tp5605 Kohler

RV/Mobile Generator Sets
Models:
15/20CCO
15/20CCFO
15/20CCOZ
15/20CCFOZ
TP-5605 4/97a
Operationand
Installation
Engine exhaust from this product contains
chemicals knowntotheStateof Californiatocause
cancer, birth defects, or other reproductive harm.
WARNING
CaliforniaProposition65
TP-5605 4/97 Table of Contents
Tableof Contents
SUBJ ECT PAGE SUBJ ECT PAGE
SafetyPrecautions andInstructions I . . . . . . .
Introduction i . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ServiceAssistance i . . . . . . . . . . . . . . . . . . . . . . .
Routine Service Parts ii . . . . . . . . . . . . . . . . . . . .
Section1. Specifications 1-1 . . . . . . . . . . . . . . . . .
Introduction 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications 1-1 . . . . . . . . . . . . . . . . . .
Engine 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Models 15/20 kW 1-4 . . . . . . . . . . . . .
Section2. 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 . . . . . . . . . . . . . . . . . . . . . . . . . .
LowOil Pressure
Shutdown Switch 2-4 . . . . . . . . . . . . . . . . . . . . .
High Water Temperature
Shutdown Switch 2-5 . . . . . . . . . . . . . . . . . . . . .
Circuit Protection 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Section3. ScheduledMaintenance 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 . . . . . . . . . . . . . . . . . . . . . . . .
Section4. Troubleshooting 4-1 . . . . . . . . . . . . . . .
Engine 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System 4-4 . . . . . . . . . . . . . . . . . . . . . . . .
Generator 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section5. WiringDiagrams 5-1 . . . . . . . . . . . . . . .
Voltage Reconnection 5-1 . . . . . . . . . . . . . . . . . . . . . .
Voltage Reconnection Procedure 5-2 . . . . . . . . . . .
12-Lead (Three-Phase) Generator Sets 5-3 . . . . .
Section6. 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 . . . . . . . . . . . .
Section7. InstallationDrawings 7-1 . . . . . . . . . . .
AppendixA. Glossaryof Abbreviations A-1 . . . .
AppendixB. OperatingHour ServiceLog B-1 . .
TP-5605 4/97 Safety Precautions and Instructions I
SafetyPrecautions andInstructions
A generator set, like any other electromechanical
device, can pose potential dangers to life and limb if
improperly maintained or operated. The best way to
prevent accidents is to be aware of potential dangers
and act safely. Please read and follow the safety
precautions and instructions belowto prevent harmto
yourselfandothers. Thismanual contains several types
of safety precautions and instructions which are
explained below. SAVE THESE INSTRUCTIONS.
DANGER
Danger indicates the presence of a hazard that will
cause severe personal injury, death, or substantial
property damage.
WARNING
Warning indicates the presence of a hazard that can
cause severe personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a hazard that will or
can cause minor personal injury or property damage.
NOTICE
Notice communicates installation, operation, or
maintenance information that is important but not
hazard related.
Safety decals affixed to the generator set in prominent
places advise the operator or service technician of
potential hazards andhowtoactsafely. Thedecals are
reproduced in this publication to improve operator
recognition. Replace missing or damaged decals.
Accidental Starting
Accidental starting.
Cancausesevereinjuryor death.
Disconnect battery cables before working on
generator set (disconnect negative lead first and
reconnect it last).
WARNING
Disabling generator set. Accidental starting can
cause severe injury or death. Disconnect battery
cables (removenegativeleadfirstandreconnectitlast)
todisablegeneratorsetbeforeworkingonthegenerator
set or connectedequipment. The generator set canbe
started by the remote start/stop switch unless this
precaution is followed.
Battery
Sulfuric acidinbatteries.
Use protective goggles andclothes. Batteryacidcan
causepermanent damagetoeyes, burnskin, andeat
holes in clothing.
WARNING
Battery acid. 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. Always wear splash-proof safety
goggles whenworkingnearthebattery. If batteryacidis
splashed in the eyes or on skin, immediately flush the
affected area for 15 minutes with large quantities of
cleanwater. Seekimmediatemedical aidinthecaseof
eyecontact. Neveraddacidtoabatteryafterplacingthe
battery in service, as this may result in hazardous
spattering of battery acid.
II Safety Precautions and Instructions TP-5605 4/97
Battery gases. Explosion can cause severeinjury
or death. Batterygases cancause anexplosion. Do
not smoke or permit flame or spark to occur near a
battery at any time, particularly when it is charging.
Avoid touching terminals with tools, etc., to prevent
burns and sparks that could cause an explosion.
Removewristwatch, rings, andanyother jewelrybefore
handling battery. Never connect negative (--) battery
cable to positive (+) connection terminal of starter
solenoid. Do not test battery condition by shorting
terminals together. Sparks couldignitebatterygases or
fuel vapors. Ventilate any compartment containing
batteries to prevent accumulation of explosive gases.
To avoid sparks, do not disturb battery charger
connections whilebatteryis beingcharged. Always turn
battery charger off before disconnecting battery
connections. Removenegativeleadfirstandreconnect
it last when disconnecting battery.
EngineBackfire/FlashFire
WARNING
Fire.
Do not smoke or permit flame or spark to occur
near fuel or fuel system.
Servicingfuel system. A flashfirecancausesevere
injuryordeath. Donotsmokeorpermitflameorspark
to occur near carburetor, fuel line, fuel filter, fuel pump,
or other potential sources of spilled fuel or fuel vapors.
Catchall fuel inasuitablecontainer whenremovingfuel
line or carburetor.
Servicingaircleaner. Asuddenbackfirecancause
severeinjuryordeath. Donotoperatewithaircleaner
removed.
ExhaustSystem
WARNING
Carbonmonoxide.
Cancauseseverenausea, fainting, or death.
The exhaust system must be leakproof and
routinely inspected.
Generator set operation. Carbon monoxide can
cause severe nausea, fainting, or death. Never
operate the generator set inside a building unless the
exhaust gas is piped safely outside. Never operate in
any area where exhaust gas could accumulate and
seep back inside a potentially occupied building or
vehicle. Be careful when parking your vehicle to avoid
obstructingtheexhaustoutlet. Theexhaustgases must
discharge freely to prevent carbon monoxide from
deflecting into the vehicle. Avoid breathing exhaust
fumes when working on or near the generator set.
Carbonmonoxideisparticularlydangerousbecauseitis
an odorless, colorless, tasteless, nonirritating gas that
can cause death if inhaled for even a short period of
time.
Carbon monoxide symptoms. Carbon monoxide
cancauseseverenausea,fainting,ordeath. Carbon
monoxide is a poisonous gas which is present in
exhaustgases. Carbonmonoxidepoisoningsymptoms
include but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in joints and muscles
D Sleepiness, mental fatigue, inabilitytoconcentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon
monoxide poisoning is possible, affected persons
shouldseekfreshair immediately. Theyshouldremain
active. Theyshouldnotsit, liedown, orfall asleep. Alert
others to the possibility of carbon monoxide poisoning.
If the condition of affected persons does not improve
within minutes of breathing fresh air, they should seek
medical attention.
Coppertubingexhaustsystems. Carbonmonoxide
cancauseseverenausea, fainting, ordeath. Donot
use copper tubing in diesel exhaust systems. Sulfur in
diesel exhaust causes rapid deterioration of copper
tubing exhaust systems resulting in exhaust leakage.
TP-5605 4/97 Safety Precautions and Instructions III
Installingexhaust tail pipe. Carbon monoxidecan
cause severe nausea, fainting, or death. Install
exhaust systemtail pipe so discharged exhaust gases
will not be drawn into vehicle interior through windows,
doors, air conditioners, etc. Do not use flexible tail
piping because it could crack and allowlethal exhaust
fumes to enter the vehicle.
Inspectingexhaustsystem. Carbonmonoxidecan
causeseverenausea, fainting, or death. In addition
to routine exhaust systeminspection, install a carbon
monoxide detector. Consult your coach builder or
dealer for approved detector installation. Inspect your
detector before each generator set use.
Fuel System
Explosivefuel vapors.
Useextremecarewhenhandling, storing,
and using fuels.
WARNING
Fuel system. Explosive fuel vapors can cause
severeinjuryordeath. All fuels arehighlyexplosivein
a vapor state. Use extreme care when handling and
storing fuels. Store fuel in a well-ventilated area away
fromspark-producingequipmentandoutof thereachof
children. Never addfuel to the tank while the engine is
runningsince spilledfuel mayignite oncontact withhot
parts or fromignition spark. Do not smoke or permit
flame or spark to occur near sources of spilled fuel or
fuel vapors. Keepfuel lines andconnections tightandin
good condition. Do not replace flexible fuel lines with
rigid lines. Use flexible sections to avoid breakage
causedbyvibration. Donotoperategeneratorsetinthe
presence of fuel leaks, fuel accumulation, or sparks.
Repair systems before resuming generator set
operation
Draining fuel system. Explosive fuel vapors can
causesevereinjuryor death. Spilled fuel can cause
an explosion. Use a container to catch fuel when
draining fuel system. Wipe up all spilled fuel after
draining system.
Hazardous Noise
Hazardous noise.
Cancauseloss of hearing.
Never operate generator set without a muffler or
with a faulty exhaust system.
CAUTION
Hazardous Voltage/
Electrical Shock
WARNING
Hazardous voltage. Movingrotor.
Operate generator set only with all guards and
electrical enclosures in place.
WARNING
Hazardous voltage.
Backfeed to utility system can cause severe
injury, death, or propertydamage.
Connectgeneratorsettobuildingelectrical system
onlythroughanapproveddeviceandafterbuilding
main switch is open.
Grounding generator set. Hazardous voltage can
cause severe injury or death. Electrocution is
possible whenever electricity is present. Open main
circuit breakers of all power sources before servicing
equipment. Configure the installation to electrically
groundthe generator set andelectrical circuits whenin
use. Never contact electrical leads or appliances when
standing in water or on wet ground, as the chance of
electrocution is increased under such conditions.
IV Safety Precautions and Instructions TP-5605 4/97
Shortcircuits. Hazardousvoltagecancausesevere
injuryor death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections withtools or jewelrywhile adjustments are
made. Remove wristwatch, rings, and jewelry before
servicing equipment.
Engineblockheater. Hazardous voltagecancause
severeinjuryordeath. Engineblockheatercancause
electrical shock. Removeengineblockheaterplugfrom
electrical outletbeforeworkingonblockheaterelectrical
connections.
Electrical backfeed to utility. Hazardous backfeed
voltagecan causesevereinjury or death. Connect
generator set to building/campgroundelectrical system
only through an approved device and after
building/campground main switch is open. Backfeed
connections can cause serious injury or death to utility
personnel working on power lines and/or personnel in
thevicinityoftheworkarea. Unauthorizedconnectionto
utility electrical systemmay be unlawful in some states
and/or localities. Install a transfer switch to prevent
interconnection of generator set power and other
sources of power.
HeavyEquipment
Unbalancedweight.
Improper lift can causesevereinjury or death
and/or equipmentdamage.
Do not use lifting eyes.
Useslings under skidto balanceandlift generator
set.
WARNING
HotParts
WARNING
Hotcoolantandsteam.
Before removingpressure cap, stopgenerator set
and allowit to cool. Then loosen pressure cap to
relieve pressure.
WARNING
Hotengineandexhaustsystem.
Do not work on generator set until it is allowed to
cool.
Checking coolant level. Hot coolant can cause
severeinjuryordeath. Allowenginetocool. Release
pressure fromcoolingsystembefore openingpressure
cap. Toreleasepressure, coverthepressurecapwitha
thick cloth; then slowly turn it counterclockwise to the
first stop. Remove cap after pressure has been
completelyreleasedandtheenginehas cooled. Check
coolant level at tank if generator set is equipped with a
coolant recovery tank.
Servicing exhaust system. Hot parts can cause
severeinjuryordeath. Donottouchhotengineparts.
An engine becomes hot while running and exhaust
systemcomponents become extremely hot.
Combustible materials. Fire can cause severe
injury or death. Hot exhaust system can ignite
adjacentcombustiblematerials. Donotlocateelectrical
wiring, fuel lines, or combustible material above the
exhaust muffler. Exercise caution when parking your
vehicle to prevent exhaust system and hot exhaust
gases fromstarting grass fires.
TP-5605 4/97 Safety Precautions and Instructions V
injuryor death. Hot generator set can ignite debris in
compartment. Keep the compartment and generator
setcleanandfreeofdebris andcombustiblematerialsto
minimize possibility of fire. Do not block fuel/oil drain
opening in generator set mounting tray. Cut a
corresponding hole in the subfloor for drain opening if
subfloor is used.
MovingParts
WARNING
WARNING
Rotatingparts.
Do not operate generator set without all guards,
screens, and covers in place.
Tighteninghardware. Flyingprojectiles cancause
severeinjury or death. Retorque all crankshaft and
rotorhardwareafterservicing. Donotloosencrankshaft
hardware or rotor thrubolt whenmakingadjustments or
servicinggeneratorset. Rotatecrankshaftmanuallyina
clockwisedirectiononly. Turningcrankshaftboltorrotor
thrubolt counterclockwisecanloosenhardware. Loose
hardwarecancausehardwareor pulleytoreleasefrom
engine of generator set and can cause personal injury.
Servicing generator set when operating. Exposed
moving parts can cause severe injury or death.
Keep hands, feet, hair, clothing, and test leads away
frombelts and pulleys when generator set is running.
Replace guards, screens, and covers before operating
generator set.
Notice
NOTICE
This generator set has been rewired fromits
nameplatevoltageto:
246242
NOTICE
Voltage reconnection! Affix notice to generator set
after reconnecting to a voltage different than the
nameplate. Order voltage reconnection decal 246242
fromauthorized service distributors/dealers.
NOTICE
Hardwaredamage! Engineandgeneratorsetmayuse
bothAmericanStandardandmetric hardware. Usethe
correct size tools to prevent roundingof bolt heads and
nuts.
NOTICE
When replacing hardware, do not substitute with
inferior grade hardware. Screws and nuts are
available in different hardness ratings. American
Standard hardware uses a series of markings and
metric hardware uses a numeric system to indicate
hardness. Check markings on bolt head and nuts for
identification.
