 4. Optional AC Circuit Breaker(s) will trip when a then blows again, have the generator set examined current overload is detected in the AC output by an authorized Kohler service dealer/distributor. circuit. Section 4--Troubleshooting 2.

  • Page 26: Accessories

    One required for each Remote Meter Panel Kit. This silencer is engineered and designed specifically for your Kohler RV generator set to assure optimal performance and sound attenuation. Stainless steel Engine Sender Kit flexible exhaust connectors help to absorb shock and Provides gauge senders for the Remote Start and prevent damage to your genset’s exhaust system.

  • Page 27: Remote Panels (Optional)

    Remote Panels (Optional) Remote Start Panel Allows starting/stopping from a location remote of the generator set. Supplied with 15 ft. (4.6 m) connection Stop/Preheat harness. Overall mounting dimensions are 4.06 in. (103 Local 10 A. P1-9 Switch mm) by 2.12 in. (54 mm). Generator sets are equipped Fuse with a 6-pin connector on controller for connection of the 3(47)
  • Page 28 Remote Start and Water Temperature Gauge--Measures engine coolant temperature. Normal engine operating range is Two-Meter Panel Kit 180--205° F (82--96°C). Allows starting/stopping from a location remote of the generator set. The illuminated gauges include engine oil pressure gauge and water temperature gauge. Stop/Preheat Generator sets come equipped with a 6-pin connector Local...
  • Page 29 Remote Start and Hourmeter--Records total generator set operating hours for reference in maintenance scheduling. Four-Meter Panel Kit Allows starting/stopping from a location remote of the generator set. The illuminated gauges include a DC voltmeter, engine pressure gauge, water Stop/Preheat temperature gauge, and generator running time Local hourmeter which records total generator set operating 10 A.
  • Page 30 2-10 Operation TP-5606 6/02...

  • Page 31: Section 3. Scheduled Maintenance

    (**) should be performed only by problems. As part of a preventive maintenance an authorized Kohler service dealer/distributor. Tools program, service the engine (clean cylinder head, and instruments required for these additional steps are inspect valves, check compression, etc.) and generator...
  • Page 32 ....... . * Service more frequently if operated in dusty areas. ** Should be performed by an authorized Kohler service dealer/distributor. 3-2 Scheduled Maintenance...

  • Page 33: Lubrication System

    Lubrication System Oil Selection Oil Check The selection of engine oil is very important to a diesel Check crankcase oil level daily or before each start to engine. If an unsuitable oil is used or an oil change is insure that the level is in the safe range. To check oil neglected, damage and a shorter engine life may result.

  • Page 34: Oil Change

    Oil Change NOTE Too high an oil level causes high oil consumption and On a new engine, change the oil after the first 50 hours of carbonizing of the engine. Low oil level will cause engine operation and thereafter at 100-hour intervals or 3 damage.

  • Page 35: Oil Filter

    Oil Filter 1. Loosen oil filter by turning with a filter wrench in a counterclockwise direction. Use rags to clean up Replace the oil filter for the first time after 50 hours or 1 spilled oil. Remove and discard. month of operation and then every 100 hours or 3 months.

  • Page 36: Fuel System

    Fuel System Specification Fuel Filter The fuel filter serves to remove water and dirt contained Use a clean, good quality No. 2-D (DIN 51 601) diesel in the fuel. The fuel filter element is paper and no attempt fuel oil. The fuel must meet the requirements of the should be made to clean it.

  • Page 37: Bleeding The Fuel System

    Bleeding the Fuel System Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel If the generator set engine runs out of fuel, air leaks system.

  • Page 38: Fuel Solenoid

    Fuel Solenoid The fuel solenoid (Figure 3-8) serves to stop fuel flow through fuel injection pump when start-stop/preheat switch is placed in the STOP position. If the fuel solenoid is removed or the setting is believed incorrect, readjust according to the following procedure. Do not modify the solenoid linkage during reconnection.

  • Page 39: Air Cleaner Service

    Air Cleaner Service 1. Loosen eyebolt and clamp enough to remove the air cleaner cover. The paper element should be replaced at 300-hour or 2. Remove wing nut and slide air cleaner element 6-month intervals; change more frequently if operating from the threaded rod.

