Kohler 10CCOZ61 Service Manual
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Kohler 10CCOZ61 Service Manual

Kohler 10CCOZ61 Service Manual

Mobile generator sets
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Service Manual
Mobile Generator Sets
Model:
10CCOZ61
Brushless Single Phase
TP-5648 9/93

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Summary of Contents for Kohler 10CCOZ61

  • Page 1 Service Manual Mobile Generator Sets Model: 10CCOZ61 Brushless Single Phase TP-5648 9/93...

  • Page 2: Table Of Contents

    Table of Contents SUBJECT PAGE SUBJECT PAGE Glossary of Abbreviations ....Generator Service ..... . . 3-16 General .

  • Page 3: Glossary Of Abbreviations

    Glossary of Abbreviations Abbreviations are used throughout this manual. Normally in the text they will appear in complete form with the abbreviation following in parenthesis the first time they are used. After that they will appear in the abbreviated form. The commonly used abbreviations are shown below.
  • Page 4 Abbreviation Description Abbreviation Description kilometers per hour not required kilovolt overcrank kilovolt amperes outside diameter kilowatt, kilowatts original equipment manufacturer kilowatt hour overspeed, oversize liter, liters overvoltage LxWxH length x width x height ounce, ounces LED, LEDs light emitting diode power factor lb., lbs.
  • Page 5 Safety Precautions and Instructions A generator set, like any other electro-mechanical device, can pose potential dangers to life and limb if CAUTION improperly maintained or imprudently operated. The best way to prevent accidents is to be aware of the potential dangers and to always use good common Caution is used to indicate the presence of a hazard that sense.
  • Page 6 EXHAUST SYSTEM ACCIDENTAL STARTING WARNING WARNING Accidental starting. Can cause severe injury or death. Carbon monoxide. Disconnect battery cables before working on Can cause severe nausea, fainting, or death. generator set (negative lead first and reconnect it last). The exhaust system must be leakproof and routinely inspected.
  • Page 7 MOVING PARTS ENGINE BACKFIRE/FLASH FIRE WARNING WARNING Fire. Hazardous voltage. Moving rotor. Can cause severe injury or death. Can cause severe injury or death. Do not smoke or permit flame or spark to occur Do not operate generator set without all guards near fuel or fuel system.
  • Page 8 HAZARDOUS VOLTAGE/ Hazardous voltage can cause severe injury or death. The heat sink of the voltage regulator contains ELECTRICAL SHOCK high voltage. Do not touch voltage regulator heat sink when testing or electrical shock will occur. WARNING Hazardous voltage can cause severe injury or death.
  • Page 9 FUEL SYSTEM HAZARDOUS NOISE WARNING CAUTION Explosive fuel vapors. Hazardous noise. Can cause severe injury or death. Can cause loss of hearing. Never operate generator without a muffler or Use extreme care when handling, storing, with faulty exhaust system. and using fuels. Explosive fuel vapors can cause severe injury or death.
  • Page 10 BATTERY Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flame or spark to occur near a battery at any time, particularly when it is being charged. Avoid contacting terminals with tools, etc. to prevent burns and to prevent WARNING sparks that could cause an explosion.
  • Page 11 HOT PARTS Hot parts can cause severe injury or death. Do not touch hot engine parts. An engine gets hot while running WARNING and exhaust system components get extremely hot. Hot coolant can cause severe injury or death. Allow engine to cool and release pressure from cooling system before opening pressure cap.
  • Page 12 Consult an proper coolant level. After the coolant has been authorized Kohler service dealer for further fuel system drained, it normally requires some time before complete installation information. refill of the engine water jacket takes place.

  • Page 13: Section 1. Introduction

    Section 1. Introduction Service requirements are minimal, but are very available at time of printing. Kohler Co. reserves the important to the safe and efficient operation of the right to make changes to this literature and the products generator set.
  • Page 14 CV-250000 Figure 1-1. Service View - Typical (10CCOZ). 1-2 Introduction TP-5648 8/93...

  • Page 15: Service Views

    Service Views 1. Controller 17. Oil Filter 2. Voltage Regulator 18. Oil Drain 3. High Water Temperature Shutdown Switch 19. Fuel Filter 4. Fuel Return Connection Point 20. Equipment Ground Location 5. Intake Manifold 21. Fuel Pump 6. Injectors 22. Fuel Inlet Connection Point 7.