NOTICE
Canadianinstallations only:
For standbyserviceconnectoutputof generatorsettoa
suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
NOTICE
This generator set does not comply with United
States Coast Guard (U.S.C.G.) requirements and
mustnotbeusedformarineapplications. Use only
generator sets specified for marine use in marine
installations. U.S.C.G. Regulation33CFR183 requires
a generator set to be ignition protected when used in a
gasoline-fueled environment.
VI Safety Precautions and Instructions TP-5605 4/97
Notes
TP-5605 4/97 Introduction i
Introduction
All information in this publication represents data
available at time of printing. Kohler Co. reserves the
right to change this literature and the products
represented without incurring obligation.
Read through this manual and carefully follow all
procedures and safety precautions to ensure proper
equipment operation and to avoid bodily injury. Read
and follow the Safety Precautions and Instructions
section at the beginning of this manual. Keep this
manual with equipment for future reference.
Equipment service requirements are minimal but are
veryimportanttosafeandefficientoperation; therefore,
inspect parts often and performrequired service at the
prescribed intervals. An authorized service
distributor/dealer should perform required service to
keep equipment in top condition.
ServiceAssistance
For sales and service in the U.S.A. and Canada check
the yellow pages of the telephone directory under the
headingGENERATORSELECTRIC foranauthorized
service 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 the
company directly at the following address or number:
KOHLER CO., Kohler, Wisconsin 53044 U.S.A.
Phone: 414-565-3381
Fax: 414-459-1646 (U.S.A. Sales)
414-459-1614 (International)
To ensure supply of correct parts or information, make
note of the following identification numbers in the
spaces provided:
GENERATORSET
Model No.
Specification No.
Serial No.
MODEL, SPEC, andSERIALnumbersarefoundonthe
nameplate attached to the generator set.
Accessory Nos.
GENERATORSETACCESSORIES
An alternate nameplate inside the junction box
identifies factory-installed generator set accessories.
ENGINE
Engine Serial No.
The engine serial number is found on the engine
nameplate.
ii Introduction TP-5605 4/97
RoutineServiceParts
Kohler generator distributor/dealers have a complete
listingof parts for eachgenerator set. Contact thelocal
Kohler generator distributor/dealer for service.
PartDecsription Kohler PartNo.
Air cleaner element 258646
Oil filter 229841
Fuel filter 225010
Alternator V-belt 225626
Black spray paint 221292
TP-5605 4/97 Specifications 1-1
Section1. Specifications
Introduction
Your vehicle is equipped with a dependable Kohler
alternating-current RV/Mobile Generator Set. Service
requirements of the generator set are minimal, but it is
importantthattherequiredservices beperformedatthe
prescribed intervals. Please take a few moments to
read through this manual; then carefully follow all
service recommendations to keep your set in top
condition. In the space provided, record the MODEL,
SPECIFICATION, SERIAL and ENGINE SPEC.
numbers as foundonthenameplateattachedtothebelt
guard of the engine for remote-radiator models and on
the radiator bracket for in-line radiator models (see
Section 8 Service Ordering Instructions). This
information will enable your Kohler Generator Service
Dealer/Distributor to supply the correct part or data for
yourparticularversion. Keepthis manual inyourvehicle
for futurereference. Theillustrations inthis manual are
representative of most units. Your generator set may
differ slightly fromthose shown.
General Specifications
15kW(60Hz) 20kW(60Hz)
Dimensions L x Wx 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)
Weightdry, 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(M
3
/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%
15kW 0.6 (2.3) 0.8 (3.0) 1.1 (4.2) 1.4 (5.3)
20kW 0.9 (3.4) 1.2 (4.5) 1.5 (5.7) 1.9 (7.2)
DERATION: All units are rated1.0power factor. The kilowatts of the generator set will decrease 3.5%for each1,000 feet (305 meters) above
500 feet (152 meters) above sea level and 1%for each 10_F (5.5_C) above 85_F (30_C).
TP-5605 4/97 1-2 Specifications
Engine
Some general engine specifications are listed below.
Refer to the appropriate service sectionandtheengine
service manual for specific service details.
15kW 20kW
Manufacturer 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. (cm
3
) 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 DieselASTMD975 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 SystemCapacity qts. (L)
Remote Radiator (Engine Water J acket) 2.85 (2.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In-line Radiator 4 qts. 16 oz. (4.26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timing 16_ 1_ 12_ 1_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Cleaner Dry Paper Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator
Models 15CCO/CCFO/CCOZ/CCFOZ
Model Voltage Amps/
Series Code Voltage Wire Pole kW PH
60Hz Models:
15CCO 61 120/240 3 62.5 15.0 1
15CCO 101 100/200 3 75.0 15.0 1
15CCOZ 01 120/240 4 45.1 15.0 3
15CCOZ 51 139/240 4 45.1 15.0 3
15CCOZ 51 127/220 4 49.2 15.0 3
15CCOZ 71 227/480 4 22.6 15.0 3
15CCOZ 71 240/416 4 26.0 15.0 3
15CCOZ 81 120/208 4 52.0 15.0 3
50Hz Models:
15CCFO 101 120/240 3 52.1 12.5 1
15CCFO 61 110/220 3 56.8 12.5 1
15CCFO 11 100/200 3 62.5 12.5 1
15CCFO 41 220 2 56.8 12.5 1
15CCFOZ 51 110/190 4 47.5 12.5 3
15CCFOZ 51 115/200 4 45.1 12.5 3
15CCFOZ 71 220/380 4 23.7 12.5 3
15CCFOZ 71 230/400 4 22.6 12.5 3
15CCFOZ 71 240/416 4 21.7 12.5 3
15CCFOZ 81 120/208 4 43.4 12.5 3
15CCFOZ 81 110/220 4 41.0 12.5 3
Models 20CCO/CCFO/CCOZ/CCFOZ
Model Voltage Amps/
Series Code Voltage Wire Pole kW PH
60Hz Models:
20CCO 61 120/240 3 83.3 20.0 1
20CCO 101 100/200 3 100.0 20.0 1
20CCOZ 01 120/240 4 60.1 20.0 3
20CCOZ 51 139/240 4 60.1 20.0 3
20CCOZ 51 127/220 4 65.6 20.0 3
20CCOZ 71 227/480 4 30.1 20.0 3
20CCOZ 71 240/416 4 34.7 20.0 3
20CCOZ 81 120/208 4 69.4 20.0 3
50Hz Models:
20CCFO 101 120/240 3 69.4 16.5 1
20CCFO 61 110/220 3 75.8 16.5 1
20CCFO 11 100/200 3 83.3 16.5 1
20CCFO 41 220 2 75.8 16.5 1
20CCFOZ 51 110/190 4 63.3 16.5 3
20CCFOZ 51 115/200 4 60.1 16.5 3
20CCFOZ 71 220/380 4 31.7 16.5 3
20CCFOZ 71 230/400 4 30.1 16.5 3
20CCFOZ 71 240/416 4 28.9 16.5 3
20CCFOZ 81 120/208 4 57.8 16.5 3
20CCFOZ 81 110/220 4 54.7 16.5 3
Generator Models 15/20kW
Single-PhaseModels Three-PhaseModels
RPM(60-Hz Models) 1800 1800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RPM(50-Hz Models) 1500 1500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15kW:
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20kW:
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 PowerBoostIIIE PowerBoostV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insulation (Rotor and Stator) Class 155, Epoxy Varnish, VacuumImpregnated . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 considered
good if a lowresistance reading (continuity) is obtained and there is no evidence of shorted windings
(discoloration). Do not confuse a lowresistance reading with a reading indicating a shorted winding.
1-933
1
2
3
4
5 6
7
8
9
10
11 12
13 14
15
16
17
18
19
20
21
22
23 24 25
26
27
28
29
30
31
32
33
34
1. Optional AC circuit breaker
2. Voltage regulator fuse
3. Start-stop/preheat switch
4. Fuel solenoid fuse
5. Controller fuse
6. Hourmeter
7. Controller
8. Remote connection (at rear of controller)
9. Air cleaner
10. Lifting eye
11. Intake heater
12. Fuel solenoid
13. Oil fill
14. Lifting eye
15. High water temperature shutdown
16. Coolant inlet
17. Oil fill
18. Generator nameplate
19. Mechanical governor
20. Oil filter
21. Fuel filter
22. Ground connection
23. Oil drain
24. Fuel pump
25. Fuel inlet connection point
26. Fuel return connection point
27. Oil check
28. Heater coil relay
29. Lowoil pressure shutdown
30. Voltage regulator
(inside junction/circuit breaker box)
31. Coolant outlet
32. Exhaust outlet
33. Battery charging alternator (behind guard)
34. Starter
Figure1-1. ServiceViewof 20CCORVwithRemoteRadiator (Typical)
1-933
1
2
3
4
5 6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24 25 26
27 28
29 30
31
32
33
34
35
2. Voltage regulator fuse
3. Start-stop/preheat switch
5. Controller fuse
6. Hourmeter
7. Controller
8. Remote connection (at rear of controller)
9. Air cleaner
10. Lifting eye
11. Intake heater
12. Fuel solenoid
13. Oil fill
14. Lifting eye
15. High water temperature shutdown
16. Pressure cap/initial coolant fill
17. Generator nameplate
18. Oil fill
19. In-line radiator
20. Mechanical governor
21. Oil filter
22. Coolant drain
23. Ground connection
24. Oil drain
25. Fuel inlet connection point
26. Fuel pump
27. Fuel return connection point
28. Oil check
29. Fuel filter
30. Heater coil relay
31. Lowoil pressure shutdown
32. Voltage regulator
(inside junction/circuit breaker box)
33. Exhaust outlet
34. Batterychargingalternator (behindguardonnon-servicesideof
unit)
35. Starter (on non-service side of unit)
Figure1-2. ServiceViewof 20CCORVIn-lineRadiator (Typical)
TP-5605 4/97 Operation 2-1
Section2. Operation
To ensure continued satisfactory operation, check the
following items before each startup and at regular
intervals.
PrestartChecklist
Air Cleaner. Keep air cleaner element clean. Install
element to keep unfiltered air fromentering engine.
Air Shrouding. Keep tight and in position.
Air Inlets. Keep clean and unobstructed.
Battery. Ensuretightbatteryconnections. Maintainfull
battery electrolyte level.
Coolant Level. For cooling systems equipped with a
coolant recovery tank, check coolant level at tank after
the 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 provides
freezing protection of --34F (--37C) and overheating
protectionto265F (129C). Acoolantsolutionwithless
than 50% ethylene glycol may not provide adequate
freezingandoverheatingprotection. A coolant solution
withmorethan50%ethyleneglycol cancauseengineor
component damage. Do not use alcohol or methanol
antifreeze or mix them with the specified coolant.
Consulttheenginemanufacturers operationmanual for
engine coolant specifications.
Donotaddcoolanttoahotengine. Waituntil enginehas
cooled. Adding coolant to a hot engine can cause the
cylinder block or cylinder head to crack.
NOTE
Do not energize block heater before filling cooling
system. Beforeenergizingblockheater, runengineuntil
itis warmandrefill radiator topurgeairfromthesystem.
Immerse heater element in coolant to prevent block
heater failure.
Drive Belts. Check belt condition and tension of
radiator fan, water pump, and battery charging
alternator belt(s).
Exhaust System. Keep exhaust outlet clear. Keep
muffler and piping tight and in good condition.
Fuel Level. Keep tank(s) full to ensure adequate fuel
supply.
Oil Level. Maintain oil level at or near full mark on
dipstickbutnotover. Keeptheoil level inthemechanical
governor (if equipped) at or near the full level.
Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Donotleaverags, tools, or debris onor near the
generator set.
ExercisingtheGenerator
Run the generator set under load once each week for
one hour with an operator present.
Operator should perform all prestart checks before
startingtheexerciseprocedure. Whilethegeneratorset
is running, listen for a smooth-running engine and
visuallyinspectthegenerator settoensurethereareno
fluid or exhaust leaks.
Start the generator set according to the starting
procedure in the controller section of this manual.
TP-5605 4/97 2-2 Operation
Controller (Single-Phase)
Depending on application, the Kohler relay controller
maybelocatedatthesetoratalocationremotefromthe
generator. Remote harnesses for the controller are
available in 7.5- and 15-foot (2.3- and 4.6-meter)
lengths. If the generator set has automaticallystopped
because of high water temperature (230_F/110_C) or
lowoil pressure (6.8 psi/46.9 kPa or less), correct the
cause before restarting the set.
Refer to Figure 2-1 or Figure 2-2 and the following
descriptions to identify controller components.
Generator Start and Stop/Preheat Switch. Switch
serves the dual function of generator operation and
generator preheat. When pressed to the preheat
position, the preheat switch aids in cold weather
starting. RefertoStart/StopandPreheatingprocedures
following.
Fuel Solenoid Fuse. 10-amp fuse protects fuel
solenoid circuitry.
Controller Fuse. 10-amp fuse protects controller
circuitry against damage if a short develops in the
engine wiring system or the wiring to the remote
start/stop switch.
Remote Switch Connection (located at rear of
controller). Connect the remote start/stop switch to
operate the generator set at a locationremote fromthe
set. Controller connections are made through the plug
connector at the rear of the unit.
Hourmeter. Meterrecords total generatorsetoperating
hours for reference in maintenance schedule.
DC Circuit Breaker. Circuit breaker shuts down the
generator set automatically after fault. See Circuit
Protection following.
AC Circuit Breaker (optional). Circuit breaker trips
when a fault is detected in the output circuit. Used to
disconnect generator set during maintenance on
vehiclewiring. Toclosecircuitbreaker(s), placebreaker
in ON position.
1-932
1 2 3
4
5
1. Generator start and stop/preheat switch
3. Controller fuse
4. Remote switch connection
5. Hourmeter
Figure2-1. Single-PhaseController
1
2 3
4
A-229301-L
5
1. Generator start and stop/preheat switch
2. Hourmeter
3. DC circuit breaker
4. Remote switch connection
5. AC circuit breaker
Figure2-2. Single-PhaseController
(spec PA-135322)
Controller (Three-Phase)
For identification of three-phase controller, see
Figure 2-3.
1-932
1
2 3
4
5
1. Generator start and stop preheat switch
3. Hourmeter
4. AC circuit breaker
Figure2-3. Three-PhaseController
GeneratorStartandStopPreheatSwitchserves the
dual function of generator operation and generator
preheat. When pressed to the preheat position, the
preheat switch aids in cold weather starting. Refer to
Start/Stop and Preheating procedures following.