  • Page 40: Governor

    Governor The centrifugal, mechanical-type governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. No regular service is required on the unit. The governor is adjusted during run-in at the factory, and further adjustment should not be needed unless greatly varying load conditions are encountered or if poor governor control develops after...

  • Page 41: Cooling System

    Cooling System Cooling System Description cooling passages of the engine. Depending upon the generator set model, the radiator may be mounted The generator set engine is water cooled. The closed in-line (on the front of the engine) or at a remote location loop cooling system includes the engine water pump, by the coach manufacturer.
  • Page 42 Water Pump To Engine CM-250000 1. Upper Radiator Hose 10. Engine Mounting Bracket 2. Hose Clamp 11. Right Belt Guard 3. Radiator Pressure Cap 12. Top Belt Guard 4. Radiator Assembly 13. Left Belt Guard 5. Lower Radiator Hose 14. Fan Shroud 6.
  • Page 43 ADV-5834-B 1. Initial Coolant Fill 2. Coolant Drain Figure 3-12. Initial Coolant Fill and Coolant Drain Locations (In-line-Radiator Model) ADV-5834-B 1. Coolant Outlet (Thermostat Housing) 3. Coolant Inlet (Water Pump) 2. Belt Guard Figure 3-13. Coolant Inlet and Outlet Connections (Remote-Radiator Model) TP-5606 6/02 Scheduled Maintenance 3-13...

  • Page 44: Cooling System Servicing

    Cooling System Servicing for remote radiator cooling system capacity. Drain WARNING petcocks are provided on the bottom tank of the radiator and another in the engine block to drain the system. When draining the coolant, remove the radiator cap and open the block drain located near the flywheel housing;...

  • Page 45: Battery Charging

    Battery Charging Belt Tension WARNING The tension of the alternator/fan belt should be adjusted so that it can be depressed about 0.4--0.6 in. (10--15 mm) when finger pressure is applied. See Figure 3-15. Use the following procedure to adjust the belt. Rotating parts.

  • Page 46: Battery

    Battery Use a 12-volt battery with a rating of at least 625 cold Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause cranking amps. When using a Maintenance-Free battery, it is not necessary to check the specific gravity or blindness and burn skin.

  • Page 47: Cleaning

    Cleaning Keep battery clean by wiping it with a damp cloth. Keep all electrical connections dry and tight. If corrosion is present, disconnect cables from battery and remove corrosion with a wire brush. Clean battery and cables with a solution of baking soda and water. Be careful that cleaning solution does not enter battery cells.

  • Page 48: Checking Specific Gravity

    Checking Specific Gravity ° ° Correction 71.1 + .032 Use a battery hydrometer to check the specific gravity of + .030 the electrolyte in each battery cell. While holding the 65.6 + .028 EXAMPLE NO. 1 - - hydrometer vertical, read the number on the glass bulb + .026 Temperature below 80°F at the top of the electrolyte level.

  • Page 49: Engine Cylinder Head

    Engine Cylinder Head WARNING Rotating parts. Can cause severe injury or death. Operate the generator set only when all guards, screens, and covers are in place. Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury.

  • Page 50: Wattage Requirements

    Wattage Requirements If the rated capacity of the generator is exceeded, the Motor circuit breaker(s) located in the controller will trip to Starting Running protect the generator against damage. This could be Construction Tools Watts Watts caused by a short in the AC circuit in the vehicle or Air Compressor (Small) 1500 simply by having too many appliances (or tools) turned...

  • Page 51: Generator Service

    Generator Service General dirty conditions, use dry compressed air to blow dust out the generator at frequent intervals. Do this with the Under normal conditions, generator service will not be generator set operating and direct the stream of air in required on a regular basis.
  • Page 52 3-22 Scheduled Maintenance TP-5606 6/02...