  • Page 16: Section 2. Operation

    Section 2. Operation To insure continued satisfactory operation, the following below the filler neck [approx. 3/4 to 1 1/2 in. (19.38 mm)] items should be checked before each startup. when the engine is cold. BATTERY: Check connections and level of battery Prestart Checklist electrolyte.

  • Page 17: Manual Controller Operation

    Manual Controller Operation The manual controller is designed for prime power controller components and an explanation of their applications and is used on the 10CCOZ-Mobile function, refer to Figure 2-1 and the following diesel generator. For identification of manual descriptions. A-225296 Figure 2-1.

  • Page 18: Features

    Features shuts down. Fault lamp will only light as fault occurs. Fault lamp will also light for an emergency stop.) 1. Frequency Meter measures frequency (Hz) of generator output voltage. 7. Voltage Toggle Switch selects the Line 1 (L1) or 2.

  • Page 19: Starting Procedure

    Starting Procedure Ambient Temperature Preheating Time Above 23_ F (--5_ C) Approx. 5 Seconds The generator is equipped with a preheat feature. Place controller start switch (Figure 2-2) in STOP/PREHEAT Approx. 10 Seconds Below 23_ F (--5_ C) position for the amount of time shown in Figure 2-3 Limit of Continuous Use 20 Seconds before attempting to start the generator set.

  • Page 20: Coolant System Filling

    Coolant System Filling conditions occur, the shutdown may be due to low coolant level in the radiator. As a remedy for this, add one to two cups of coolant to the radiator. Be sure to connect the coolant recovery tank to the system, as it is The low-profile coolant system of the 10CCOZ-Mobile an integral and required part of the cooling system.

  • Page 21: Circuit Protection

    Circuit Protection Refer to the following descriptions to identify controller components. WARNING 1. Input (Controller) Fuse (10 Amp) protects Accidental starting. controller circuitry. If the generator will not crank Can cause severe injury or death. and the battery and/or connections appear okay, Disconnect battery cables before working on the controller fuse may be “...

  • Page 22: Fault Shutdowns

    Fault Shutdowns High Water Temperature Shutdown Switch Low Oil Pressure The generator set is also equipped with a high water Shutdown Switch temperature (HWT) shutdown switch. See Figure 2-5. The unit will automatically shut down when the engine The low oil pressure (LOP) shutdown feature protects coolant temperature exceeds 230_ F (110_ C).

  • Page 23: Accessories

    Accessories Low Coolant Level Low Fuel Level Shutdown Switch Shutdown Switch If the engine coolant falls below the “ safe”range in the Provisions have been made in the wiring harness for radiator, the generator will automatically shutdown. The wiring a Low Fuel Level (LFL) switch to the generator. A generator set will not run until coolant is added to the LFL switch will shut the unit down in the event that the specified level.

  • Page 24: Section 3. Scheduled Maintenance

    Items WARNING identified with two asterisks (**) should be performed Accidental starting. only by an authorized Kohler service dealer/distributor. Can cause severe injury or death. Of items marked with three asterisks (***) the Disconnect battery cables before working on...

  • Page 25: Maintenance Schedule

    ..............Service more frequently if operated in dusty areas. Should be performed by an authorized Kohler service dealer/distributor. Manufacturer suggests frequent inspection, change when recommended.

  • Page 26: Lubrication System

    Lubrication System Oil Check This engine has a positive pressure lubrication system and a low oil pressure shutdown. Check crankcase oil level daily or before each start to Oil Selection insure that the level is in the “ safe range.”To check oil level, remove oil dipstick and wipe dipstick clean.
  • Page 27 1. Place a container below the oil drain and open the 6. Stop the generator set. Remove the dipstick and oil drain valve. See Figure 3-2. Allow sufficient wipe clean, reinsert as far as possible, and time for the old oil to drain completely. Close the oil remove to check oil level.

  • Page 28: Oil Filter

    Oil Filter 1. With oil system drained, loosen oil filter by turning it counterclockwise with a filter wrench . Use rags Replace the oil filter for the first time after 50 hours or 1 to clean up spilled oil. Remove and discard filter. month of operation;...

  • Page 29: Fuel System

    Fuel System Specification NOTE Never store diesel fuel in galvanized containers; diesel Use a clean, good quality No. 2-D (DIN 51 601) diesel fuel and the galvanized coating react chemically to fuel oil. The fuel must meet the requirements of the produce flaking which quickly clogs filters or causes the American Society of Testing and Materials (ASTM) fuel pump or injectors to fail.