DC CircuitBreakertrips whenafault is detectedinthe
DC circuitry. The generator set shuts down
automatically after fault. See Circuit Protection
following.
Hourmeterrecords total generator set operatinghours
for reference in maintenance schedule.
AC Circuit Breaker (optional) trips when a fault is
detected in the output circuit. Used to disconnect
generator set duringmaintenance of vehicle wiring. To
close circuit breaker(s), place in ON position.
Fuel Solenoid Fuse (located inside the controller).
10-amp fuse protects fuel solenoid circuitry.
PreheatFeature
During cold weather starts (below23_F [--5_C]), place
controller start switch in STOP/PREHEAT position for
15 to 20 seconds before attempting to start the
generatorset. This provides energizingof theairheater
coil. Do not energize preheat feature for more than
30 seconds or damage may occur.
StartingProcedure
Move the START-STOP/PREHEAT switch to the
START positionandholdinthis positionuntil theengine
is running, then release. Do not crank engine
continuouslyfor more than10seconds at a time. If the
engine does not start, allow a 60-second cooldown
period between cranking attempts. If the unit fails to
startafter threeattempts, contactanauthorizedservice
dealer/distributor for repair. Failure to follow these
guidelines may result in burnout of the starter motor.
NOTE
If the engine starts and then stops, allowthe engine to
come to a complete stop before making a restart
attempt. If theflywheel ringgearis still rotatingwhenthe
starter piniongear is engaged, thepiniongear will clash
which may damage the ring gear teeth.
NOTE
If ambient temperature is below 23_F (--5_C), see
Preheat Feature.
StoppingProcedure
Whenever possible, allow a brief cooling period by
running the set at lowor no load for a fewminutes just
priortoshutdown. Tostop, movetheswitchtotheSTOP
positionandholduntil thesetcomes toacompletehalt.
If the generator set shuts down automatically, identify
and correct the problembefore attempting to restart.
NOTE
DonotplaceStart-Stop/PreheatswitchinStop/Preheat
position for more than 30 seconds or damage to the
preheat feature may occur.
FaultShutdowns
LowOil Pressure
ShutdownSwitch
The lowoil pressure (LOP) shutdown feature protects
the engine against internal damage if the oil pressure
drops below6.8 psi (46.9 kPa) because of an oil pump
fault or other engine malfunction. The LOP shutdown
does not protect the set fromdamage due to operating
with the oil level below the safe rangeIT IS NOT A
LOW OIL LEVEL SHUTDOWN. Check the oil level
regularlyandaddoil as neededtopreventrunningoutof
oil. Location of the LOP shutdown switch is shown in
Figure 2-4.
NOTE
This is not a lowoil level shutdown. Maintainproper oil
level to enable low oil pressure shutdown switch to
function.
1-933
1
1. Lowoil pressure switch
Figure2-4. LowOil PressureShutdownSwitch
HighWater Temperature
ShutdownSwitch
The generator set is also equipped with a high water
temperature (HWT) shutdown switch. See Figure 2-5.
The unit will automatically shut down when the engine
coolant temperature exceeds 230_F (110_C). Correct
the cause of the shutdown before restarting the
generator.
NOTE
The high water temperature (HWT) shutdown switchis
not a lowcoolant level switch. Maintain proper coolant
level to enable HWT switch to function.
1-933
1
1. High water temperature switch
Figure2-5. HighWater Temperature
ShutdownSwitch
CircuitProtection
Refer to Figure 2-6 and the following descriptions to
identify controller components.
10-AmpFuel SolenoidFuse. A replaceable 10-amp
fuseprotects thefuel solenoid. (Onthree-phasemodels
the in-line fuse is mounted inside the controller.) If this
fuse is blown, the generator shuts down. If the fuse is
replaced and then blows again, have the generator set
examined by an authorized Kohler service
distributor/dealer.
10-Amp Controller-Input Fuse (Single-Phase) or
Circuit Breaker (Three-Phase). A replaceable
10-amp fuse or circuit breaker protects the controller
circuitry. If the generator will not crank and the battery
and/or connections are intact, the controller
fuse/breaker may be blown or tripped. Contact an
authorized Kohler service distributor/dealer if
fuse/breaker blows/trips repeatedly.
10-Amp PBIIIE Voltage Regulator Fuse
(Single-Phase Models Only). A replaceable 10-amp
fuseprotectsthevoltageregulatorcircuitry. Ifthis fuseis
blown, the generator set shuts down. If this fuse is
replaced and then blows again, have the generator set
examined by an authorized Kohler service
distributor/dealer.
Optional AC Circuit Breaker(s) trips when a fault is
detected in the AC output circuit. See Section
4Troubleshooting to determine cause of fault. After
fault is corrected, reset AC circuit breaker by placingin
ON position.
DC Circuit Breaker will trip when a fault occurs in the
controller circuit. See Section 4Troubleshooting to
determine cause of fault. After fault is corrected, reset
DC circuit breaker by depressing center button.
1-933
Single-Phase
Controller
Three-Phase
Controller
1
2
3
4
1
2
4
5
4
Spec PA-135322
1. 10-amp fuel solenoid fuse
2. 10-amp controller-input fuse or circuit breaker
3. 10-amp PBIIIE voltage regulator fuse
Figure2-6. CircuitProtection
TP-5605 4/97 Scheduled Maintenance 3-1
Section3. ScheduledMaintenance
General
Schedule routine maintenance using the Maintenance
Schedule following and the hourmeter located on the
generator controller. If the generator will be subject to
extreme operating conditions, service the unit more
frequently. Instructions to perform most of the
scheduledservices areprovidedinthefollowingpages.
Items in the maintenance schedule marked with an
asterisk (*) should be performed more often if the
generator set is operated in dirty, dusty conditions.
Items identified withasterisks (**) should be performed
only by an authorized Kohler service dealer/distributor.
Tools and instruments required for these additional
steps are usually not available to the generator set
owner. For this reason, returnthe set periodicallytoan
authorized service distributor/dealer for complete
servicing and tune-up. Such service improves
performance and continuous satisfactory operation
during a long trouble-free service life.
NOTE
Performtheitems listedinthemaintenancescheduleat
thedesignatedintervals for thelifeof thegenerator. For
example, anitemservicedevery100hours or 3months
must alsobeservicedafter 200 hours or 6months, 300
hours or 9 months, etc. The generator will eventually
accumulate enough hours to warrant a complete
overhaul. Theexacttimeatwhichextensiveservicewill
be necessary cannot be predicted. However, rough
operation, lack of power, andexcessiveoil useindicate
serious generator setproblems. As partof apreventive
maintenance program, service the engine (clean
cylinder head, inspectvalves, checkcompression, etc.)
andgenerator (replace bearing, inspect wiring, remove
debris, etc.) at the earliest indication that a serious
problemexists.
TP-5605 4/97 3-2 Scheduled Maintenance
FUEL SYSTEM
Check the fuel level X . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fill fuel tank X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remove sediment fromfuel 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATIONSYSTEM
Check 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)
COOLINGSYSTEM
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIRCLEANER
Replace the air cleaner element* X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the breather pipe* X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM
Verify 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)
CYLINDERHEAD
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR
Blowdust out of generator* X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean slip rings and inspect brushes (Single-phase units only)** X . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PerformServiceatIntervals Indicated(X)
Before
Each
Startup
Every50
Hours or
1Month
Every100
Hours or
3Months
Every500
Hours or
Yearly
Every300
Hours or
6Months
* Service more frequently if operated in dusty areas.
** Should be performed by an authorized Kohler Service Dealer/Distributor.
LubricationSystem
Oil Selection
The selection of engine oil is very important to a diesel
engine. If an unsuitable oil is used or an oil change is
neglected, damageandashorter enginelifemayresult.
Oil must meet the American PetroleumInstitute (API)
classificationofCCorCD. Avoidmixingdifferentbrands
ofoilsandlubricants; oilsofdifferentmanufacturersmay
be incompatible and deteriorate when mixed.
Recommended SAE viscosity designations for given
temperature ranges in which the generator set will be
operated are listed in Figure 3-1.
NOTE
Failure to observe these standards may cause
inadequate oil pressure and cold-starting difficulties.
S.A.E. Service
Grade
C
F
--30 --20 --10 0 10 20 30 40
0 20 40 60 80 100
Operating Temperature
RecommendedValue
UsableLimit
5W
10W
20W
SAE 20
SAE 30
SAE 40
C
F
5W
10W
20W
20
30
40
5W20
10W30
20W40
Figure3-1. EngineOil Selection.
Oil Check
Check crankcase oil level daily or before each start to
ensure that the level is in the safe range. To check oil
level, remove oil dipstick and wipe dipstick clean (see
Figure 3-2). Repositiondipstickincrankcase andpush
it all the way down into the tube. Remove dipstick and
checkthelevel. Oil level shouldreadbetweenMINand
MAX marks on dipstick. Do not operate set if oil level
exceeds theMAXmarkorregisters belowtheMINmark
on dipstick.
1-933
1 2
1. MAX level
2. MIN level
Figure3-2. Oil Level Check
NOTE
Do not check oil level whenthe set is inoperation. The
engine must be stopped and on a level surface when
checking oil. Obtain the most accurate oil reading by
shutting down the generator and waiting several
minutes before checking oil.
Oil Change
Onanewengine, changetheoil afterthefirst50hoursof
operation and thereafter at 100-hour intervals or
3 months, whichever occurs first. Change oil more
frequently under dirty, dusty conditions. Change oil
while the engine is still warm.
1. Place a container below the oil drain hole and
remove oil drain plug. Allowsufficient time for the
old oil to drain completely. Replace oil drain plug.
Dispose of used engine oil in an environmentally
safemanner. Takeusedoil toa suitablecollection
facilityinyourarea. DONOT POURUSEDOILON
THE GROUND, DOWN SEWERS, OR INTO
STREAMS OR OTHER BODIES OF WATER.
2. Remove oil fill cap. One is located on the
rocker-armcover and one is located near the fuel
injector pump. See Figure 3-4.
3. Fill crankcase with proper amount and type of oil;
see Figure 3-3 and Oil Selection.
4. If replacingengine 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
wipeclean, reinsertas far as possible, andremove
to check oil level. Add oil, as necessary, to bring
level up to MAX mark.
OIL CAPACITY
(with Filter)
qts. (L)
15 kW 6.1 (5.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 kW 6.1 (5.8) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure3-3.
NOTE
Too high an oil level causes high oil consumption and
carbonizing of the engine. Low oil level will cause
engine damage.
1-933
1
1. Oil fill
Figure3-4. Oil Fill Locations
Oil Filter
Replace the oil filter for the first time after 50 hours or
1 month of operation and then every 100 hours or
3 months. Change more frequentlyif operatingindirty,
dusty conditions. See Figure 3-5 and refer to the
following procedure.
1-933
1
1. Oil filter
Figure3-5. Oil Filter Location
1. Loosen oil filter by turning with a filter wrench in a
counterclockwise direction. Use rags to clean up
spilled oil. Remove and discard.
2. Clean contact surface on oil filter adapter.
3. Lightly lubricate the gasket surface of the newoil
filter with the fresh engine oil. Thread oil filter to
adapter until gasket makes contact, hand tighten
an additional one-half turn.
4. Start the generator set and check for oil leaks.
5. Stopthegenerator set. Removedipstickandwipe
clean. Reinsert as far as possible, then remove to
checkoil level. Addoil, as necessary, tobringlevel
up to MAX level.
Fuel System
Specification
Use a clean, good quality No. 2-D (DIN 51 601) diesel
fuel oil. The fuel must meet the requirements of the
American Society of Testing and Materials (ASTM)
diesel fuel classification D975 (Federal Specification
W-F-800a). Cleanliness of the fuel is especially
important on diesel engines which have easily clogged
precision fuel injectors and pumps. See chart below.
United States ASTM/D975 No. 2-DDiesel
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) . . . . . . . . . . . . . . . . . .
Belowthe lowest outside
air temperature
NOTE
Never store diesel fuel in galvanized containers; diesel
fuel and the galvanized coating react chemically to
produce flaking which quickly clogs filters or causes
failure of the fuel pump or injectors. Do not run the
generator set out of fuel; air will be drawn into the fuel
lines and the entire systemwill have to be bled before
the unit can be restarted.
NOTE
Avoidstoringfuel overlongperiodsoftime. Takespecial
precautions to keep all dirt, water, and other
contaminants out of the fuel. Storage tanks containing
diesel fuel contaminated with water may cause the
growthof microbes. Thepresenceof microbes will form
a slime which will clog fuel filters and lines.
Fuel Filter
Thefuel filter serves toremovewater anddirtcontained
in the fuel. The fuel filter element is paper and no
attemptshouldbemadetocleanit. Its useful lifewill be
determined largely by the quality and condition of the
fuel used. Under normal conditions, replace the fuel
filter element for the first time after 50 hours or one
month and then every 300 hours or six months. See
Figure 3-6 for locationand use the followingprocedure
to service the fuel filter.
1. Loosen the fuel filter by turning in a
counterclockwise direction. Use rags to clean up
spilled fuel oil. Remove and discard filter.
2. Clean contact surface on the fuel filter adapter.
3. Lightlylubricate the gasket surface of the newfuel
filter withfreshfuel oil. Threadthe fuel filter to the
adapter until the gasket makes contact, hand
tighten an additional one-half turn.
SeeBleedingsectionfollowing.
1-933
1
1. Fuel filter
Figure3-6. Fuel Filter Location
BleedingtheFuel System
If the generator set engine runs out of fuel, air leaks
developinthesuctionsideof thefuel system, or thefuel
filter is replaced, bleed the entire system to prevent
startingfailures and/orerraticoperation. SeeFigure 3-7
and refer to the following procedure.
1. Disconnect lead 71A from the starter relay to
disable 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 fromthe loosened connection. Tighten the
fuel line connection.
5. Loosenthesmall ventscrew(withPhillips head) on
the fuel filter.
6. Crank the engine until fuel (free from bubbles)
flows fromthis point. Tighten vent screw.
7. Loosenthelineconnection(bleedpoint) atthefuel
injection pump inlet.
8. Cranktheenginetooperatethefuel pumpuntil fuel
(free from bubbles) flows from this loosened
connection. Tighten line connection.