  • Page 53: Section 4. General Troubleshooting

    Section 4. General Troubleshooting Use the following tables as a quick reference in When troubles occur, don’t overlook simple causes. A troubleshooting individual problems. Generator set starting problem could be caused, for example, by faults are listed by specific groups and include likely improper fuel or an empty fuel tank.
  • Page 54 Problem Possible Cause Corrective Action Reference ENGINE Will not Controller 10-amp Replace fuse. Section 7. Engine/ crank (dead) supply fuse blown If fuse Generator Components failure continues, Section 8. Wiring Diagrams replace fuse and troubleshoot DC circuit and wiring. Battery disconnected Check connections Section 9.

  • Page 55: Tp-5606

    Problem Possible Cause Corrective Action Reference Will not No fuel in tank Replenish start (cranks Defective fuel Check continuity Section 7. Fuel Solenoid okay) solenoid Defective fuel Replace fuel pump Engine Service Manual pump NOTE: Fuel pump is polarity sensitive and will fail if the lead connections are made in reverse.
  • Page 56 Problem Possible Cause Corrective Action Reference Will not start Weak or dead battery Recharge battery. Section 3. Battery (cranks okay) Check electrolyte level (continued) and specific gravity (batteries with filler caps only). Perform load test, or replace battery. Defective air heater Check/replace air heater Engine Service Manual Defective C1 relay...
  • Page 57 Problem Possible Cause Corrective Action Reference Hard starting Stale or bad fuel Replace Air in fuel system Bleed air Section 3. Fuel System Water, dirt in fuel Drain fuel system system and/or replace fuel filters Dirty or faulty injectors Check injectors Engine Service Manual Improper type of fuel Use proper type of fuel;...
  • Page 58 Section 3. Governor adjusted or defective tachometer or (Engine not operating frequency meter. at rated rpm) NOTE: For 60 Hz--1800 RPM For 50 Hz--1500 RPM Engine in need Contact Kohler Engine Service of overhaul distributor Distributor 4-6 General Troubleshooting TP-5606 6/02...
  • Page 59 Problem Possible Cause Corrective Action Reference Will not Fuel line restriction Inspect fuel lines and carry load tank. or runs rough Vent in fuel tank cap Clean cap in solvent, blow (continued) obstructed Dirty fuel filter Replace fuel filter Section 3. Fuel System Improper type of fuel Use proper type of fuel;...
  • Page 60 Problem Possible Cause Corrective Action Reference Will not Defective injection Check injection pump Engine Service Manual carry load pump or runs rough Improper lube oil Use proper viscosity Section 3. Lubrication (continued) System Problem Possible Cause Corrective Action Reference Lacks power Governor not properly Check engine speed Section 3.
  • Page 61 Problem Possible Cause Corrective Action Reference Overheats Low coolant Replenish cooling Section 3. Cooling System system Air cleaner clogged Clean or replace Section 3. Air Cleaner element Service Fan belt broken Tighten/replace Section 3. Drive Belt or loose fan belt Radiator clogged Clean radiator or dirty...
  • Page 62 Install fireproof Operation and Installation sound insulation insulation Manual--Compartment Size Excessive vibration-- Check rotor, crankshaft, Section 8. Disassembly/ engine/generator bearing, etc. Reassembly (Disassembly of engine Engine Service Manual and/or generator may Kohler Service be required) Distributor 4-10 General Troubleshooting TP-5606 6/02...
  • Page 63 Problem Possible Cause Corrective Action Reference ELECTRICAL SYSTEM Battery will Loose or corroded Clean and tighten Section 3. Battery not charge or connections connections goes dead Sulfated or worn-out Check electrolyte level Section 3. Battery battery and specific gravity (batteries with filler caps only) Defective alternator Test and replace,...
  • Page 64 Problem Possible Cause Corrective Action Reference Starter Low battery output Check electrolyte level Section 3. Battery cranks and specific gravity slowly (batteries with filler caps only) Too heavy viscosity Use proper viscosity Section 3. Lubrication lube oil System Loose or corroded Clean and tighten Section 3.
  • Page 65 Problem Possible Cause Corrective Action Reference GENERATOR Optional AC output Check position of Section 2. Circuit generator circuit breaker open circuit breaker Protection output or defective Check AC voltage on Section 9. Wiring Diagrams voltage generator side of circuit breakers Optional AC circuit Reduce load Section 3.
  • Page 66 Problem Possible Cause Corrective Action Reference GENERATOR Rotor slip rings dirty Check and/or service Section 8. Brushes generator or corroded output (1-phase models only) voltage (continued) Broken, weak, or Check condition Section 8. Brushes missing brush spring (1-phase models only) Fuse blown in Replace fuse.
  • Page 67 Problem Possible Cause Corrective Action Reference High Defective voltage Test and/or replace Section 7. Voltage generator regulator Regulator output voltage Voltage regulator Readjust Section 7. Voltage misadjusted Regulator Open or poor splice Check continuity Section 7. Stator connection at and clean connections Section 9.
  • Page 68 4-16 General Troubleshooting TP-5606 6/02...