  • Page 30: Fuel Filter

    Fuel Filter Fuel Filter (Supplied Loose) The fuel filter serves to remove water and dirt contained The fuel filter, supplied loose with the unit, serves as a in the fuel. The engine-mounted fuel filter element is preliminary source to remove dirt and metal particles paper and no attempt should be made to clean it.

  • Page 31: Bleeding The Fuel System

    Bleeding the Fuel System If the generator set engine runs out of fuel, air leaks develop in the suction side of the fuel system, or the fuel filter is replaced, it will be necessary to bleed the entire system to prevent starting failures and/or erratic operation.

  • Page 32: Air Cleaner Service

    Air Cleaner Service Governor The mechanical-type governor is designed to keep the The air cleaner for this unit is not provided by Kohler engine speed constant by automatically adjusting the Co., but has been specified by the trailer manufacturer. amount of fuel supplied to the engine as the load The element should be replaced at 400-hour or 6-month changes.

  • Page 33: Cooling Systems

    Cooling Systems Filling and Checking Flushing and Cleaning Before filling the cooling system, verify that all petcocks For optimum protection, the cooling system should be are closed and all hose clamps are tight. Remove periodically drained, flushed, and refilled, see Service pressure cap located on the top of the engine and fill with Schedule.

  • Page 34: Filling Sequence

    Filling Sequence To prevent the inconvenience of having the generator operate the engine until the thermostat opens and the set shut down or become damaged due to overheating, radiator upper hose becomes hot. Stop the engine and keep the cooling air inlets to the system clean and allow to cool.

  • Page 35: Servicing Cooling System

    Servicing Cooling System For servicing the 10CCOZ generator set, refer to Observe the following recommendations for properly Figure 3-10 for proper coolant system disassembly and maintaining the generator set’ s coolant system: reassembly sequence. During reassembly D Never use dirty water or sea water as coolant. procedure, follow the General Torque Specifications found in Section 10.
  • Page 36 To Engine Block Bracket and nuts (4) are installed on both sides Engine Block CE-250000 Figure 3-10. 10CCOZ Coolant System Exploded View Coolant Fill Fan Shroud Pressure Cap 13 psi (89 kPa) Engine Mounting Bracket Upper Radiator Hose Engine Mounting Bracket To Engine Suction Fan To Engine Water Pump...
  • Page 37 Seal End Bracket to Compartment Wall or Duct Seal Radiator to Compartment Wall Figure 3-11. 10CCOZ Air Flow Direction Using Push Fan 1840 RPM 1533 RPM (L/min.) Discharge (U.S. gas/min.) 10CCOZ Water Pump RPM @ 1800 is 1840 RPM 10CCOZ Water Pump RPM @ 1500 is 1533 RPM 1.

  • Page 38: Drive Belt

    Drive Belt WARNING The alternator, fan, and water pump are belt driven. The drive belt must be properly adjusted at all times since a loose drive belt can overheat and results in improper operation of belt-driven components. Overtightening the belt may cause excessive wear on the alternator and Rotating parts.

  • Page 39: Generator Service

    Generator Service General Abrasive dust on the slip rings could, however shorten the life of the brushes. If brush replacement becomes necessary due to poor or no AC output, contact an Under normal conditions generator service will not be Authorized Service Dealer to have this done. required on a regular basis.

  • Page 40: 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 41 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 42 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 43 Problem Possible Cause Corrective Action Reference Will not start Weak or dead battery Recharge battery. Section 3. Battery (cranks Check electrolyte level okay) (cont’ d.) and specific gravity (batteries with filler caps only). Perform load test, or replace battery. Defective glow plugs Check/replace glow plugs Engine Service Manual Defective GP relay...
  • Page 44 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 45 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-5648 8/93...
  • Page 46 Problem Possible Cause Corrective Action Reference Will not Fuel line restriction Inspect fuel lines and carry load tank. or runs Vent in fuel tank cap Clean cap in solvent, blow rough (cont’ d.) obstructed Dirty fuel filter Replace fuel filter Section 3.
  • Page 47 Problem Possible Cause Corrective Action Reference Will not Defective injection Check injection pump Engine Service Manual carry load pump or runs Improper lube oil Use proper viscosity Section 3. Lubrication rough (cont’ d.) System Problem Possible Cause Corrective Action Reference Lacks power Governor not properly Check engine speed...
  • Page 48 Problem Possible Cause Corrective Action Reference Overheats Low coolant Replenish water coolant 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 49 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-5648 8/93...
  • Page 50 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 51 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 52 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 53 Problem Possible Cause Corrective Action Reference Defective voltage Excite (rotor) Section 7. Separate output regulator separately Excitation voltage Misadjusted voltage Section 7. Voltage (cont’ d.) regulator Regulator generator Problem Possible Cause Corrective Action Reference Low engine rpm Check engine speed Section 3.
  • Page 54 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 55: Section 5. Controller Troubleshooting