9. Reconnect lead 71A to the starter relay.
WARNING
and using fuels.
draining system.
1-933
1 2
3 4
5
6
1. Line connection (bleed point)
2. Vent screw
3. Line connection (bleed point)
4. Fuel injection pump
5. Electric fuel pump
6. Fuel filter
Figure3-7. BleedingtheFuel System
Fuel Solenoid
The fuel solenoid (Figure 3-8) stops fuel flow through
the fuel injection pump when the start-stop/preheat
switch is placed in the STOP position. If the fuel
solenoidis removedor the settingis believedincorrect,
readjust according to the following procedure. Do not
modify the solenoid linkage during reconnection.
1. Withthefuel solenoidmountedtotheengineblock,
compress the plunger andadjust thefuel-solenoid
linkage so that the linkage connects to the fuel
control lever 1/16 in (1.6 mm) before the lever
contacts internal full-open stop.
2. Attach the balljoint to the fuel-solenoid linkage.
1-933
1
1. Fuel solenoid
Figure3-8. Fuel SolenoidLocation
Air Cleaner Service
Replace the paper element at 300-hour or 6-month
intervals; change more frequently if operating under
dirty, dustyconditions. Operatingtheset withadirtyair
cleaner element may cause engine damage and
increased fuel consumption. At the time of service,
clean the air cleaner breather pipe andremove all dust
and foreign matter fromthe air cleaner housing. See
Figure 3-9 and refer to the following procedure.
1-932
1
2
3
4
5 6
1. Eyebolt/clamp
2. Base
3. Cover
4. Element
5. Threaded rod
6. Wing nut
Figure3-9. Air Cleaner Components
1. Loosen eyebolt and clamp to remove the air
cleaner cover.
2. Remove wing nut and slide air cleaner element
fromthe threaded rod.
3. Clean dry element by tapping edges on a hard
surface. Replace if damaged or very dirty.
NOTE
Do not attempt to clean dry-type element in any
liquid or with compressed air as this will damage
paper filter material.
4. Wipe dirt or dust accumulation from cover and
base. Checkthatall clamps aretightoninlet/outlet
connections.
5. Install air cleaner element on threaded rod.
Tighten wing nut making sure parts fit properly.
6. Position cover with arrow up; place clamp over
base and cover, and tighten eyebolt.
Governor
The centrifugal, mechanical-type governor keeps 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, andfurther adjustment is not necessary unless
encountering greatly varying load conditions or poor
governor control develops after extended usage.
60-Hz generator sets are designed to operate at
60--63 Hz, 1800rpmunderfull loadand1890rpmunder
no load.
50-Hz generator sets are designed to operate at
50-52.5 Hz, 1500 rpm under full load and 1575 rpm
under no load.
To check speed, use a hand-held tachometer or
frequencymeter. See Figure 3-10. Loosenthelocking
nut on the speed-adjusting screw. Turn the screwin a
counterclockwise direction to increase speed and
frequencyorinaclockwisedirectiontodecreasespeed.
Tighten the lock nut to secure at newsetting.
1-933
1
1. Locking nut
Figure3-10. Governor
CoolingSystem
WARNING
Hotcoolantandsteam.
Before removingpressure cap, stopgenerator set
and allowit to cool. Then loosen pressure cap to
relieve pressure.
Checking coolant level. Hot coolant can cause
severeinjuryordeath. Allowenginetocool. Release
pressure fromcoolingsystembefore openingpressure
cap. Toreleasepressure, coverthepressurecapwitha
thick cloth; then slowly turn it counterclockwise to the
first stop. Remove cap after pressure has been
completelyreleasedandtheenginehas cooled. Check
coolant level at tank if generator set is equipped with a
To prevent the generator set from shutting down or
becoming damaged because of overheating, keep the
cooling 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 or
cloth to avoid damaging radiator fins. Check all hoses
and connections for leaks and replace any hoses that
are cracked, frayed, or spongy. When making coolant
level checks, checkconditionof theradiator caprubber
seal; replace if cracked or deteriorating. Remove dirt
and other debris fromthe radiator cap and filler neck.
Coolantcapacityfor the15/20kWin-lineradiator model
is 4qts. 16oz. (4.26L). Consultthecoachmanufacturer
for remote radiator cooling system capacity. Drain
petcocks areprovidedonthebottomtankof theradiator
and another in the engine block to drain the system.
Whendrainingthecoolant, removetheradiator capand
opentheblock drainlocatednear the flywheel housing;
this will allowthe entire systemto drainand prevent air
pockets fromformingandrestrictingcoolantpassagein
the block. To refill the cooling system, close the drain
petcock and fill the radiator to the proper level with the
recommended coolant mixture. See Figure 3-12 for
coolant fill location. Replace the radiator cap and
operate the engine until the thermostat opens and the
radiator upper hosebecomes hot. Stopthe engineand
allowto cool. Add coolant to the radiator to just below
theoverflowtubeonthefillerneck. Replacetheradiator
cap.
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 improve
cooling. The antifreeze should contain a rust inhibitor
andbechangedeverytwoyears. Donotusealcohol or
methanol antifreeze or mix themwith the coolant. Do
notaddcoolanttoanoverheatedengineuntil theengine
has cooled. Addingcoolant to anextremely hot engine
can cause a cracked block or cylinder head.
Check coolant level frequently and add antifreeze
solution as needed to maintain level just below the
overflowtubeandattheminlevel inthecoolantrecovery
tank when cold (max when hot).
NOTE
Givespecial attentionwhencheckingfor proper coolant
level. After a radiator has been drained, some time is
normallyrequiredbeforecompleterefill of all air cavities
takes place.
1
2
ADV-5834-B
1. Coolant outlet 2. Coolant inlet
Figure3-11. CoolantFill andCoolantDrainConnections (RemoteRadiator Model)
1
ADV-5834-
2
1. Initial coolant fill 2. Coolant drain
Figure3-12. Initial CoolantFill andCoolantDrainLocations (In-lineRadiator Model)
BeltTension
Adjustthetensionof thealternator/fanbeltsothatitcan
be depressed about 0.4-0.6 in. (10-15 mm) when
applying finger pressure. See Figure 3-13. Use the
following procedure to adjust the belt.
1
2
3
4
5605313
1. Adjusting screw
2. Battery charging alternator pulley
3. Alternator pivot screw
4. Check alternator belt tension here
Figure3-13. BeltTension
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.
NOTE
Also, checkfanbeltfor cracks or tears andreplace
if necessary.
WARNING
Rotatingparts.
Do not operate generator set without all guards,
screens, and covers in place.
Exposed moving parts can cause severe injury or
death. Keep hands, feet, hair, and clothing away from
belts andpulleys whenunit is running. Replaceguards,
covers, and screens before operating generator set.
BatteryCharging
Your generator is equipped with a 40-amp, belt-driven
battery charging alternator. See Figure 3-14. It is
attachedtotheengineblockbyabracketandkeeps the
batteryconstantlycharged. Be sure to observebattery
polarity when connecting the battery to the generator
set. Thealternator requires nomaintenanceother than
maintaining belt tension. To adjust the alternator belt
tension, see Belt Tension.
1-933
1
1. Battery charging alternator
Figure3-14. BatteryChargingAlternator
Battery
Use a 12-volt battery with a rating of at least 625 cold
cranking amps. When using a Maintenance-Free
battery, itisnotnecessarytocheckthespecificgravityor
electrolyte level. Otherwise performthese procedures
at the intervals specified inthe Maintenance Schedule.
Anegativegroundsystemis used. Batteryconnections
are shown on the wiring diagrams. Make sure that the
batteryisproperlyconnectedandtheterminals aretight.
NOTE
Thegeneratorsetwill notstartif thebatteryconnections
are made in reverse.
holes in clothing.
WARNING
Battery acid. 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. Always wear splash-proof safety
goggles whenworkingnearthebattery. If batteryacidis
splashed in the eyes or on skin, immediately flush the
affected area for 15 minutes with large quantities of
cleanwater. Seekimmediatemedical aidinthecaseof
eyecontact. Neveraddacidtoabatteryafterplacingthe
battery in service, as this may result in hazardous
spattering of battery acid.
Cleaning
Keepbatterycleanbywipingitwithadampcloth. 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
withasolutionof bakingsodaandwater. Becareful that
cleaning solution does not enter battery cells. When
cleaningis complete, flushbatteryandcables withclean
water andwipewithadrycloth. After thebatterycables
are reconnected, coat terminals with petroleumjelly or
other nonconductive grease.
CheckingElectrolyteLevel
Check the electrolyte level before each startup.
Removefiller caps andcheckthatelectrolytelevel is up
to bottoms of filler holes. See Figure 3-15. Refill as
necessary with distilled water or clean tap water. DO
NOT addfreshelectrolyte! Be sure filler caps are tight.
1-046
Figure3-15. BatteryElectrolyteLevel
CheckingSpecific Gravity
Useabatteryhydrometertocheckthespecificgravityof
the electrolyte in each battery cell. While holding the
hydrometer vertical, readthe number onthe glass bulb
atthetopof theelectrolytelevel. If thehydrometerused
does not have a correction table, use the one in
Figure 3-16. Determine specific gravity andelectrolyte
temperature of battery cells. Locate temperature in
Figure 3-16 and adjust specific gravity by amount
shown. Thebatteryis fullychargedif thespecificgravity
is 1.260at anelectrolyte temperature of 80F (26.7C).
The difference between specific gravities of each cell
should not exceed 0.01. Charge the battery if the
specific gravity is below 1.215 at an electrolyte
temperature 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. 1
Temperaturebelow80F
(26.7C)
Hydrometer Reading1.250
AcidTemperature20F
(-6.7C)
Subtract.024Sp. Gravity
CorrectedSp. Gravityis
1.226
EXAMPLE NO. 2
Temperatureabove80F
(26.7C)
Hydrometer Reading1.235
AcidTemperature100F
(37.8C)
Add.008Sp. Gravity
CorrectedSp. Gravityis 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
Figure3-16. Specific Gravity
TemperatureCorrection
GaugeConnections for Single-PhaseModels
The 15/20 kW generator sets may be equipped with
sending devices for optional connection to oil pressure
and water temperature gauges (not provided).
Because lead 10 (fromwater temperature sender) and
lead 11 (fromoil pressure sender) may not appear at
controller plugJ 4or P4, it may be necessary to access
these leads in the engine harness or remote harness if
used. Leads 10 and 11 do not run the full length of the
remoteharness. Retrieve theends of these leads from
theharness for connectiontotheoil pressureandwater
temperaturegauges. Theinstaller mayalsoelecttorun
separateleads fromeachsender directlytothegauges
and bypass the harnesses entirely. See Figure 3-17
andrefertothewiringdiagraminSection5. Useinsulink
or similar connectors at all spliced connections to
ensure reliable operation of the senders and gauges.
Oil
Pressure
Sender
Water
Temperature
Sender
11
10
11
10
P4-10
J 4-10
P4-13
J 4-13
11
10
P3-6
J 3-3
P3-3
J 3-2
Light Blue
Tan
Oil
Pressure
Gauge
S +
Water
Temperature
Gauge
S +
J 3-4
P3-2
To
Controller
Violet (53)
Violet (53)
B+
Figure3-17. Oil Pressure/Water TemperatureSender Connections
WattageRequirements
If the ratedcapacity of your generator is exceeded, the
circuitbreaker(s) locatedinthecontroller trips toprotect
thegeneratoragainstdamage. This couldbecausedby
a short in the AC circuit in your vehicle or simply by
having too many appliances or tools turned on
simultaneously time resulting in an overload condition.
If the circuit breaker(s) trips, the set may continue
running but there will be no AC output to the protected
circuit. Before resetting the circuit breaker(s), turn off
some of the appliances or tools and lights inside the
vehicle to bring the load down within the rated limits of
the set. If this is done and the circuit breaker(s) trips
againafterbeingreset, ashortcircuitis indicated. Inthis
event, turn off the set and have a qualified electrician
locate and correct the cause of the short circuit.
The average wattage requirements of some common
RV/Mobileappliances/tools andmotorloadsarelistedin
the following charts. Use these figures to calculate the
total loadonyour set toavoidhavingthecircuitbreaker
trip because of overload. The lighting load is easily
determinedbyaddingthewattageratingof eachbulbin
the circuit. Check the nameplate rating on motors and
appliances in your vehicle for exact wattage
requirements.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure3-18. ApplianceAverage
WattageRatings
Motor
Starting
Watts
Air Compressor (Small) 1500 725
Air Compressor, 3/4 hp 4000+ 2000
Drill, 1/4 in. 500 250
Drill, 3/8 in. 600 350
Drill, 1/2 in. 800 600
Grinder, 1/2 hp 1500 1200
Hammer, Demolition 2000 1800
Hammer, HDRotary 1500 1200
Paint Sprayer (Airless) 400 240
Polisher, Orbit 500 360
Power Paint Roller 120 90
Power Plane 600 450
Router 900 700
Saw, Circular 6 1/2 in. 2200 1000
Saw, Circular 7 1/4 in. 2500 1200
Saw, Table 10 in. 4000 1500
Saw, Sabre (WormDrive) 2500 1200
Sander, Belt 1500 600
Sander, Finishing 900 360
Screwdriver, Power 1000 530
Shear, 12 gauge 1800 720
Soldering Gun 250
VacuumCleaner, Wet/Dry 1500 1260
Wrench, Impact 1/2 in. 2000 840
Running
Watts ConstructionTools
Figure3-19. ConstructionTool Average
WattageRatings.
NOTE
Motor-driven equipment generally takes 2 to 3 times
morethelistedrunningamperageorwattagetostartthe
motor. Always check the tool or motor nameplate tobe
sure.
Generator Service
General
Under normal conditions, generator service will not be
requiredonaregularbasis. If operatingunderdustyand
dirtyconditions, usedrycompressedairtoblowdustout
of the generator at frequent intervals. Do this with the
generator set operating and direct the streamof air in
through the cooling slots at the end of the generator.
StorageProcedure
If your generator set is to be out of service for a
considerable length of time (2 months or more),
complete the followingsteps to preserve the set before
placing it in storage.
1. Drain the oil (while hot) fromthe crankcase then
refill with regular grade oil. See Section 3, Oil
Selection in this manual.
2. Drain the fuel from the fuel tank to prevent
accumulated moisture frommixing with the fuel.