  • Page 69: Section 5. Controller Troubleshooting

    Section 5. Controller Troubleshooting Data in this section describes the controller sequence of Energizing the K25 relay closes a set of normally open operation during starting, running, and stopping of the contacts to energize the hold coil of the fuel solenoid to generator set.

  • Page 70: Running

    Running 12 VDC AIR HEATER During engine start-up, flashing current is provided to the generator field through a normally open contact of the K2 relay, two diodes, and the normally closed K1A and K1B contacts. The flashing current plus the rotation 10 A.

  • Page 71: Stopping

    Stopping 12 VDC A normal stop is initiated by rocking the Start/Stop AIR HEATER Switch on the controller front panel to the Stop position and then releasing the switch. Holding the switch in the Stop position energizes the C1 relay, causing further, unnecessary heating of the intake manifold.

  • Page 72: Automatic Safety Shutdowns

    Automatic Safety Shutdowns 12 VDC AIR HEATER The engine is equipped with two switches that monitor critical operating conditions. These switches are: 10 A. D A High Engine Temperature Switch that closes STOP/ when engine coolant temperature rises toward an B.C.

  • Page 73: Three-Phase Generator Sequence Of Operation

    Three-Phase Generator Releasing the Start/Stop switch allows the switch to return to its neutral position. If the switch is released Sequence of Operation before the engine starts (the K1 relay is still de-energized), the K2 relay de-energizes. The normally open contacts of the K2 relay then open to interrupt power to the engine start-up circuits.

  • Page 74: Running

    Running 12 VDC During engine start-up, flashing current is provided to AIR HEATER the generator exciter field through a normally open contact of the K2 relay and normally closed contacts of the K1 relay. The resulting generator output from the B1/B2 stator winding, rectified and regulated to a 12 VDC level, energizes the K1 relay (LED1 lights).

  • Page 75: Stopping

    Stopping 12 VDC Normal Stop—A normal stop is initiated by rocking the AIR HEATER Start/Stop Switch on the controller front panel to the Stop position and then releasing the switch. Holding the switch in the Stop position energizes the AH relay, causing further, unnecessary heating of the air heater.

  • Page 76: Automatic Safety Shutdowns

    Automatic Safety Shutdowns 12 VDC AIR HEATER Overspeed—The overspeed protection circuit board monitors the output frequency of the generator set. If the frequency is too high, the SDR relay on the circuit board energizes. Normally open SDR contacts then close to energize the K4 relay (LED4 lights).

  • Page 77: Section 6. Generator/Controller Troubleshooting

    Section 6. Generator/Controller Troubleshooting The section contains flow charts to troubleshoot the Where a check or test is referenced, go to the procedure generator set including the controller circuit board. for detailed instructions. Before beginning the troubleshooting, read all safety precautions at the beginning of this manual.
  • Page 78 Rock and hold Go to A Start/Stop (Sheet 2) Start Switch to Start (Engine Position. Does Stopped) Engine Crank? Is LED2 lit Is LED3 lit Is 12 VDC Is 12 VDC Replace Is 12 VDC while Start/Stop while Start/Stop present across present across S present across starter...
  • Page 79 Does engine Go to B start? (Sheet 3) (From Sheet 1) Was intake air Rock Start/Stop Rock and hold Go to B preheated? Switch to Stop Start/Stop Switch (Sheet 3) Position and hold in Start Position. there for time given Does engine start? in Section 2 to activate air heater.
  • Page 80 Does engine continue to run Go to C after Start/Stop (Sheet 4) Switch is (From released? Sheet 2) Observe LED’s Does LED4 Does LED5 Replace while starting set light? light less than 5 controller circuit again. Does seconds after board. LED1 light? LED1 lights? Is generator a...
  • Page 81 Rock Start/Stop Complete Switch to Stop Generator (From Position. Does Set checks Sheet 3) engine stop? out okay. Observe LED4 Check for 12 Is 12 VDC while Start/Stop VDC across hold present across coil Replace circuit Switch is in coil of fuel of relay K25 board.
  • Page 82 6-6 Generator/Controller Troubleshooting TP-5606 6/02...

