Kohler 10CCE Operation And Installation Manual
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Kohler 10CCE Operation And Installation Manual

Kohler 10CCE Operation And Installation Manual

Mobile generator sets
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Operation and
Installation
Mobile Generator Sets
Models:
10CCE
10CEZ
12CCE
12CEZ
U.S.A. Plant ISO Registered
TP-5977 7/98a

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Summary of Contents for Kohler 10CCE

  • Page 1 Operation and Installation Mobile Generator Sets Models: 10CCE 10CEZ 12CCE 12CEZ U.S.A. Plant ISO Registered TP-5977 7/98a...
  • Page 2 California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ... 3.8 Cooling System ....... . . 3.8.1 Wet Manifold .

  • Page 4: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting A generator set, like any other Battery acid. Sulfuric acid in electromechanical device, can pose batteries can cause severe injury or potential dangers to life and limb if death. Sulfuric acid in battery can WARNING improperly maintained or operated.
  • Page 5 Engine Backfire/Flash Generator set operation. Carbon Installing exhaust tail pipe. Carbon monoxide can cause severe nausea, monoxide can cause severe nausea, Fire fainting, or death. Never operate the fainting, or death. Install exhaust generator set inside a building unless system tail pipe so discharged exhaust WARNING the exhaust gas is piped safely outside.
  • Page 6 Fuel system. Explosive fuel vapors LP liquid withdrawal fuel leaks. WARNING can cause severe injury or death. All Explosive fuel vapors can cause fuels are highly explosive in a vapor severe injury or death. Fuel leakage state. Use extreme care when handling can cause an explosion.
  • Page 7 Hot Parts Moving Parts Engine block heater. Hazardous voltage can cause severe injury or WARNING WARNING death. Engine block heater can cause electrical shock. Remove engine block heater plug from electrical outlet before working on block heater electrical connections. Hot coolant and steam. Hazardous voltage.
  • Page 8 Notice NOTICE NOTICE Canadian installations only: Hardware damage! Engine and NOTICE For standby service connect output of generator set may use both American generator set to a suitably rated Standard and metric hardware. Use This generator set has been transfer switch in accordance with the correct size tools to prevent rewired from its nameplate voltage Canadian Electrical Code, Part 1.
  • Page 9 Notes VI Safety Precautions and Instructions TP-5977 7/98...

  • Page 10: Introduction

    Introduction California Emission Certification All information in this publication represents data available at time of print. Kohler Co. reserves the right to If your engine/generator has this identification label, it is change this literature and the products represented certified for operation in the state of California.

  • Page 11: Service Parts/Publications

    Model(s) Model 10/12CCE/CEZ 10/12CCE/CEZ Literature Type Part Description Kohler Part Number Operation Manual TP-5977 Air Cleaner Element 254772 Parts Catalog* TP-5411 Oil Filter...

  • Page 12: Section 1. Service Views

    Section 1. Service Views 4 5 6 ADV-5687-D 1. Circuit breaker 8. Oil fill 2. Start/stop switch 9. Air cleaner 3. Hourmeter 10. Cooling system fill 4. Fault lamp 11. Radiator petcock 5. Controller fuse 12. Oil drain 6. Controller 13.
  • Page 13 Notes 2 Service Views TP-5977 7/98...

  • Page 14: Section 2. Operation

    If the unit fails to Do not add coolant to a hot engine. Wait until engine has start after three attempts, contact an authorized Kohler cooled. Adding coolant to a hot engine can cause the distributor/dealer for repair.

  • Page 15: Controls And Indicators

    2.3.1 Controls and Indicators NOTE The following table describes the generator set Do not crank engine continuously for more than controller controls and indicators. 10 seconds at a time. Allow a 60 second cooldown Name Description period between cranking attempts if the engine does not Start/Stop Switch Use switch to start and stop the start.

  • Page 16: Section 3. Scheduled Maintenance

    (--) lead last when Contact an authorized Kohler service distributor/dealer reconnecting battery.) to obtain engine service literature. Disabling generator set. Accidental starting can cause Generator set service. If the generator set operates severe injury or death. Before working on the generator set...

  • Page 17: Service Schedule

    Torque intake manifold bolts** Check throttle and governor operation and adjust as necessary** Check nuts and bolts for tightness * Service more frequently if operated in dusty areas. ** Have an authorized Kohler Service Distributor/Dealer perform. 6 Scheduled Maintenance TP-5977 7/98...

  • Page 18: Lubrication System

    3.2 Lubrication System NOTE The following paragraphs describe the engine Do not operate the generator set with the oil level below lubrication system. the minimum mark or above the maximum mark on the dipstick. 3.2.1 Oil Specifications NOTE Use oils labeled API SG alone or in combination with Do not check oil level when the generator set is other classifications (SG/CC, SG/CD) because they operating.

  • Page 19: Oil Filter Change

    10. Start generator set and check for oil leaks. Use unleaded gasoline because it leaves fewer combustion chamber deposits. Regular grade leaded 11. Stop generator set. Check oil level. Add oil as gasoline may be used; however, be aware the necessary to bring oil level up to MAX mark.