3. Check the engine coolant protection. See
Section 3Cooling System for additional
information.
4. Disconnect battery (negative lead first) and place
in storage.
5. Seal all openings intheenginewithnon-absorbent
adhesive tape. Mask off all areas to be used for
electrical contact.
6. Clean exterior surface of the generator. Spread a
light film of oil over unpainted metallic surfaces
which could rust or corrode.
Notes
TP-5605 4/97 Troubleshooting 4-1
Section4. Troubleshooting
Whentroubles occur, donot overlooksimple causes. A
starting problem, for example, could be caused by
incorrectfuel oranemptyfuel tank. Thefollowingcharts
list some common problems. If procedures in this
manual do not explainhowto correct the problem, take
the generator set to an authorized Kohler service
distributor/dealer. Tell thedealerexactlywhathappened
when the problem occurred and of any adjustments
made to the set.
Engine
Problem PossibleCause CorrectiveAction
Enginehardto startor
will notstart
Weak or dead battery Recharge or replace Enginehardto startor
will notstart
Battery connections made in reverse Correct
Faulty ground Clean and retighten
Fuse blown Replace
Out of fuel Replenish
Incorrect type of fuel Use correct type of fuel; consult fuel and engine
supplier (see fuel systemspecification)
Fault shutdown Check lowoil pressure and high water
temperature shutdown switches
Clogged fuel filter Replace filter element
Air cleaner clogged Clean or replace element
Defective fuel feed pump Replace fuel feed pump
Air in fuel system Bleed air fromfuel system
Incorrect type of crankcase lube oil Use correct lube oil (see oil selection)
Water, dirt in fuel system Drain, flush fuel systemand replace fuel
Dirty or faulty injectors See authorized service distributor/dealer
Incorrect compression See authorized service distributor/dealer
Injection pump malfunctioning See authorized service distributor/dealer
Incorrect valve clearance See authorized service distributor/dealer
Engineknocks Faulty injector See authorized service distributor/dealer Engineknocks
Incorrect type of fuel Use correct type of fuel; consult fuel supplier
(see fuel specifications)
Incorrect fuel injection timing See authorized service distributor/dealer
Incorrect cylinder top clearance See authorized service distributor/dealer
Defective piston or piston ring See authorized service distributor/dealer
Defective crankshaft bearing or piston pin
bearing
See authorized service distributor/dealer
Air in injectors Bleed air in fuel system
TP-5605 4/97 4-2 Troubleshooting
Engine(continued)
Engineruns irregularly
or stalls frequently
Vent in fuel tank cap obstructed Clean cap in solvent; blowdry Engineruns irregularly
or stalls frequently
Clogged fuel filter Replace fuel filter element
Water, dirt, or air in fuel system Drain, flush, fill, and bleed air in fuel system
Faulty governor linkage See authorized service distributor/dealer
Defective fuel feed pump Replace fuel feed pump
Stops suddenly Out of fuel Replenish fuel supply Stops suddenly
Air intake restriction Service air cleaner
Fuse blown in controller Replace fuse. If fuse blows again, see
authorized service distributor/dealer
High water temperature (HWT) shutdown* Check engine coolant level, loose fan belt,
radiator obstructions, etc.
Lowoil pressure (LOP) shutdown* Check engine lube oil level
Defective fuel pump See authorized service distributor/dealer
Clogged fuel filter Replace filter
Lackof enginepower Engine overload Reduce load Lackof enginepower
Air intake restriction Service air cleaner
Clogged fuel filter Replace filter element
Incorrect engine compression See authorized service distributor/dealer
Vent in fuel tank cover obstructed Clean cap in solvent; blowdry
Overfueling (rich) See authorized service distributor/dealer
Engineoverheats Engine overloaded Reduce load Engineoverheats
Defective cooling system Check water pump
Loose or defective water pump v-belt Adjust belt tension or replace belt
Cooling systemneeds flushing Flush cooling system
Defective thermostat Replace thermostat
Defective high water temperature (HWT) switch Replace switch
Cooling water leaks frompassages Check water passages
Radiator clogged with dirt or oil Clean with water soluble grease remover and
flush cooling system
Radiator cap defective Replace
Cylinder head gasket defective See authorized service distributor/dealer
*See Section 2Fault Shutdowns
TP-5605 4/97 Troubleshooting 4-3
Engine(continued)
Engineemits blackor
grayexhaustsmoke
Fuel filter clogged Clean or change Engineemits blackor
grayexhaustsmoke
Overload Reduce load
Incorrect type of fuel Use correct fuel
Clogged or dirty air cleaner Service air cleaner element
Defective injection pump See authorized service distributor/dealer
Faulty injectors See authorized service distributor/dealer
Lube oil level too high Drain out surplus
Incorrect lube oil Use correct viscosity (see Oil Selection)
Engineemits whiteor
bluesmoke
Excessive engine oil Reduce to specified level Engineemits whiteor
bluesmoke
Piston ring and liner worn See authorized service distributor/dealer
Incorrect injection timing See authorized service distributor/dealer
Lowlubeoil pressure Lowlube oil level Add lube oil Lowlubeoil pressure
Incorrect lube oil viscosity Drain, fill with correct viscosity oil
Defective lube oil pump See authorized service distributor/dealer
Defective oil pressure switch Replace switch
Worn engine components Rebuildconsult engine service manual
Highlubeoil
consumption
Too light viscosity oil Use correct viscosity oil (see oil selection) Highlubeoil
consumption
Oil leaks Check for leaks in lines, around gaskets, and
drain plug
Incorrect type of oil Use oil of correct viscosity
Clogged breather system Clean breather system
Defective piston ring, piston cylinder liner, valve
guide, or valve seat
Highfuel consumption Incorrect type of fuel Use correct fuel (see Fuel Specifications) Highfuel consumption
Clogged or dirty air cleaner element Service air cleaner element
Engine overloaded Reduce load
Lowengine temperature Check thermostat
Fuel leakage Check for leaks at fuel tank, lines, and engine
fuel system
TP-5605 4/97 4-4 Troubleshooting
Electrical System
Batterywill notcharge Loose or corroded connections Clean and tighten connection Batterywill notcharge
Sulfated or worn-out battery Check electrolyte level and specific gravity
(batteries with filler caps only)
Defective alternator Replace alternator
Loose or defective alternator belt Adjust belt tension or replace belt
Starter does notwork
correctly
Loose or corroded connections Clean and tighten connection Starter does notwork
correctly
Lowbattery output Check electrolyte level and specific gravity
Defective starter solenoid Replace starter solenoid
Defective starter switch Replace starter switch
Defective wiring Check wiring
Starter cranks slowly Lowbattery output Check electrolyte level and specific gravity
Too heavy viscosity lube oil Use correct viscosity (see Oil Selection)
Loose or corroded wiring Clean and tighten loose connections
High starter current draw Rebuild or replace starter
Generator
No AC output AC circuit breaker(s) in OFF position Reset to ON position No AC output
No DC power to controller Check battery connections
Fuse blown Replace fuse
AC circuit breaker tripping because of overload
on generator set
Reduce load (see Wattage Requirements)
Short circuit in vehicle circuit causing breaker to
trip
Reset. If breaker trips repeatedly, stop
generator set and contact authorized service
distributor/dealer
General malfunction such as faulty component
or other internal fault
Lowoutputor
excessivedropin
Engine speed too low See authorized service distributor/dealer
excessivedropin
voltage
Generator overloaded Reduce load
Engineinpoor
condition
If routine services are performed and condition
persists, see an authorized service
distributor/dealer
TP-5605 4/97 Wiring Diagrams 5-1
Section5. WiringDiagrams
VoltageReconnection
The reconnection procedure explains voltage
reconnections only. Adjust the governor and voltage
regulator at time of frequency adjustment.
Thefollowinginformationillustrates thereconnectionof
4-leador 12-leadgenerator sets. Inall cases, followthe
National Electrical Code (NEC) guidelines.
Reconnect the stator leads of the generator set to
change output phase (12-lead models only) or voltage.
Refer to the following procedure and the connection
schematics. Followall safetyprecautions atthefrontof
this manual and in the text while performing this
procedure.
NOTE
Order voltage reconnection decal 246242 from an
authorized service distributor/dealer and affix decal to
generator set after reconnecting to a voltage different
than the nameplate.
Accidental starting.
Disconnect battery cables before working on
generator set (disconnect negative lead first and
reconnect it last).
WARNING
Disabling generator set. Accidental starting can
cause severe injury or death. Turn generator set
master switch to OFF position, disconnect power to
battery charger, and remove battery cables (remove
negative lead first and reconnect it last) to disable
generator set before working on the generator set or
connectedequipment. Thegeneratorsetcanbestarted
by an automatic transfer switch or remote start/stop
switch unless these precautions are followed.
WARNING
Grounding generator set. Hazardous voltage can
cause severe injury or death. Electrocution is
possible whenever electricity is present. Open main
circuit breakers of all power sources before servicing
equipment. Configure the installation to electrically
groundthe generator set andelectrical circuits whenin
use. Never contact electrical leads or appliances when
standing in water or on wet ground, as the chance of
electrocution is increased under such conditions.
Shortcircuits. Hazardousvoltagecancausesevere
injuryor death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections withtools or jewelrywhile adjustments are
made. Remove wristwatch, rings, and jewelry before
servicing equipment.
TP-5605 4/97 5-2 Wiring Diagrams
VoltageReconnection
Procedure
Four-Lead(Single-Phase) Generator Sets
See Figure 5-1 for four-lead reconnectable
(single-phase) generator set options.
60 Hz 50 Hz
120/240 or 100/200 volt X
110/220 or 100/200 volt X
Figure5-1. Four-Lead, Single-PhaseGenerator Set
VoltageConnectionOptions
120/240-Volt(or 110/220-Volt,
100/200-Volt) Configurations
Circuit breaker must be a circuit breaker manufacturer
two-pole circuit breaker. Two single-pole circuit
breakers do not conform to NEC requirements when
supplyinga240-volt(or220-volt) load. This is trueeven
if they are mechanically attached together. Leads L1
and L2 are different phases and must never be
connected together.
TP-5631-5
L0-L1 120volt 110volt
Leads 60Hz 50Hz
4 3 2 1
Stator Leads
LO
GRD
L2
L1
LO (Neutral)
Line
Side
Factory
Two-Pole
Circuit
Breaker
Ground
Load
Side
Figure5-2. 100-120Volt, 3WireConfigurations
200-240-VoltConfigurations
This system uses a single-pole circuit breaker with
200-240 Volt, 2 wire.
TP-5631-5
4 3 2 1
Stator Leads
LO
GRD
L1
LO (Neutral)
Line
Side
Single-Pole Circuit
Breaker
Ground
Load
Side
Tape to insulate
fromground
Leads 60Hz 50Hz
Figure5-3. 100-120Volt, 2WireConfigurations
12-Lead(Three-Phase) Generator Sets
Reconnect three-phase, 12-lead generator sets to the
voltages and phases shown in Figure 5-4. If the
generator setis reconnectedtoobtaina differentoutput
voltage, voltage regulator voltage adjustments may be
necessary to obtain desired voltage.
L1
1
4
7 10
L0
6
3
9
12
11
8
5
2
L2
60 Hz120/240 volt, 1 PH. 3 WIRE
50 Hz110/220 volt, 1 PH. 3 WIRE
8
11
1
4
L2
7
10
L1
6
3 L3
L0
12 Lead Stator
60 Hz120/208 volt or 139/240 volt
3 PH. 4 WIRE LOWWYE
50 Hz120/208 volt or 110/190 volt
3 PH. 4 WIRE LOWWYE
L2
L1 L3
8
11
2
5
12
9
9 12 3 6
7
10
1
4
12 Lead Stator
60 Hz120/240 volt 3 PH. 4 WIRE DELTA
50 Hz110/220 volt 3 PH. 4 WIRE DELTA
L0
L2
L1
L3
8
11
2
5
9
12
3
6
7
10
1
4
L0
L0
12 Lead Stator
60 Hz277/480 volt, 3 PH. 4 WIRE HIGH WYE
50 Hz220/380 volt, 3 PH. 4 WIRE HIGH WYE
5
2
Figure5-4. Generator Reconnection
225570-G
Figure5-5. WiringDiagram(Schematic) for 15/20CCORVSinglePhase
225570-G
Figure5-6. WiringDiagram(Point-to-Point) for 15/20CCORVSinglePhase
225652-F
Figure5-7. WiringDiagram(Schematic) for 15/20CCOZMobileThreePhase
225652-F
Figure5-8. WiringDiagram(Point-to-Point) for 15/20CCOZMobileThreePhase
225446-A
Figure5-9. WiringDiagram(Schematic) for 20CCORV(spec PA-135322)
225446-A
Figure5-10. WiringDiagram(Point-to-Point) for 20CCORV(spec PA-135322)
Notes
TP-5605 4/97 Installation 6-1
Section6. Installation
Introduction
Use this section as a guide wheninstalling a generator
set inthe vehicle; thenrefer to theoperationsectionfor
specific service instructions. When installing an
RV/Mobile generator set, the installation must comply
with the Kohler-detailed installation instructions. Any
additional requirements can also be found in the
following sources: (1) ANSI A 119.2/NFPA 501 C, (2)
article 551 of ANSI/NFPA 70, National Electrical Code,
(3) C.S.A. (Canadian Standards Association) standard
C22.2#100, and(4) C.E.C. (CanadianElectrical Code)
C22.1. Generator setinstallationmustalsocomplywith
state and local requirements.
NOTE
These generator sets do not comply with United
States Coast Guard (U.S.C.G.) requirements and
mustnotbeusedformarineapplications. Use only
generator sets specified for marine use in marine
installations. U.S.C.G. Regulation 33CFR183 requires
a generator set to be ignition protected when used in a
gasoline-fueled environment.
Features
These generator sets feature Yanmar 4TN84E-RK or
4TN84TE-RK diesel engines, rotating-field,
alternating-current generator, and relay controller. The
generator is directly connected to the engine for
permanent alignment. Each controller includes a
Start-Stop/Preheat switch for test operating the set at
the controller. The single-phase controller also has a
keyed connector for connecting a wiring harness to a
remote start-stop switch (usually located on the
dashboardofthevehicle). Afterthesetisattachedtothe
frameofthevehicleandthecoach-suppliedradiatorand
hoseconnections areinstalled, thefollowingareall that
is usually required to make it operational:
D Attach exhaust system.