  • Page 83: Section 7. Component Testing And Adjustment

    Section 7. Component Testing and Adjustment This section is a guide for checking generator, controller, WARNING and some engine components for improper operation. Follow the safety precautions at the beginning of this manual during all test procedures. Additional safety precautions are included with the tests; OBSERVE THESE PRECAUTIONS! Moving rotor.
  • Page 84 WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles clothing. Battery acid may cause blindness and burn skin. PowerBoostä III E 1-850 Single-Phase Generator Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.
  • Page 85 3. The approximate ammeter reading should be Voltage Regulator 10 AMP battery voltage divided specified rotor PowerBoost IIIE FUSE (single-phase generator) exciter field (three-phase generator) resistance. resistances, see Specifications--Generator in Section 1. Black (+) White (-) Example: D.C. 12 Volts (Battery Voltage) 2.6 Amps A.M.

  • Page 86: Powerboostä Iiie Voltage Regulator

    PowerBoostä IIIE Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical Voltage Regulator connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. The voltage regulator used on single-phase generator Grounding electrical equipment.

  • Page 87: Powerboostä Iiie Voltage Regulator Test Procedure

    PowerBoostä IIIE Voltage voltage adjustment pot clockwise. If the light still does not go on, the voltage regulator is defective Regulator Test Procedure and should be replaced. This would correspond to a low- or no-voltage output condition. 1. Disconnect P10 of wiring harness from connector on voltage regulator.

  • Page 88: Powerboostä Iiie Voltage Regulator Adjustment

    PowerBoostä IIIE Voltage been tampered with, readjust according to the following procedure. Voltage regulator components are identified Regulator Adjustment in Figure 7-4 and described in the following paragraphs. NOTE The voltage regulator is factory set for proper generator The voltage regulator is located in the junction box. operation under a variety of load conditions.
  • Page 89 The 15/20CCO generator sets have the Volts/Hz feature disabled by turning the Volts/Hz pot out (fully counterclockwise). NOTE For optimum results, full load should be applied when adjusting stability pot. 1. With generator set off, turn remote rheostat (if equipped) to midpoint. Turn Voltage and Stability pots fully counterclockwise.

  • Page 90: Powerboostä V Voltage Regulator

    PowerBoostä V Voltage Regulator D 120 Volt, 100 watt Lamp The voltage regulator used on three-phase generator models is PowerBoostä V. See Figure 7-6. D AC Voltmeter 250 Volt (minimum) D 1 Amp Fuse D 1 SPST Switch, 1 Amp (minimum) D 120 Volt AC Plug D #14 AWG Copper Wire (minimum) LED 2...

  • Page 91: Powerboostä V Voltage Regulator Test Procedure

    PowerBoostä V Voltage Regulator volt system it would be 220 volts, etc. If the voltage regulator functions as described, the voltage Test Procedure regulator is okay. 1. Disconnect P5 of wiring harness from connector If the lamp does not turn on, turn the voltage on voltage regulator.

  • Page 92: Powerboostä V Voltage Regulator Adjustment

    PowerBoostä V Voltage Regulator the generator speed returns to normal (60 Hz or 50 Hz) as load is accepted, generator output also returns to Adjustment normal. The voltage regulator is factory set for proper generator operation under a variety of load conditions. The PowerBoostä...