  • Page 20: Fuel Regulators

    3.4.1 Fuel Regulators consumption. At the time of service remove all foreign matter from the air cleaner housing. Fuel regulators are compatible with both natural gas and LP gas. Install the spring and retainer when using Every 50 hours (more often if operating under dusty or natural gas.

  • Page 21: Wet Manifold

    Use only a permanent-type coolant that meets 5. Open the petcock on the bottom of the radiator and remove the drain plug from the engine block. specifications. Use a coolant solution of 50% ethylene glycol and 50% clean, softened water to inhibit corrosion 6.

  • Page 22: High Engine Temperature Shutdown

    3.8.3 High Engine Temperature Shutdown 4. Loosen the alternator mounting hardware if the tension is not set to specifications. The engine automatically shuts down 10-20 seconds 5. While prying the alternator outward, tighten after the engine temperature reaches 218_ F (103_ C). alternator adjusting hardware.

  • Page 23: Generator Storage Procedure

    3.11 Generator Storage Procedure Exterior Preparation 5. Clean exterior of generator set and spread a light Follow the procedure below when storing the generator film of oil or silicon spray over any exposed set for a period of 2 months or more. surfaces which may be subject to rust or corrosion.

  • Page 24: Section 4. Troubleshooting

    No generator output voltage Check AC voltage Service Manual run after start switch run after start switch No/low oil pressure Check oil. See authorized Kohler is released service distributor/dealer Defective low oil pressure (LOP) Replace LOP shutdown switch Service Manual...
  • Page 25 Check fuel lines and tank Section 6. Installation Dirty fuel filter Replace fuel filter Section 3. Fuel Filter No/low oil pressure See authorized Kohler service distributor/dealer Fuse blown in controller Replace fuse. If fuse blows again, Section 2. Operation see authorized Kohler service distributor/dealer Engine—...
  • Page 26 ON position. appliances fail appliances fail Circuit breaker tripped in controller Reset circuit breaker Section 2. Operation Generator malfunction such as See authorized Kohler service defective rotor, faulty voltage distributor/dealer regulator, or other internal fault TP-5977 7/98 Troubelshooting 15...
  • Page 27 Notes 16 Troubleshooting TP-5977 7/98...

  • Page 28: Section 5. Wiring Diagrams

    Section 5. Wiring Diagrams 5.1 Voltage Reconnection WARNING Procedure reconnection procedure explains voltage reconnections only. If frequency changes are required, the governor and voltage regulator need adjustment. Hazardous voltage. Moving rotor. See the generator set service manual for information Can cause severe injury or death. regarding frequency adjustment.
  • Page 29 120/240 Volt (60 Hz), 110/220 Volt (50 Hz), 60 Hz 50 Hz 120/240 Volt (50 Hz), 115/230 Volt (50 Hz) 120 volt Voltage Connection 120/240 volt 115/230 volt Do not use the jumper lead in these systems. If the 110/220 volt generator set was originally wired for straight 120 volt (60 Hz) or 110 volt (50 Hz), be sure to remove jumper Figure 5-1.

  • Page 30: 12-Lead (3-Phase) Generator Sets

    5.1.2 12-Lead (3-Phase) Generator Sets Three-phase, 12-lead generator sets are reconnectable NOTE to the voltages and phases shown in Figure 5-4. If the generator set is reconnected to obtain a different output Generator sets equipped with controllers with meters voltage, voltage regulator adjustments may be have current transformers (CTs).

  • Page 31: Wiring Diagrams

    5.2 Wiring Diagrams 10/12CCE/CEZ Drawing Page Schematic Diagram 1-phase ADV-5719-F 3-phase ADV-5720-F Point-to-Point Wiring Diagram 1-phase 226543-C 1-phase remote mounted 226546-C 3-phase 226539-C 3-phase remote mounted 226547-B Figure 5-5. Wiring Diagrams TP-5977 7/98 Generator Reconnection...

  • Page 32: Adv-5719-F

    ADV-5719-F Figure 5-6. Schematic Diagram, 1-Phase TP-5977 7/98 Generator Reconnection...

  • Page 33: Adv-5720-F

    ADV-5720-F Figure 5-7. Schematic Diagram, 3-Phase TP-5977 7/98 Generator Reconnection...

  • Page 34: 226543-C

    226543-C Figure 5-8. Point-to-Point Wiring Diagram, 1-Phase TP-5977 7/98 Generator Reconnection...

  • Page 35: 226546-C

    226546-C Figure 5-9. Point-to-Point Wiring Diagram, 1-Phase Remote Mounted TP-5977 7/98 Generator Reconnection...

  • Page 36: 226539-C

    226539-C Figure 5-10. Point-to-Point Wiring Diagram, 3-Phase TP-5977 7/98 Generator Reconnection...