D Addproper amount of radiator coolant. Mount the
D Add oil to crankcase until dipstick indicates full.
D Connectfuel lines (inletandreturn), remoteswitch,
load leads, and battery terminals.
TP-5605 4/97 6-2 Installation
Generator SelectionAnd
WattageRequirements
Consider total wattage requirements (lights, motors,
appliances) in selecting a generator set, or sizing
wattage requirements when available space and
construction may limit the size of the generator set.
Refer to the following when figuring wattage
requirements.
InstallationFactors
Each generator set is shipped as a unit except for the
optional exhaust system components which are
shipped loose for assembly after the set is installed in
the vehicle.
When preplanning the installation, consider the
following factors.
1. Electrical Load: Does the set selected have
adequate capacity to handle the load?
2. CompartmentSize: Will there be sufficient room
around the set to maintain minimumclearances?
3. AirRequirements: Arethecompartmentairinlets
and outlets sized to allowadequate circulation of
air for cooling and combustion?
4. Compartment Floor: Is the compartment floor
strong enough to support the weight of the
generator set?
5. Cooling System: Is the cooling system large
enough to adequately cool the generator set?
6. Fuel System: Is the systemproperly designedto
prevent fuel starvationof either themainengineor
generator set engine?
7. ExhaustSystem: Will the systemmeet all safety
requirements after installation?
8. Electrical Connections: Will all systems (battery,
load, and remote switch) be compatible with
vehicle systems?
Each of these installation considerations is covered in
detail on the following pages.
Electrical Load
Whiletheelectrical loadof thevehicleshouldhavebeen
calculated prior to purchase of the generator set,
recheck the load before installing the set to make sure
that the capacity is ample to meet demands without
possible overloading.
LightingLoad
The lightingloadis usuallyeasiest to calculate. Inmost
cases, simply add the wattage of each lamp to be
operated off the generator set. Note that in many
applications, not all of the lights or lamps are in the
generator setAC circuitsomeareDC poweredbythe
12-volt battery in the vehicle. Make sure the total
wattage includes only lights actually on the generator
set AC circuit.
The lighting load is usually not too heavy in mobile
installations; however, it must be accurately calculated
topreventoverloadingwhichcouldoccur, forexample, if
all lights happenedto be onwhenthe air conditioner or
other motor loads startup.
Motor Loads
When figuring generator set capacity requirements for
installation involving motor loads, do not overlook the
highcurrentdemandedbythemotorduringstartup. The
in-rushor startingcurrent maybe 2-5times higher than
that requiredwhenthemotor reaches normal operating
speed. Reserve capacity must be allowed for in-rush
demands plus other loads whichcouldbeonthelineas
the motor starts.
Air conditioning units are perhaps the most common
type of motor load for generator sets in recreational
vehicles. The starting characteristics of the different
makes of air conditioners vary greatlyone particular
13,500 BTU unit has, for example, lower starting
requirements thanan11,000BTUunitof another make.
When only one unit is involved, there is usually no
starting problem, provided the lighting and appliance
load is not too high when the unit is started.
The trend seems to be toward larger capacity air
conditioners andtheuseof morethanoneunit inlarger
vehicles. Simultaneous startingof twounits canpresent
problems if the capacity is marginal. Because of the
variationinstartingcharacteristics of thevarious makes
of air conditioners, no definite statements are made in
this publication regarding multiple motor-starting
capabilities of the mobile generator sets covered.
Delayed starting or use of easy-starting devices on air
conditioner units should be considered whenever
simultaneous starting of more than one motor is
involved. The starting and running requirements of
some motor loads common to mobile applications are
listedinFigure 6-1. Use this as aguide whenselecting
generator set capacity requirements involving motor
loads.
Motor Requirements 1/4HP 1/3HP 1/2HP 3/4HP 1HP 2HP 3HP
Starting (In-Rush)
Running Watts
750 1000 1500 2000 3300 4000 5000
350 400 600 750 1100 2000 3000
Figure6-1. Motor Requirements
Electrical Appliance Ratings (Watts)
Blanket 50-250
Blender 600
Dryer, Hair 500-1200
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
Figure6-2. ApplianceRatings (60Hz)
Motor
Starting
Watts
Air Compressor (Small) 1500 725
Air Compressor 3/4 hp 4000+ 2000
Drill, 1/4 in. 500 250
Drill, 3/8 in. 600 350
Drill, 1/2 in. 800 600
Grinder 1/2 hp 1500 1200
Hammer, Demolition 2000 1800
Hammer, HDRotary 1500 1200
Paint Sprayer (Airless) 400 240
Polisher, Orbit 500 360
Power Paint Roller 120 90
Power Plane 600 450
Router 900 700
Saw, Circular 6 1/2 in. 2200 1000
Saw, Circular 7 1/4 in. 2500 1200
Saw, Table 10 in. 4000 1500
Saw, Sabre (WormDrive) 2500 1200
Sander, Belt 1500 600
Sander, Finishing 900 360
Screwdriver, Power 1000 530
Shear, 12 gauge 1800 720
Soldering Gun 250
VacuumCleaner, Wet/Dry 1500 1260
Wrench, Impact 1/2 in. 2000 840
Running
Watts ConstructionTools
Figure6-3. ConstructionTool Ratings (60Hz)
ApplianceLoads
Generatorsets inrecreational vehicles areoftenusedto
furnish AC for appliances such as TV, stereo, electric
water heaters, etc. With the exception of the
resistance-type loads such as the water heater,
requirements forappliances areusuallylow. Suchloads
must not, however, be overlooked when figuring total
requirements. Reservecapacityshouldbeavailablefor
anticipated appliance loads to avoid overloading of a
set. Theaveragepowerrequirementsof someelectrical
appliances are listed in Figure 6-2 and Figure 6-3.
KilowattDerating
All units arerated1.0power factor. Thekilowatts of the
generator set will decrease 3.5% per 1000 ft. (305 m)
above 500 ft. (152 m) above sea level. Derate 1%for
every 10_F (5.5_C) above 85_F (30_C).
CompartmentSize
When planning compartment size requirements, allow
theminimumclearances for coolingof thegenerator set
as shown in Figure 6-4.
NOTE
Because the sets are flexibly mounted, the minimum
clearanceswill ensurethatthesidesof thecompartment
and the set will not rub while the set is in operation or
while the vehicle is in transit.
Front 1 1/2 in. (38 mm) . . . . . . . . . . . . . . . . . . . . .
Side 1 1/2 in. (38 mm) . . . . . . . . . . . . . . . . . . . . . .
Top 1 1/2 in. (38 mm) . . . . . . . . . . . . . . . . . . . . . . .
Rear 1 1/2 in. (38 mm) . . . . . . . . . . . . . . . . . . . . . .
Figure6-4. MinimumClearanceRequirements
NOTE
Minimumclearances arelistedforcoolingaircirculation.
Additional clearance is required for routine servicing of
the generator set.
Consider the thickness of insulating and
sound-deadeningmaterial usedtolinethecompartment
when planning clearances. If necessary, enlarge the
compartment to maintain minimum clearance
requirements. Securely fasten the generator set to
avoid unwanted movement from vibration and road
shock. If the unit is equipped with a mounting tray, the
tray is usually supportedonthe ends by angle ironand
hasafull doorforserviceaccess. Usethesamenumber
ofboltsasmountingholesinthetraytosecurethetrayto
the support structure. Units not equipped with a
mounting tray are secured by attaching the generator
set mounts directlyto the vehicleframe. Skid-mounted
units canbe either affixedto a tray for tray mountingor
attached directly to the vehicle frame by the installer.
The generator is easily removed from the coach if a
carriage with rollers is incorporated into the support
structure. See Figure 6-5. Avoid road splash and the
possibility of igniting combustible material beneath the
coachbyenclosingall unnecessaryfreespacebeneath
the generator compartment.
Whendesigningthecompartment, allowsufficientroom
for the set to be easily removed when major service is
required. See Figure 6-5. Also keep in mind that the
compartment door must have air-intake openings
havingafreeareaequal toor greaterthanthatspecified
under Air Requirements following.
Make sure the compartment is vapor tight and
completely sealed from the inside of the vehicle to
prevent exhaust or other fumes from entering the
vehicle.
Figure6-5. SlideTrayFeaturefor Easeof Service
Line the compartment with a good sound-deadening
material. The material selected must be fireproof or
highlyresistanttofire. Anavailabletypeof 3-layer foam
material does anefficientjobof absorbingsound. Some
materials have a self-adhesive back; others are easily
cut to size with scissors and quickly installed using
special fire-retardantadhesivewhichbonds thematerial
to almost any clean, dry surface.
NOTE
Be careful not to place combustible insulation near
exposed exhaust-systemcomponents.
Air Requirements
Eachengineis equippedwithahighwater temperature
shutdown switch automatically shuts down the set if
operating temperatures climb too high. To prevent the
generator set from shutdown, make sure the
compartment openings are large enough to allow
adequate circulation of the cooling and combustion air.
The minimum free-air opening in the compartment is
showninFigure 6-6. Remember louvres, screens, and
protective grill work restrict effective air flow. Even a
simple, relatively open mesh screen, as shown in
Figure 6-7, will restrict air flow as much as 45%.
Increase the intake openings to compensate for such
restrictions. Air inlet anddischarge openings for in-line
radiator-mounted models are shown in Figure 6-8 and
Figure 6-9.
Air
Inlet
Air
Outlet
15 kWRemote Radiator 140 (903) 216 (1393)
15 kWIn-line Radiator 430 (2775) 330 (2128)
20 kWRemote Radiator 140 (903) 216 (1393)
20 kWIn-line Radiator 430 (2775) 330 (2128)
Figure6-6. Min. Air Requirements
sq. in. (sq. cm.)
1
560567
1. Wide mesh screen
Figure6-7. InletScreen
Remote and in-line radiator generator sets will require
an air outlet in the compartment floor and an air inlet in
the generator-end wall. See Figure 6-11 for proper
sizes and positions. An additional 3 in. (7.62 cm)
diameter hole is required in the compartment so
combustionair fromtheoutsideof thecompartmentcan
be brought into the air cleaner using a 2 in. (5 cm) I.D.
hose.
NOTE
Install two supplemental cooling fans, capable of 265
cfm(7.49 m
3
/min) each, to supply adequate air to the
generator compartment.
NOTE
Seal the air inlet openings, at theengine in-lineradiator
and/orgenerator-endbracket, againstthecompartment
wall. This is tomakesurethat onlyexterior air is drawn
into the generator compartment.
15/20 kWGenerator Free-Air Opening: 140 sq. in. (903 sq. cm)
15/20 kWRadiator Free-Air Opening: 290 sq. in. (1872 sq. cm)
Seal End Bracket to
Compartment Wall or
Duct
Seal Radiator
to Compartment Wall
ADV-5834-
Figure6-8. Air FlowRequirements for In-lineRadiator Model withSuctionFan.
15 kWIn-line-Radiator Model
20 kWIn-line-Radiator Model
ADV-5833-A
ADV-5834-A
Figure6-9. Air FlowRequirements for In-lineRadiator Models (withSuctionFan)
RemoteRadiator CoolingSystem
Use the following data to design and install the
generator set cooling system. To ensure a safe,
effective installation, be sure the cooling system
selected follows these parameters. Kohler Co. offers
radiator assemblies which meet these requirements
and adequately cool the generator. Select the radiator
assembly appropriate for the generator installation.
Duetothemultitudeof coachmanufacturers andvariety
of generator installations, only general guidelines are
provided. Adapt these recommendations to the
installation. In a typical installation, install the radiator
assembly the same compartment as the generator. If
usingthe blower fanradiator assemblyis used, cooling
air is drawn across the generator and engine and then
throughtheradiator. If thesuctionfanradiatorassembly
is used, the suction fan pulls cooling air through the
radiator andthenpast the generator set. If the radiator
assembly alone is used, the installer must supply an
electric blower or suctionfanto circulate the coolingair
throughthe radiator. See Figure 6-10 andFigure 6-11.
Depending on space limitations, locate the radiator in
front of, adjacent to, or in a ventilated location remote
fromtheengine(maximumhorizontal distancefromthe
generator is 10 ft.). To prevent recirculation of heated
air, besuretomaintainatight seal betweentheradiator
andthedischargechute. Generally, thedischargechute
openingshouldbeapproximately11/2times thesizeof
the radiator core.
NOTE
If locating the radiator in a compartment separate from
the engine, remember the engine combustion air and
heatrejectionrequirements of thealternator andengine
block when designing the cooling system. Two
supplemental cooling fans capable of 265 cfm
(7.49 m
3
/min) should be installed to supply air to the
generator compartment for these requirements.
NOTE
If installinga non-Kohler radiator assembly, be surethe
radiator fanmotor rotates inthe correct directionandis
of the proper voltage.
If sizing a non-Kohler radiator, follow these general
guidelines for radiator selection.
Heat Rejection:
15 kW 792.99 Btu per min.
20 kW1050.58 Btu per min.
Cooling SystemWater Flow:
Typical: 35 liters per min. at 1800 rpm*
31 liters per min. at 1500 rpm*
Max. water head allowed:
230_F (110_C) 3_
Connection Points to Radiator 15/20CCO:
Coolant Inlet: 1.10 in. (28 mm) I.D. Hose
Coolant Outlet: 1.10 in. (28 mm) I.D. Hose
*If the applicationrequires excessive runs betweenthe
generator set and the remote radiator, check the water
flow. Becertainthe radiator is sizedaccordinglyfor the
installation.
NOTE
The cooling system fill (radiator or coolant recovery
tank) must be the highest point in the cooling system.
(SeeFigure 6-12.) Ifthecoolingsystemfill is notlocated
as directed, cooling water will not completely fill the
engine and result in overheating of the engine and
disablement of the high water temperature shutdown
switch.
A close relationship exists between the cooling system
designandthegeneratorcompartmentsize. Availability
of space is often the determining factor in cooling
systemdesign. See Compartment Size section of this
manual prior to designing and installing the generator
cooling system.
Generator CooledbySuctionFan
Maintain tight
seal around radiator
Air Flow
TopView
Air
Inlet
Discharge chute
through compartment floor
Figure6-10. Typical CoolingSystemInstallation
for RemoteRadiator MountedintheGenerator Compartment
Generator
End
Generator
End
NOTE:
The dimensions shown are compartment inside measurements.