  • Page 93: Adjustment Procedure

    Hazardous voltage can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. contact electrical connections with tools or jewelry while adjustments are made. Remove wristwatch, rings, and jewelry that can cause short circuits. LED 2 LED 1 Hazardous voltage can cause severe injury or death.

  • Page 94: Controller Circuit Board

    Controller Circuit Board It is possible to check some controller circuit board follow the manufacturer’s instructions. To obtain components (relays) without removing the component accurate readings when testing, remove all circuit board from the board. These checks should be made prior to connectors conformal coating...
  • Page 95 E-239563- P1- -9 LED2 1/4 W P1- -14 P1- -15 12 VDC 12 VDC P1- -4 P2- -2 12 VDC LED4 12 VDC 1/4 W 12 VDC P1- -1 P1- -13 1/4 W 5 VDC LED3 1/4 W P1- -7 P2- -1 5 VDC P1- -10...

  • Page 96: Engine/Generator Components

    Engine/Generator Components With the generator set battery connected, the wiring switch in the prescribed position and check for 12 volts harness and some engine/generator components can DC at each component using a DC voltmeter. This will be checked with a voltmeter as described in verify that the switches function and 12 volt DC is Figure 7-12.
  • Page 97 To further check generator set components, disconnect WARNING the battery and remove wiring harness plugs from the controller circuit board. Use an ohmmeter to check continuity and to isolate defective components as described in Figure 7-13. Also refer to the proper wiring diagram in Section 9.
  • Page 98 Ohmmeter Component Remarks Results Connections Controller switch P2-6 and P2-4 Ohmmeter on R x 1 scale. If good--zero ohms Place rocker switch in START (continuity). Any resistance position. other than zero or very low ohms--replace switch. P2-6 and P2-5 Ohmmeter on R x 1 scale. If good--zero ohms Place rocker switch in STOP (continuity).
  • Page 99 Ohmmeter Component Remarks Results Connections P1 ground P1-9 and ground Ohmmeter on R x 1 scale. If good--zero ohms connection (continuity). Any other reading indicates a poor ground connection. Low oil pressure P1-15 and engine block Ohmmeter on R x 1 scale. If good--zero ohms (LOP) safety (ground)

  • Page 100: Rotor

    Rotor The four-pole rotor creates the magnetic field needed to sustain alternating current in the stator windings. Prior to testing, inspect the rotor for visible damage to pole shoes, insulation, exposed coil windings, and slip ring surfaces. Check rotor bearing for noisy operation, excessive wear, and heat discoloration.

  • Page 101: Stator

    To check for rotor shorted to ground, adjust ohmmeter Stator to zero ohms. Touch one ohmmeter lead to either rotor lead and other lead to rotor poles or shaft. Meter should The stator consists of a series of coils of wire placed in a register no continuity.
  • Page 102 D There must be continuity between leads 1 and 2. Figure 7-16. Stator Resistance Check D There must be continuity between leads 3 and 4. D There must be continuity between leads 33 and 44. D There must be continuity between leads 33 and 55. D There must be continuity between leads B1 and D There must be NO continuity between lead 1 and leads 3, 4, 33, 44, and 55.

  • Page 103: Checking Three-Phase Stator Continuity And Resistance

    D There must be NO continuity between lead 7 and Checking Three-Phase Stator leads 8, 9, 11, 12, B1, B2, 55, or 56. Continuity and Resistance D There must be NO continuity between lead 8 and 1. To check stator continuity, set ohmmeter on R x 1 leads 9, 12, B1, B2, 55 or 56.

  • Page 104: Exciter Field

    Exciter Field WARNING The exciter field, used only on three-phase generator sets, is magnetized by DC current. When the exciter armature is rotated within the magnetized exciter field windings, an electrical current develops within the Moving rotor. Hazardous voltage. exciter armature. Test the exciter field according to the Can cause severe injury or death.