  • Page 37: 226547-B

    226547-B Figure 5-11. Point-to-Point Wiring Diagram, 3-Phase Remote Mounted TP-5977 7/98 Generator Reconnection...

  • Page 38: Section 6. Installation

    RV/Mobile generator set installations must comply with cooling during operation. Minimum clearance for the Kohler-detailed installation instructions following. vibration and cooling (top, front, rear, and sides) is Find additional installation requirements in the following 1 1/2 in. (38 mm). Observe the minimum clearances to...

  • Page 39: Mounting

    6.2 Mounting 6.3 Cooling System Securely fasten the generator set to avoid unwanted See Section 3— Cooling System for a description of the movement from vibration and road shock. Attach the generator sets cooling system. generator set vibromounts directly to the vehicle’ s Air Requirements frame.

  • Page 40: Exhaust System

    Never operate in any area where exhaust gas materials. Kohler Co. recommends a clearance of could accumulate and seep back inside a potentially occupied building or vehicle. Be careful when parking your vehicle to 1.5 in.

  • Page 41: Fuel System

    LP gas fuel systems. Contact an the fuel lines from the main tank to the generator set. authorized Kohler service distributor/dealer for further Keep fuel lines as short as possible but maintain fuel system installation information. adequate clearance from exhaust system. Route the 6.5.1 Gasoline...

  • Page 42: Electrical System

    AC load lead L0 (white or gray) indicates the neutral lead water column; adjust inlet pressure on the primary on Kohler generator sets. Make sure to connect the regulator. neutral of the AC circuit in the vehicle to the lead L0 (white or gray).

  • Page 43: Circuit Protection

    Disabling generator set. Accidental starting can cause severe injury or death. Before working on the generator set AC Vehicle Circuit or connected equipment, disable the generator set as follows: 1) Disconnect power to battery charger, if equipped. 2) Remove battery cables (remove negative (--) lead first). Reconnect negative (--) lead last when reconnecting battery.

  • Page 44: Remote Switch Connection

    Circuit Circuit Circuit Breaker Breaker Breaker 10 12 120/240V. Gen. Gen. Gen. 120V. 110/220V. 110/220V. 110V. 120/240V. 115/230V. 1 , 3 Wire 1 , 3 Wire 1 , 3 Wire Circuit Circuit Circuit Breaker Breaker Breaker 10 11 4 11 5 220/380V.

  • Page 45: Battery And Connections

    Always turn battery charger off before disconnecting battery connections. Remove negative (--) lead first when disconnecting battery. Reconnect negative (--) lead last when reconnecting battery. Battery Starting battery. Kohler Co. recommends a separate Vehicle Frame 12-Volt Positive Battery 12-volt battery for the generator set.
  • Page 46 ADV-5687-D Figure 6-9. 10/12CCE/CEZ, Gasoline, 1-Phase Dimension Drawing TP-5977 7/98 Installation 35...
  • Page 47 ADV-5697-B Figure 6-10. 10/12CCE/CEZ, Gasoline, 3-Phase Dimension Drawing 36 Installation TP-5977 7/98...
  • Page 48 ADV-5688-D Figure 6-11. 10CCE/CEZ, Straight Gas, 1-Phase Dimension Drawing TP-5977 7/98 Installation 37...
  • Page 49 ADV-5698-C Figure 6-12. 10CCE/CEZ, Straight Gas, 3-Phase Dimension Drawing 38 Installation TP-5977 7/98...
  • Page 50 ADV-5753-C Figure 6-13. 10CCE/CEZ, Straight Gas, LP Liquid, Combination Gas/Gasoline, 3-Phase Dimension Drawing TP-5977 7/98 Installation 39...
  • Page 51 ADV-5755-D Figure 6-14. 10CCE/CEZ, Straight Gas, LP Liquid, Combination Gas/Gasoline, 3-Phase Dimension Drawing 40 Installation TP-5977 7/98...

  • Page 52: Appendix A. Glossary Of Abbreviations

    Appendix A. 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 53 Notes A-2 Appendix TP-5977 7/98...

  • Page 54: Appendix B. Operating Hour Service Log

    Appendix B. Operating Hour Service Log The following is provided to help you keep a cumulative dates required services were performed. Enter hours to record of operating hours on your generator set and the the nearest quarter hour. OPERATING HOURS SERVICE RECORD HOURS TOTAL...
  • Page 55 Notes TP-5977 7/98 Appendix...
  • Page 56 Index AC Circuit Breaker, 4 Fault Lamp, 4 Oil, 3, 7 Change, 7 Air Cleaner, 3, 9 Fuel, 3 Check, 7 Air Inlets, 3 Fuel System, 8 Filter Change, 8 Combination Gas/Gasoline, 9 Specifications, 7 Alternator service, 5 Gaseous, 8 Fuel Regulators, 9 Gasoline, 8 Fuel Filter, 8...
  • Page 57 Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 KohlerrPower Systems Asia Pacific Headquarters TP-5977 7/98a 7 Jurong Pier Road Singapore 619159 E Kohler Co., 1998. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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