The compartment must allow1 1/2 in. (38 mm) clearance on all sides of generator.
Compartment MinimumSize in. (mm)
15 kW 20 kW
Length 42.57 (1081.3) 42.57 (1081.3)
Width 23.89 (606.8) 23.89 (606.8)
Height 28.61 (726.7) 32.38 (822.5)
BottomDischarge Outlet in. (mm)
15/20 kW:
Length: 6 (152.4)
Width: 19 (482.6)
Distance in. (mm)
A: 2.5 (63.5) . . . . . . . . . . . . .
B: 0.48 (12.0) . . . . . . . . . . . .
C: 2.39 (60.7) . . . . . . . . . . . .
D: 36.09 (917.0) . . . . . . . . . . .
E: 2.5 (63.5) . . . . . . . . . . . . .
F: 5.14 (13.06) . . . . . . . . . . . .
G: 15 kW 13.11 (333.0) . . . . .
G: 20 kW 16.88 (428.8) . . . . .
H: 5.75 (146.1) . . . . . . . . . . . .
5.5 in.
(139.7 mm)
A
B
C
D
E
F
G
H
Figure6-11. Typical CoolingSystemInstallation(CompartmentMinimumSizes) for
RemoteRadiator MountedOutsidetheGenerator Compartment
NOTE
Mountthecoolantrecoverytanksothatits surfacelevel
is thesameheightor 2in. (5cm) max. belowthelevel of
the pressure cap. See Figure 6-12. If the cooling
system fill (coolant recovery tank) is not located as
directed, coolingwater will notcompletelyfill theengine
and result in overheating of the engine.
To Radiator Inlet
FromRadiator Outlet
1
2
5605612
1. Initial coolant fill 2. Coolant fill at coolant recovery tank
Figure6-12. CoolingSystemFill (CoolantRecoveryTank)
Fuel System
WARNING
and using fuels.
Fuel system. Explosive fuel vapors can cause
severeinjuryordeath. All fuels arehighlyexplosivein
a vapor state. Use extreme care when handling and
storing fuels. Store fuel in a well-ventilated area away
fromspark-producingequipmentandoutof thereachof
children. Never addfuel to the tank while the engine is
runningsince spilledfuel mayignite oncontact withhot
parts or fromignition spark. Do not smoke or permit
flame or spark to occur near sources of spilled fuel or
fuel vapors. Keepfuel lines andconnections tightandin
good condition. Do not replace flexible fuel lines with
rigid lines. Use flexible sections to avoid breakage
causedbyvibration. Donotoperategeneratorsetinthe
presence of fuel leaks, fuel accumulation, or sparks.
Repair systems before resuming generator set
operation
draining system.
The diesel fuel system for the generator set must be
designedtooperateindependentlyof thesystemfor the
vehicle engine if bothengines are to be operatedat the
same time. The best wayto dothis is to haveseparate
fuel tanks; however, this is usually impractical because
of spacerestrictions. Inmostinstallations, bothengines
operate off a common tank with a separate dip tube
arrangement as shown in Figure 6-13. This prevents
the smaller engine from being starved of fuel by the
larger engine. The generator set dip tube is generally
shorter than the vehicle dip tube. With this
arrangement, fuel maynotbeavailabletothegenerator
set when fuel supply is low.
Asimpleteefittingis sometimes usedtoprovidefuel for
both engines off a common tank; however, this usually
prohibits simultaneous operation. There is also the
possibility that operation of either engine could
completely drain the fuel line of the other engine, thus
making starting difficult if not impossible. Therefor, the
tee arrangement should not be used.
Keep Fuel Line
Away FromExhaust
1
2
5605613
1. Fuel line to generator set
2. Fuel line to vehicle engine
Figure6-13. TwoDipTubes inFuel Tank
NOTE
Donotteeintofuel-injectedfuel systems. Useatwodip
tubearrangementforfuel supply. Consultanauthorized
Kohler service dealer/distributor for further fuel system
installation information.
Takecarewhenroutingthefuel linefromthefuel tankto
the generator set. Keep fuel lines as short as possible
but maintain adequate clearance from the exhaust
system. Run fuel lines along the frame or
undercarriagenever run fuel lines inside the coach.
Locate fuel lines belowthe generator set compartment
withentrypointnearfuel pump(max. liftof thefuel pump
is 1 meter or 39 inches). The fuel line must be of
adequate size to handle the flowof fuel and withstand
roadshock andyear-roundclimate conditions. If using
steel tubing, itshouldbe5/16in. (8mm) I.D. (minimum)
with an 8 in. (230 mm) (minimum) flexible section to
allowfreemovementof thegeneratorset. Fuel inletand
return connections are 1/4-18 N.P.S.F.
Locatethefuel returnlineas faras practical fromthefuel
pickup. This will allowreturned fuel to be cooled by the
tank fuel before delivery back to the fuel injectors.
Incoming fuel cools the injectors and achieves
maximum engine efficiency supplying cool fuel to the
engine. The fuel tank capacity and the amount of fuel
will affect cooling capability.
Fuel Line Sizes:
Fuel Inlet 1/4-18 N.P.S.F.
Fuel Return 1/4-18 N.P.S.F.
Fuel Lines
If using metal lines fromthe fuel tank, a flexible hose
sectionshouldconnectthemetal linetothefuel pump. A
flexiblehosesectionshouldconnect themetal linefrom
the fuel tank to the engine fuel-return connectionpoint.
The flexible sections allow vibrational motion of the
generator setduringoperation. SeeFigure 6-14forfuel
inlet- and return-line connections.
NOTE
Diesel-fueled engines require type B1 hose.
1 2
ADV-5834
1. Fuel inlet connection 2. Fuel return connection
Figure6-14. Fuel InletandReturnConnectionPoints
ExhaustSystems
Carefullyplanthegeneratorexhaustsystemtoensurea
safe, quiet installation. Be sure the installation will
comply with all state and local requirements and
applicablearticles of thecodes listedatthebeginningof
this section.
WARNING
Hotengineandexhaustsystem.
Do not work on generator set until it is allowed to
cool.
injury or death. Hot exhaust system can ignite
adjacentcombustiblematerials. Donotlocateelectrical
wiring, fuel lines, or combustible material above the
exhaust muffler. Exercise caution when parking your
vehicle to prevent exhaust system and hot exhaust
gases fromstarting grass fires.
WARNING
Carbonmonoxide.
Cancauseseverenausea, fainting, or death.
The exhaust system must be leakproof and
routinely inspected.
Installingexhaust tail pipe. Carbon monoxidecan
cause severe nausea, fainting, or death. Install
exhaust systemtail pipe so discharged exhaust gases
will not be drawn into vehicle interior through windows,
doors, air conditioners, etc. Do not use flexible tail
piping because it could crack and allowlethal exhaust
fumes to enter the vehicle.
Generator set operation. Carbon monoxide can
cause severe nausea, fainting, or death. Never
operate the generator set inside a building unless the
exhaust gas is piped safely outside. Never operate in
any area where exhaust gas could accumulate and
seep back inside a potentially occupied building or
vehicle. Be careful when parking your vehicle to avoid
obstructingtheexhaustoutlet. Theexhaustgases must
discharge freely to prevent carbon monoxide from
deflecting into the vehicle. Avoid breathing exhaust
fumes when working on or near the generator set.
Carbonmonoxideisparticularlydangerousbecauseitis
an odorless, colorless, tasteless, nonirritating gas that
can cause death if inhaled for even a short period of
time.
Coppertubingexhaustsystems. Carbonmonoxide
cancauseseverenausea, fainting, ordeath. Donot
use copper tubing in diesel exhaust systems. Sulfur in
diesel exhaust causes rapid deterioration of copper
tubing exhaust systems resulting in exhaust/water
leakage.
NOTE
Suspend exhaust system components beneath the
undercarriage with automotive-type tailpipe hangers
(shock mounted) only. Position hangers in vertical
positiondirectlyaboveexhaustpipetoreducevibration.
Excessive vibration caused by angular hanger
mounting could cause exhaust pipe damage. If the
tailpipe extends more than 18 in. (45.7 cm) beyond
muffler, attach an additional hanger for support. Use
only automotive-type, U-bolt muffler clamps in exhaust
systeminstallation.
NOTE
The muffler material must be aluminized steel or other
corrosion-resistant material of welded or crimped
construction. The muffler must be a USDA-approved
typeor themuffler mustbefittedwithaUSDA-approved
spark arrestor.
Becauseof thedifferentlocations of mufflers andpiping
to these mufflers, follow clearance requirements to
protect generator set components and to avoid igniting
adjacent combustible materials. A clearance of 1.5 in.
(38 mm) is recommended between exhaust system
parts and fuel system, electrical system, and all
combustible components.
Routetheexhaustpipingthroughthecompartmentfloor
or walls provided minimumclearances are maintained
andexhaustpipingbends areminimized. Useatail pipe
as short as possible with as few gradual bends as
possible to reduce back pressure; maximum back
pressureallowedis 21.65in. watercolumnforthe15kW
and11.81in. water columnfor the20kW. Theexhaust
pipingmust include anexhaust sleeve or thimble when
routed through a combustible wall. Extend tail pipe a
minimumof 1 in. (25 mm) past perimeter of vehicle. If
thegeneratortail pipeis locatedonthesamesideas the
compartment air intake, position tail pipe so exhaust
gases will notberecirculated. Install 1.61in. I.D. flexible
tubing between the exhaust manifold flange and the
silencer.
Electrical Systems
Battery, loadlead, andremoteswitchpanel connections
are needed to complete the installation. Make final
connections to the battery only after all other
connections have been made as this will prevent
unintentional starting. Some specific details on each
connection are stated in the following paragraphs.
Refer to the wiring diagram for specific details.
Connections should be made only by qualified
electricians. Securelysupportedor harness all wiringto
the generator set to prevent abrasion. Additional
support is required to prevent exposure to the exhaust
systemanddrippageof fuel, oil, orgreaseatleast2in.
(51mm) clearancemustbeprovidedbetweenelectrical
wiringandhot exhaust parts. Also, donot locatewiring
directly belowor in close proximity to fuel systemparts
or oil fill tube. Some other points to consider when
making AC load connections are covered in the
following paragraphs.
NOTE
Wiring connections made at the time of installation
should be accessible for inspection and servicing.
BatteryAndConnections
A separate 12-volt battery is recommended for the
generator set. With a separate battery, cables can be
kept short which eliminates the problem of excessive
voltage drop through long cables. See Figure 6-15 for
lengthandsizes. RefertoFigure 6-16(ViewA) forcable
connections (note that a ground strap must be
connectedbetweenthegroundlugonthegenerator set
and frame of the vehicle with this arrangement).
If thestartingbatteryfor thevehicleenginemustalsobe
used for starting the generator engine, the negative
battery terminal must be groundedto the vehicle frame
and heavy gauge (#4) ground strap must connect the
groundlugonthe generator set to the vehicle frame as
illustrated in Figure 6-16 (ViewB).
Distance Between
Generator Set
And Battery
Cable
Size (AWG)
at 0F
(-18C)
Cable
Size (AWG)
at 32F
(0C)
Cable
Size (AWG)
at 75F
(24C)
40 ft. (12.2 m) 0 0 1
30 ft. (9.1 m) 0 1 2
25 ft. (7.6 m) 1 2 4
20 ft. (6.1 m) 2 2 6
15 ft. (4.6 m) 2 4 6
10 ft. (3.0 m) 4 6 8
5 ft. (1.5 m) 6 6 8
2.5 ft. (0.8 m) 8 8 8
Figure6-15. BatteryCableSize
-- +
Battery
Positive
Vehicle
Frame
12-Volt
Battery
Using Same Battery
as Vehicle Engine
N
Battery Negative
to Vehicle Frame
Ground Strap
Vehicle Frame
-- +
Battery
Positive
Vehicle Frame
12-Volt
Battery
Using Separate Battery
for Generator Set
N
ViewA
ViewB
Figure6-16. BatteryConnectionDetails
holes in clothing.
WARNING
NOTE
A groundconnectionis requiredbetweenthegenerator
andthevehicleframeevenif thebatteryusedtostartthe
generator is not the same as the vehicle.
AC LoadLeadConnections
Each set has four color-coded load leads. The black
leads (L1andL2) are hot, the white lead(L0) is neutral
andthegreenleadis thehazardground. Routetheload
leads directly fromthe junction box to the vehicle AC
circuit or transfer-switch connection. All installations
require that the load leads be routed through flexible
conduit fromthe generator end bracket to the junction
box location. The load lead junction box must be
accessible for servicing and inspection.
NOTE
Keep load lead circuit away from the generator,
specifically fuel and exhaust systemcomponents.
NOTE
All field-suppliedwiringmustbecapableof withstanding
temperatures of 167_F (75_C).
ACloadleadL0(whiteorgray)is alwaystheneutral lead
onKohler generator sets. Make sure the neutral of the
AC circuit in the vehicle is connected to the lead L0
(white or gray). If equipment ground-type plugs and
receptacles (3-pronged) are used in the vehicle, the
greenwiremustbeconnectedtotheU-shapedpin. On
vehicles whichalsohaveprovisions forusinganoutside
AC power source, the neutral as well as the hot (or
black) leads must be completely isolated from the
generator set when power is switched to the outside
source. See Figure 6-17.
NOTE
Useatriple-pole, double-throwtransfer switchratedfor
the calculated load of the RV to transfer the load from
one source to the other. Install a ground-fault circuit
interrupter in the wiring system to protect all branch
circuits.
NOTE
The AC load circuit of the generator set must be
protected by a circuit breaker(s) against overload or
short circuit.
120-V
Outside
Power
AC Vehicle Circuit
Ground Fault
Circuit Protection
L1
L2
Gen.
Set
N N N
L0
120 Volt
240-V
Outside
Power
AC VehicleCircuit
Ground Fault
Circuit Protection
L1
L2
Gen.
Set
N N N
L0
120/240 Volt
Figure6-17. Transfer SwitchConnections, 3-WireAC Circuit
Do not connect to any building electrical system
without connecting through an approved device
and after building main switch is open.
WARNING
Hazardous voltage.
Backfeed to utility system can cause severe
injury, death, or propertydamage.