  • Page 105: Exciter Armature

    Exciter Field 7 10 Voltage Controller Regulator Megohmmeter Exciter Main Field Armature FP F2 Rectifier Stator Windings Module Stator Exciter Field Ohmmeter Frame Exciter Connection Rotor Armature Exciter Field Stator Figure 7-20. Megohmmeter Connections on Exciter Field Figure 7-21. Exciter Armature Ohmmeter Test Exciter Armature The exciter armature, used only on three-phase...
  • Page 106 3. Check exciter armature for a grounded condition. Using a megohmmeter, apply 500 volts DC to Exciter either armature lead and armature frame. (Follow Field 7 10 instructions megohmmeter manufacturer when performing this test.) See Exciter Figure 7-22. A reading of approximately 500K Main Field Armature ohms (1/2 megohm) and higher indicates the...

  • Page 107: Fuel Solenoid

    Fuel Solenoid Fuel Solenoid Reading “pull” current 31 amps “hold” current 0.8 amps Plunger “pull” resistance 0.387 ohms Plunger “hold” resistance 14.94 ohms The fuel solenoid serves to pull the injector pump lever to the “fuel on” position when energized. The fuel solenoid is spring loaded to return the injector pump Figure 7-23.

  • Page 108: Remote Start Panels (Optional)

    Remote Start Panels Panel Tests (Optional) Panels can be tested with an ohmmeter as described in Figure 7-27 or with a voltmeter as detailed in Figure 7-28. Three remote panels are offered. The first uses a start/stop switch. The second has a start/stop switch and two gauges.
  • Page 109 Voltmeter Component Remarks Results Connections Remote switch “ON” light, Red test lead to P3-2 If 12 volt DC is present Voltmeter setting 12 volts gauge lights, DC (P3-4 for three phase) and component does not or greater. Generator set voltmeter, and hourmeter (socket side) and black function after P3 plug is does not need to be...
  • Page 110 7-28 Component Testing and Adjustment TP-5606 6/02...

  • Page 111: Section 8. Disassembly/Reassembly

    Section 8. Disassembly/Reassembly Prior to disassembly, the generator set must be unbolted from the vehicle compartment. Disconnect all external connections—battery cables at battery (negative lead first), AC output leads in controller, remote start panel at controller connector, fuel line at fuel pump filter inlet, and exhaust connections.
  • Page 112 3. Loosen the screws on the junction box cover using box from the stator mounting bracket. See a 5/16-inch nut driver or 5/16-inch wrench. See Figure 8-4. Figure 8-3. 1-932 1-932 Figure 8-4. Removing the Junction Box Figure 8-3. Removing the Junction Box Cover 13.
  • Page 113 14. Raise brushes in holders (two sets) by pushing leads upward in the slots. Retain brushes by inserting a length of wire or a paper clip. See Figure 8-6. 1-932 Figure 8-8. Using Hoist to Raise Generator Set 1-932 NOTE Figure 8-6.
  • Page 114 1-932 1-932 Figure 8-12. Removing the Cooling Fan Figure 8-10. Removing the End Bracket 22. Support the rotor with a strap and hoist. Remove 20. Carefully remove the stator by pulling the stator eight bolts connecting the drive disk to the engine over the rotor assembly.

  • Page 115: Single-Phase Generator Brushes

    The brushes must be free to move within the holder and Replace the new slip ring (Kohler part number 238134) be held in proper contact by the springs. When properly onto the rotor shaft (with the terminal end pointing positioned, spring pressure on the brush surface will outward) using a press with a proper size fixture.

  • Page 116: Single-Phase Generator Reassembly

    2. Position the rotor with the drive disk onto the engine flywheel using eight bolts. Torque bolts to 14 ft. lbs. (168 in. lbs.). Follow the tightening sequence as shown above. 3. Attach the generator cooling fan using eight screws and four spacers.