    Section 5. Controller Troubleshooting Sequence of Operation Releasing the Start/Stop switch allows the switch to return to its neutral position. If the switch is released before the engine starts (the K1 relay is still The following text describes the controller sequence of de-energized), the K2 relay de-energizes.

  • Page 56: Running

    Running 12 VDC GLOW PLUGS During engine startup, flashing current is provided to 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 limited to a 12 VDC level, 10 A.

  • Page 57: Stopping

    Stopping 12 VDC GLOW PLUGS Normal Stop. A normal stop is initiated by rocking the 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 GP 10 A.

  • Page 58: Automatic Safety Shutdowns

    Automatic Safety Once the normally open contacts of K5 close, the engine safety switches are enabled. If any of the switches close, Shutdowns the K4 relay is energized to produce a shutdown in the same manner as described above for an Overspeed condition.

  • Page 59: 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 60 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 Does starter Replace S while Start/Stop while Start/Stop present across present across S motor turn (starter)
  • Page 61 Does engine Go to B start? (Sheet 3) (From Sheet 1) Were glow Rock Start/Stop Rock and hold Go to C plugs Switch to Stop Start/Stop Switch (Sheet 3) preheated? Position and hold in Start Position. there for time given Does engine start? in Section 2 to preheat glow plugs.
  • Page 62 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 light? light less than 5 controller circuit set again. seconds after board. Does LED1 light? LED1 lights? Does controller...
  • Page 63 Rock Start/Stop Complete Switch to Stop Generator (From Position. Does Set checks engine stop? out okay. Sheet 3) Observe LED4 Check for 12 Is 12 VDC while Start/Stop VDC at fuel present across coil Replace circuit Switch is in solenoid. Is 12 of relay K25 board.

  • Page 64: 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! Hazardous voltage.
  • Page 65 WARNING Sulfuric acid in batteries. Can cause severe injury or death. Use protective goggles and clothes. Can cause permanent damage to eyes, burn skin, and eat holes in clothing. Sulfuric acid in batteries can cause severe injury or death. Sulfuric acid in battery can cause permanent damage to eyes, burn skin, and eat holes in clothing.
  • Page 66 3. The approximate ammeter reading should be 5. Check for AC output across stator leads (see battery voltage divided by specified rotor Stator heading later in this section) and compare resistance. rotor resistance, to readings in Specifications--Generator of Specifications--Generator in Section 1. Section 1.

  • Page 67: Voltage Regulator Powerboostä

    Voltage Regulator D 120 Volt, 100 watt Lamp D AC Voltmeter 250 Volt (minimum) Powerboostä V D 1 Amp. Fuse The voltage regulator used on these models is D 1 SPST Switch, 1 Amp. (minimum) PowerBoostä V. See Figure 7-3. D 120 Volt AC Plug D #14 AWG Copper Wire (minimum) WARNING...

  • Page 68: Voltage Regulator Test Procedure

    Voltage Regulator If the lamp does not turn on, turn the voltage regulator Volts adjustment pot. to the approximate Test Procedure midpoint and repeat test. If the lamp fails to go on after adjusting the Volts pot., replace the voltage regulator.
  • Page 69 POWERBOOSTä V VOLTAGE REGULATOR 120 Volt, Volts 100 Watt Lamp Voltmeter 250 Volt (min.) 100-120 VOLTS AC Variable 1:2 Step-up Transformer Transformer 100-120 VOLTS AC Black SPST 1 Amp. Switch Fuse White Figure 7-4. PowerBoostä V Voltage Regulator Test 7-6 Component Testing and Adjustment TP-5648 8/93...