Electrical backfeed to utility. Hazardous backfeed
voltagecan causesevereinjury or death. Connect
generator set to building/campgroundelectrical system
only through an approved device and after
building/campground main switch is open. Backfeed
connections can cause serious injury or death to utility
personnel working on power lines and/or personnel in
thevicinityoftheworkarea. Unauthorizedconnectionto
utility electrical systemmay be unlawful in some states
and/or localities. Install a transfer switch to prevent
interconnection of generator set power and other
sources of power.
NOTE
For standby service connect output of generator to
suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
RemoteSwitchConnection
(Single-PhaseModels Only)
Controllers include an accessory plug (P3) for easy
connectionoftheremoteswitchtothepreheatswitch, oil
pressuregauge(if equipped), water temperaturegauge
(if equipped) and generator ON lamp wiring harness
(available separately). One endof the15in. (38.1cm)
P3wiringharness plugs directly into the controller. The
pigtail leads on the remaining end of the harness
connect to the appropriate remote panel terminals via
customer-supplied wiring. Be sure to connect the
remoteoperatingcontrols tothecorrectP3wireharness
lead. SeeFigure 6-18andFigure 6-19for identification
of P3 harness leads.
1-933
1
1. Remote connection
Figure6-18. Controller RemoteConnection
11
2
53 3
10
6 4 2
5 3 1
53
3
2
4
ONLamp
Start
Stop/Preheat
Ground
PinNo. LeadNo. Function
1 4 Ground
2 53 On Lamp
3 10 Water Temperature
4 3 Start
5 2 Stop/Preheat
6 11 Oil Pressure
4
11
Oil Pressure
Gauge, if equipped
10
Water Temperature
Gauge, if equipped
P3
Figure6-19. Panel Wiring(P3WiringHarness)
Notes
TP-5605 4/97 Installation Drawings 7-1
Section7. InstallationDrawings
15CCORVRemoteRadiator Single-PhaseModel
ADV-5833A-C
NOTE: Dimensions in ( ) are millimeter equivalents.
TP-5605 4/97 7-2 Installation Drawings
15CCORVRemoteRadiator Single-PhaseMountingPattern
ADV-5833A-C
15CCORVRemoteRadiator(Suction)
ADV-5833B-A
15CCORVRemoteRadiator(withAirbagMounts)Single-PhaseModel
ADV-5833C-A
15CCORVRemoteRadiator (withAirbagMounts) Single-PhaseMountingPattern
ADV-5833C-A
15CCORVInline(Suction) Radiator Single-PhaseModel
ADV-5833D-A
15CCORVIn-lineRadiatorSingle-PhaseMountingPattern
ADV-5833D-A
15CCOMOBILE In-line(Suction)Radiator Three-PhaseModel
ADV-5879-B
15CCOZMOBILEIn-lineRadiatorThree-PhaseModel
ADV-5879-B
TP-5605 4/97 7-10 InstallationDrawings
20CCORVRemoteRadiator Single-PhaseModel
ADV-5834A-C
20CCORVRemoteRadiatorSingle-PhaseMountingPattern
ADV-5834A-C
20CCORVRemoteRadiator(Suction)
ADV-5834B-A
TP-5605 4/97 InstallationDrawings 7-13
20CCORVRemoteRadiator(withAirbagMounts)Single-PhaseModel
ADV-5834C-B
20CCORVRemoteRadiator(withAirbagMounts)Single-PhaseMountingPattern
ADV-5834C-B NOTE: Dimensions in ( ) are millimeter equivalents.
20CCORVIn-lineRadiatorSingle-PhaseModel
ADV-5834D-A
20CCORVIn-lineRadiatorSingle-PhaseMountingPattern
ADV-5834D-A
20CCOZMOBILEIn-line(Suction)RadiatorThree-PhaseModel
ADV-5880-A
20CCOZMOBILEIn-lineRadiatorThree-PhaseMountingPattern
ADV-5880-A
20kWRVRemoteRadiator (spec PA-132322)
ADV-6190A-
BATTERY CONNECTION (--)
(FAR SIDE)
FUEL INLET 1/4--18 N.P.S.F.
LIFTING EYES
4.98
(126)
4.18
(106)
3.10
(79)
12.68
(322)
29.00
(737)
6.01
(153)
FUEL RETURN 1/4--18 N.P.S.F.
OIL DRAIN
AIR CLEANER
OIL CHECK
16.02
(407)
39.57
(1005)
FOR SALES & SERVICE
& CANADA IN THE U. S.
0 0 00
R
BATTERY CONNECTION (+)
(FAR SIDE)
C COOLANT OUTLET FOR
1.10 (28) I.D. HOSE
C COOLANT INLET FOR
1.10 (28) I.D. HOSE
L
L
WARNING
CAUTION
2
1
.
9
9
(
5
5
9
)
9
.
1
1
(
2
3
1
)
2
3
.
2
6
1
7
.
7
7
6
.
3
9
1
.
5
7
(
1
6
2
)
(
4
5
1
)
(
4
0
)
(
5
9
1
)
OIL FILL
AC DC START/STOP
SWITCH
PREHEAT
STOP/
START
METER
HOUR
BREAKER
CIRCUIT
BREAKER
CIRCUIT
CIRCUIT BREAKER LOCATION
(OPTIONAL)
1 1/2 N.P.T.
EXHAUST OUTLET
6.33
(161)
COOLANT
OUTLET
3.54
(90)
.83
(21)
.51
(13) 6.75
(171)
FUEL INLET
&RETURN
COOLANT
INLET
(
6
9
2
)
10.14
(258)
20.89
(531)
2
7
.
2
5
2
5
.
1
9
(
6
4
0
)
20kWRVRemoteRadiator MountingPattern(spec PA-135322)
ADV-6190A-
2
.
5
0
(
6
4
)
2
4
.
0
0
(
6
1
0
)
.
5
3
1
(
1
3
)
D
I
A
.
4
M
T
G
.
H
O
L
E
S
W
A
L
L
C
O
M
P
A
R
T
M
E
N
T
I
N
G
E
N
E
R
A
T
O
R
A
I
R
A
I
R
I
N
L
E
T
F
R
E
E
A
I
R
G
E
N
E
R
A
T
O
R
1
4
0
S
Q
.
I
N
.
(
9
0
3
S
Q
.
C
M
)
1
3
.
0
0
(
3
3
0
)
O
C
T
A
G
O
N
A
L
I
N
L
E
T
A
R
E
A
A
R
O
U
N
D
C
O
M
P
L
E
T
E
I
N
L
E
T
T
O
C
O
M
P
A
R
T
M
E
N
T
S
E
A
L
G
E
N
E
R
A
T
O
R
A
I
R
2 . 2 8 1 4 . 4 4
1 9 . 0 0
9 . 5 0
1
.
5
0
R
E
C
O
M
M
E
N
D
E
D
M
I
N
.
C
L
E
A
R
A
N
C
E
(
3
8
)
A
R
O
U
N
D
G
E
N
E
R
A
T
O
R
S
E
T
.
( 4 8 3 )
( 3 6 7 )
( 2 4 1 )
( 5 8 )
C
O
M
P
A
R
T
M
E
N
T
W
A
L
L
A
I
R
O
U
T
L
E
T
2
1
6
S
Q
.
I
N
.
(
1
3
9
3
S
Q
.
C
M
)
I
N
C
O
M
P
A
R
T
M
E
N
T
F
L
O
O
R
2
1
.
6
0
(
5
4
9
)
1 0 . 0 0
( 2 5 4 )
20kWRVRemoteRadiator (Suction)
ADV-6190B-
20kWRVRemoteRadiator withAirbagMounts (spec PA-135322)
ADV-6190C-
20kWRVRemoteRadiatorwithAirBagsMountingPattern(spec PA-135322)
ADV-6190C-
20kWRVIn-lineRadiator(specPA-135322)
ADV-6190D-
20kWRVIn-lineRadiatorMountingPattern(spec PA-135322)
ADV-6190D- NOTE: Dimensions in ( ) are millimeter equivalents.
Notes
TP-5605 4/97 Appendix A-1
Appendix A. Glossaryof Abbreviations
Abbreviations are used throughout this manual.
Normally they will appear in the text in complete form
with the abbreviation following in parentheses the first
time they are used. After that they will appear in the
abbreviated form. The commonly used abbreviations
are shown below. Some items may not apply to this
application.
Abbreviation Description Abbreviation Description
ABDC after bottomdead center
AC alternating current
AISI American Iron and Steel Institute
AHWT anticipatory high water temp.
ALOP anticipatory lowoil pressure
AM amplitude modulation
amp ampere
amps amperes
ANSI American National Standard Institute
API American PetroleumInstitute
approx. approximate, approximately
A/R as required, as requested
A/S as supplied, as stated, as suggested
ASA American Standards Association
(former name of ANSI)
ASME American Society of
Mechanical Engineers
assy. assembly
ASTM American Society for Testing
Materials
ATDC after dead top center
aux. auxiliary
A/V audio--visual
AWG American Wire Gage
AWM appliance wiring material
BBDC before bottomdead center
BDC before dead center
BHP brake horsepower
bmep brake mean effective power
BTDC before top dead center
Btu British thermal unit
_C Celsius degree
cc cubic centimeter
CCA cold cranking amps
CEC Canadian Electrical Code
cfh cubic feet per hour
cfm cubic feet per minute
CID cubic inch displacement
cm centimeter, centimeters
cmm cubic meters per minute
co. company
contd. continued
CPVC chloropoly vinyl chloride
CRT cathode ray tube
CSA Canadian Standards Association
CT current transformer
cu. in. cubic inch (es)
CWC city-water cooled
cyl. cylinder
dB decibel
dBA decibels (A weighted)
DC direct current
DCR direct current resistance
deg. degree
dept. department
dia. diameter
DIN Deutsches Institut fur Normung e. V.
(also Deutsche Industrie
Normenausschuss)
e.g. example given
EIA Electronic Industries Association
EMI electromagnetic interference
EPA Environmental Protection Agency
etc. etcetera, (and so forth)
ext. external
_F Fahrenheit degree
fl. oz. fluid ounce(s)
FM frequency modulation
ft. foot, feet
ft. lbs. foot pound(s)
fs full scale
ga. gauge (meters wire size)
gal./gals. gallon, gallons
gph gallons per hour
gpm gallons per minute
gr. grade
grd. ground
HCHT high cylinder head temperature
HET high exhaust temperature
Hg. mercury (element)
H
2
O water
HP horsepower
hr, hrs hour, hours
HWT high water temperature
Hz hertz (cycles per second)
ID inside diameter
IEEE Institute of Electrical and
Electronic Engineers
in. inch, inches
inc. incorporated
in. lbs. inch pounds
int. internal
int.-ext. internal--external
A-2 Appendix TP-5605 4/97
Abbreviation Description Abbreviation Description
ISO International Standards Organization
J joule, joules
J IS J apanese Industry Standard
kg kilogram, kilograms
kg/cm
2
kilograms per square centimeter
kgm kilogrammeter(s)
kJ kilojoules (btu cal)
km kilometer, kilometers
kPa kiloPascal, kiloPascals
kph kilometers per hour
kV kilovolt
kVA kilovolt amperes
kW kilowatt, kilowatts
kWH kilowatt hour
L liter, liters
LxWxH length x width x height
LED(s) light emitting diode(s)
lb., lbs. pound, pounds
L/hr. liter per hour, liters per hour
L/min. liter(s) per minute
LOP lowoil pressure
LP liquified petroleum
LWT lowwater temperature
m meter, meters
m
3
cubic meter, cubic meters
max. maximum
MCM one thousand circular mils.
meggar megohmmeter
MHz megahertz
mi. mile, miles
mil one one--thousandth of an inch
min. minimum
misc. miscellaneous
mJ milli joule(s)
MJ mega joule(s)
mm millimeter
m
3
/min cubic meters per minute
MPa megaPascal
mpg miles per gallon
mph miles per hour
MS military standard
mW milliwatt(s)
MW megawatt(s)
N/A not available
NBS National Bureau of Standards
N.C. normally closed
NEC National Electrical Code
NEMA National Electrical Manufacturers
Association
NFPA National Fire Protection Association
Nm Newton meter(s)
N.O. normally open
no., nos. number, numbers
NPT National Standard taper pipe thread
per general use
N/R not required
OC overcrank
OD outside diameter
OEM original equipment manufacturer
OS overspeed
O/S oversize
OSHA Occupational Safety and Health Act
OV overvoltage
oz. ounce, ounces
PF power factor
PMG permanent magnet generator
pot potentiometer
ppm parts per million
psi pounds per square inch
pt., pts. pint, pints
PVC polyvinyl chloride
qt., qts. quart, quarts
qty. quantity
ref. reference
RFI radio frequency interference
r.h.m. round--head machine (screw)
rms root means square
RPM revolutions per minute
RTV roomtemperature vulcanization
SAE Society of Automotive Engineers
SCR silicon controlled rectifier
sec. second, seconds
spec, specs specification
sq. square
sq. cm. square centimeters
sq. in. square inch(es)
tach tachometer
TDC top dead center
tech. pub. technical publications
temp. temperature
TIF telephone influence factor
TP, TPs technical publications
turbo turbocharger
UHF ultrahigh frequency
UNC Unified coarse thread (was NC)
UNF Unified fine thread (was NF)
UL Underwriters Laboratories, Inc.
U/S undersize
U.S.A. United States of America
V volt, volts
vac volts alternating current
vdc volts direct current
VHF very high frequency
W watt, watts
TP-5605 4/97 Appendix B-1
Appendix B. OperatingHour ServiceLog
Thefollowingis providedtohelpyoukeepacumulative
recordof operatinghours onyour generator set andthe
dates requiredservices wereperformed. Enterhoursto
the nearest quarter hour.
DATE RUN
OPERATING HOURS
HOURS
RUN CUMULATIVE
SERVICE RECORD
DATE SERVICE
KOHLER CO. Kohler, Wisconsin 53044
Phone 414-565-3381, Web site www.kohlergenerators.com
Fax 414-459-1646 (U.S.A. Sales), Fax 414-459-1614 (International)
After J uly 26, 1997, use area code 920 instead of 414
For the nearest sales and service outlet in U.S.A. and Canada
Phone 1-800-544-2444 E Kohler Co., 1997. All rights reserved.
TP-5605 4/97a

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