  • Page 117: Three-Phase Generator Disassembly

    20. Replace the mounting screws securing the controller cover to the controller. 21. Remove the retaining wires from the brush holders in the end bracket. Be sure that the brushes are centered on the slip rings. Improper brush position will cause premature wear. 22.
  • Page 118 5. Remove the nuts using a 3/8-inch wrench and 10. Remove the four screws securing the exciter field disconnect the ground strap from the controller. to the end bracket. Carefully remove the exciter See Figure 8-22. field from the generator. See Figure 8-24. 1.
  • Page 119 13. Remove the screw and flat washer securing the NOTE exciter armature using a 9/16-inch wrench. Use a hoist with a lifting capacity of one-half ton or Remove the exciter armature from the rotor greater. assembly. See Figure 8-26. 16. Place a wood block under the flywheel housing and lower generator until block supports alternator.
  • Page 120 20. Remove the eight screws and four spacers securing the generator fan. Then carefully remove the cooling fan. See Figure 8-32. 1. End Bracket Figure 8-30. Removing the End Bracket 19. Carefully remove the stator by pulling the stator 1. Fan 2.

  • Page 121: Reassembly

    secure the rotor assembly by installing eight screws. Tighten these screws to a torque of 14 ft. lbs. (168 in. lbs.) in the sequence shown in Figure 8-35. 3. Slide the generator cooling fan over the rotor assembly with the blades facing the flywheel. Coat the threads of the eight mounting screws with Locktiteâ...
  • Page 122 15. Reconnect P6 to J6, P7 to J7, and P8 to J8. 19. Reconnect stator and load leads. 16. Place the controller atop the rubber bumpers. 20. Connect 22-pin harness connector J4 to fixed 17. Route any external leads into the controller and connector at rear of controller.

  • Page 123: Section 9. Wiring Diagrams

    Never unit indicating this change. A decal (part no. 246242) is contact electrical leads or appliances when standing in water available for this purpose from Authorized Kohler or on wet ground because these conditions increase the risk of Dealers/Distributors.
  • Page 124 225570-K Figure 9-1. Wiring Diagram (Schematic) for 15/20CCO-RV Single Phase 9-2 Wiring Diagrams TP-5606 6/02...
  • Page 125 225570-K Figure 9-2. Wiring Diagram (Point-to-Point) for 15/20CCO-RV Single Phase TP-5606 6/02 Wiring Diagrams 9-3...
  • Page 126 This system uses a single-pole circuit breaker with 200--240 Volt, 2 Wire. Circuit breaker MUST be a circuit breaker Stator Leads manufacturer two-pole circuit breaker. single-pole circuit breakers do not conform to NEC requirements when supplying a 240-volt (or 220-volt) load.

  • Page 127: Twelve-Lead (Three-Phase) Generator Sets

    Twelve-Lead (Three-Phase) Generator Sets Diagrams provided to support this configuration are as follows: Output Wiring Figure 9-5 Schematic Wiring Diagram (Three-Phase Models) Figure 9-6 Point-to-Point Wiring Diagram (Three-Phase Models) Figure 9-7 12 LEAD STATOR 12 LEAD STATOR 60 Hz--120/208 volt or 139/240 volt 60 Hz--120/240 volt, 3 PH.
  • Page 128 225652-G Figure 9-6. Wiring Diagram (Schematic) for 15/20CCOZ-Mobile Three Phase 9-6 Wiring Diagrams TP-5606 6/02...
  • Page 129 225652-G Figure 9-7. Wiring Diagram (Point-to-Point) for 15/20CCOZ-Mobile Three Phase TP-5606 6/02 Wiring Diagrams 9-7...
  • Page 130 9-8 Wiring Diagrams TP-5606 6/02...

  • Page 131: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute exh. exhaust ABDC after bottom dead center center of gravity ext. external alternating current cubic inch displacement Fahrenheit, female analog to digital centerline fglass.
  • Page 132 kiloampere mtg. mounting root mean square kilobyte (2 bytes) megawatt rnd. round kilogram milliwatt read only memory kg/cm kilograms per square microfarad rot. rotate, rotating centimeter N, norm. normal (power source) revolutions per minute kilogram-meter not available, not applicable right side kg/m kilograms per cubic meter nat.

  • Page 133: Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 134: Appendix C General Torque Specifications

    Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into...

  • Page 135: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 136: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 137 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts M931-06040-60 M6-1.00 x 40 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard...
  • Page 138 A-8 Appendix TP-5606 6/02...
  • Page 140 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters TP-5606 6/02a 7 Jurong Pier Road Singapore 619159 E Kohler Co., 2002. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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