  • Page 70: Voltage Regulator Adjustment

    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 71: Adjustment Procedure

    Adjustment Procedure 1. Turn Voltage, Volts/Hz, and Stability pots. fully counterclockwise. Connect voltmeter to AC circuit or an electrical outlet. 2. Start generator set. Rotate Voltage Adjustment pot. clockwise (increase voltage) counterclockwise (decrease voltage) until desired output voltage is achieved. STAB 3.

  • Page 72: Controller Circuit Board

    Controller Circuit Board It is possible to check some controller circuit board accurate readings when testing, remove all circuit board components (relays) without removing the component connectors conformal coating (transparent from the board. These checks should be made prior to insulation) from component terminals.

  • Page 73: Engine/Generator Components

    Engine/Generator Components With the generator set battery connected, the wiring prescribed position and check for 12 volts DC at each harness and some engine/generator components can component using a DC voltmeter. This will verify that the be checked with a voltmeter as described in Figure 7-8. switches function and 12 volt DC is present at each Place the controller or remote start/stop switch in the component.
  • Page 74 To further check generator set components, disconnect the battery and remove wiring harness plugs from the controller circuit board. Use an ohmmeter to check continuity and to isolate defective components as WARNING described in Figure 7-9. Also refer to the proper wiring Sulfuric acid in batteries.
  • Page 75 Ohmmeter Component Connections Remarks Results Controller P2-6 and P2-4 Ohmmeter on R x 1 If good--zero ohms switch scale. Place (continuity). Any rocker switch in resistance other than START position. zero or very low ohms-- replace switch. P2-6 and P2-5 Ohmmeter on R x 1 If good--zero ohms scale.
  • Page 76 Ohmmeter Component Connections Remarks Results P1 ground P1-9 and ground Ohmmeter on R x 1 If good--zero ohms connection scale. (continuity). Any other reading indicates a poor ground connection. Low oil P1-15 and engine Ohmmeter on R x 1 If good--zero ohms pressure block (ground) scale.

  • Page 77: Rotor

    Rotor The four-pole rotor creates the magnetic field needed to produce alternating current in the stator windings. Prior to testing, inspect the rotor for visible damage. Check rotor bearing for noisy operation, excessive wear, and heat discoloration. Replace or repair these components if any of the above conditions exist.

  • Page 78: Stator

    Stator D There must be continuity between leads 3 and 4. D There must be continuity between leads 55 and 66. The stator consists of a series of coils of wire placed in a D There must be continuity between leads B1 and laminated steel frame.

  • Page 79: Exciter Field

    Exciter Field Hazardous voltage can cause severe injury or death. Perform electrical service only as prescribed in equipment manual. Be sure that generator is properly The exciter field is magnetized by DC from the battery. grounded. Never touch electrical leads or appliances When the exciter armature is rotated within the with wet hands, when standing in water, or on wet magnetized exciter field windings, an electrical current...

  • Page 80: Exciter Armature

    Exciter Armature Hazardous voltage can cause severe injury or death. Perform electrical service only as prescribed in equipment manual. Be sure that generator is properly The exciter armature supplies excitation current to the grounded. Never touch electrical leads or appliances generator main field (through the rectifier module).

  • Page 81: Fuel Solenoid

    Fuel Solenoid 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 lever to the “ fuel off”position when de-energized. The 10CCOZ models use a three-lead fuel solenoid. This solenoid has a lead marked “...

  • Page 82: Section 8. Disassembly/Reassembly

    Section 8. Disassembly/Reassembly Prior to disassembly, the generator set must be unbolted from the vehicle compartment. Disconnect all external devices--battery cables at the battery (negative lead first), AC output loads at the controller, fuel line at the fuel pump filter inlet, and the exhaust connections. Observe all safety precautions listed at the beginning of this manual during...
  • Page 83 2. Disconnect the 22-pin harness connector from the chassis. Also disconnect and remove leads from stationary connector at the back of the controller. terminals labeled C0, C1, and C2 on the controller See Figure 8-2. chassis. See Figure 8-4. 1. Connector, 22-Pin 1.
  • Page 84 8. Remove the four screws securing the junction box 11. Remove the four screws securing the exciter field to the generator using a 3/8-inch wrench or nut to the end bracket. Carefully remove the exciter driver. Remove the junction box from the field from the generator.
  • Page 85 rotating diode circuit board from the rotor 16. Using a hoist, raise the alternator end of the assembly. generator. See Figure 8-12. 14. 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.
  • Page 86 19. Remove the end bracket by bumping the end 21. Remove the eight screws and four spacers bracket flanges with a soft rubber mallet. See securing the generator fan. Then carefully remove Figure 8-14. the cooling fan. See Figure 8-16. Figure 8-14.

  • Page 87: Reassembly

    23. Remove the eight screws securing the armature 2. Position the rotor assembly on the engine drive disks to the rotor assembly using a 9/16-inch flywheel. Align holes in armature disks and socket wrench and ratchet. See Figure 8-18. flywheel and secure the rotor assembly by installing eight screws.
  • Page 88 13. Secure the exciter field to the end bracket using 19. Install the four nuts to secure the controller to the four screws. Tighten these screws to a torque of mounting bumpers. 70 in. lbs. 20. Connect leads from junction box labeled C0, C1, 14.

  • Page 89: Section 9. Wiring Diagrams

    A decal (part View A no. 246242) is available for this purpose from an 120/240 volt, 3 wire authorized Kohler dealer/distributor. Stator Leads 120/240-volt (or 110/220-volt) Configurations--Figure 9-1 (View A) Figure 9-1. 120/240-volt (or 110/220-volt)
  • Page 90 WARNING WARNING Accidental starting. Can cause severe injury or death. Hazardous voltage. Moving rotor. Disconnect battery cables before working on generator set (negative lead first and reconnect it Can cause severe injury or death. last). Do not operate generator set without all guards Accidental starting can cause severe injury or and electrical enclosures in place.
  • Page 91 CUSTOMER CONNECTIONS OPTION 1 SHUNT TRIP OPTION 2 12 VOLT 2 POLE W/ AUX. 3 POLE W/O AUX. SCHEMATIC GLOW PLUGS SHUNT TRIP SHUNT TRIP P4--1 P4--22 P5--2 P5--1 P4--14 P5--4 SHUNT TRIP P4--9 P4--8 P4--12 LOW FUEL LEVEL (CUSTOMER SUPPLIED) P1--9 HIGH ENGINE LED2...
  • Page 92 BLACK BLUE 225699-B Figure 9-3. Point-to-Point Wiring Diagram for 10CCOZ Single Phase 9-4 Wiring Diagrams TP-5648 8/93...

  • Page 93: Section 10. Common Hardware

    1/2 in. diameter will be SAE flat washers with preloading (torque) of the bolt/screw. Kohler Specification G-585 gives common hardware See “ General Torque Specifications” and other application guidelines. Use the information below and torque specifications in the service literature.
  • Page 94 Common Hardware Application (G-585) Steps for common hardware application: 1. Determine entry hole type: round, or slotted. 2. Determine exit hole type: fixed female thread (weld nut), round, or slotted. For round and slotted exit holes, determine if hardware is greater than 1/2 in. in diameter, or 1/2 in.
  • Page 95 Common Hardware Identification Common hardware has many different head, drive, and Figure 10-4, next page. This is a guide for identification grade (hardness) styles. Some of the more common purposes. Not all generator hardware used is shown. types are shown in Figure 10-3, below, and in Screws/Bolts/Studs HEAD STYLES Hex.
  • Page 96 Nuts STYLES Hex. Head Lock Nut or Square Nut Cap Nut or Wing Nut Nylock Nut Acorn Nut GRADE (HARDNESS) American Standard Metric 10.9 12.9 Grade 2 Grade 5 SAMPLE DIMENSIONS American Standard 1/4-20 Major Thread Diameter In Fractional Threads Per Inch Inches Or Screw Number Size Metric M8-1.25...
  • Page 97 General Torque Specifications The values given are for clean, dry threads. AMERICAN STANDARD Assembled in Cast Iron or Steel Assembled in Aluminum Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5 8-32 in. lbs. (Nm) 20 (2.3) 25 (2.8) 20 (2.3) 10-24...
  • Page 98 TP-5648 8/93 KOHLER CO. KOHLER, WISCONSIN 53044 PHONE 414-565-3381 PRINTED IN U.S.A. FAX 414-459-1646 (North American Sales), 414-459-1614 (International) FOR SALES & SERVICE IN U.S.A. & CANADA PHONE 1-800-544-2444...

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