Kohler 10CCOZ61 User manual

Mobile Generator Sets
Model:
10CCOZ61
Brushless SinglePhase
TP-5648 9/93
Service Manual

TP-5648 8/93
Table of Contents
SUBJECTPAGE SUBJECTPAGE
GlossaryofAbbreviationsi................
SafetyWarningsand Instructionsiii..........
Section 1. Introduction 1-1...................
Specifications1-1...........................
Generator1-1............................
Engine 1-1...............................
ServiceGuidelines1-1....................
ServiceViews1-3..........................
Section 2. Operation 2-1.....................
PrestartChecklist2-1.......................
Exercising the Generator2-1...............
Manual ControllerOperation 2-2..............
Features2-3.............................
Starting Procedure 2-4......................
Stopping Procedure 2-4.....................
CoolantSystemFilling 2-5...................
CircuitProtection 2-6........................
FaultShutdowns2-7........................
LowOil PressureShutdownSwitch 2-7......
High WaterTemperatureShutdownSwitch 2-7
Accessories2-8............................
Low CoolantLevelShutdownSwitch 2-8.....
LowFuelLevelShutdownSwitch 2-8........
Section 3.ScheduledMaintenance 3-1........
MaintenanceSchedule 3-2...................
Lubrication System3-3......................
Oil Selection 3-3..........................
Oil Check 3-3............................
Oil Change 3-3...........................
Oil Filter3-5.............................
FuelSystem3-6............................
Specification 3-6.........................
FuelFilter3-7............................
FuelFilter (Supplied Loose)3-7............
Bleeding the FuelSystem3-8..............
AirCleanerService 3-9......................
Governor3-9...............................
Cooling Systems3-10........................
Filling and Checking 3-10...................
Flushing and Cleaning 3-10.................
PressureCap 3-10.........................
Filling Sequence 3-11........................
Servicing Cooling System3-12................
DriveBelt3-15..............................
BeltTension 3-15..........................
BatteryCharging 3-15........................
GeneratorService 3-16.......................
General3-16..............................
Storage Procedure 3-16......................
Section 4. GeneralTroubleshooting 4-1.......
Section 5.ControllerTroubleshooting 5-1.....
Sequence of Operation 5-1..................
Starting 5-1..............................
Running 5-2.............................
Stopping 5-3.............................
AutomaticSafetyShutdowns5-4.............
Section 6. Generator/Controller
Troubleshooting 6-1.........................
ControllerCircuitBoard 6-1..................
Section 7.ComponentTesting
and Adjustment7-1..........................
SeparateExcitation 7-1......................
Voltage RegulatorPowerboostäV7-4.........
Voltage RegulatorTestProcedure 7-5.......
Voltage RegulatorAdjustment7-7..........
AdjustmentProcedure 7-8.................
ControllerCircuitBoard 7-9..................
Engine/GeneratorComponents7-11...........
Rotor7-15..................................
Stator7-16..................................
Checking StatorContinuityand Resistance 7-16
ExciterField 7-17............................
ExciterArmature 7-18........................
FuelSolenoid 7-19...........................
Section 8.Disassembly/Reassembly 8-1.......
Disassembly8-1............................
Reassembly8-6............................
Section 9.Wiring Diagrams 9-1...............
Four-Lead Reconnectable(Single-Phase)
GeneratorSetsWhereGeneratorOutput
Can BeReconnected For120/240 volt, 60
Hz;or110/220 volt, 50 Hz9-1..............
120/240-volt(or110/220-volt)
Configurations--Figure 9-1(ViewA)9-1......
Section 10.Common Hardware 10-1............
Application Guidelines,Specification G-585 10-1.

TP-5648 8/93 GlossaryofAbbreviationsi
Glossary of Abbreviations
Abbreviationsare used throughout thismanual.Normallyinthe text theywill appearincompleteformwiththe
abbreviation following in parenthesisthe first timetheyare used.Afterthat theywill appearinthe abbreviated form.
The commonlyused abbreviationsareshown below.
Abbreviation Description
ACalternating current
AHWTanticipatoryhigh watertemp.
ALOPanticipatorylowoil pressure
AMamplitude modulation
Amp.ampere
Amps.amperes
ANSIAmerican NationalStandardInstitute
APIAmerican PetroleumInstitute
approx.approximate,approximately
A/Rasrequired,asrequested
A/Sas supplied,as stated,as suggested
ASA American StandardsAssociation
assy.assembly
ASTMAmerican SocietyforTesting
Materials
ATDC aftertop dead center
ATSautomatictransferswitch
aux.auxiliary
AWGAmerican WireGauge
AWMappliancewiring material
bhp brake horsepower
bmep brakemean effective power
BtuBritishthermalunit
°C Celsiusdegree
cc cubic centimeter
CCAcoldcranking Amps.
CEC Canadian ElectricalCode
cfhcubicfeetperhour
cfmcubicfeetperminute
CIDcubicinch displacement
cmcentimeter,centimeters
cmm cubicmetersperminute
co.company
cont’d.continued
C.S.A.Canadian StandardsAssociation
cu.in.cubicinch,cubicinches
cyl.cylinder
dBA decibels
DC directcurrent
DCR directcurrentresistance
deg.degree
Abbreviation Description
dept. department
dia.diameter
e.g.example given
EMIelectromagneticinterference
etc.etcetera,(and soforth)
ext. external
°F Fahrenheitdegree
fl.oz. fluid ounce, fluid ounces
FMfrequency modulation
fsfull scale
ft. foot, feet
ft. lbs. footpound, footpounds
ga.gauge
gal., gals.gallon,gallons
gal./hr.gallonsperhour
gph gallonsperhour
gpmgallonsperminute
gr.grade
grd.ground
HCHThigh cylinderhead temperature
HEThigh exhaust temperature
Hgmercury(element)
H2Owater
hp horsepower
hr,hrshour
HWThigh watertemperature
Hzhertz(cyclespersecond)
IDinside diameter
in.inch(es)
inc.incorporated
in.lbs.inch pounds
int. internal
int.-ext. internal-external
ISOInternationalStandardsOrganization
Jjoule,joules
JISJapaneseIndustryStandard
kgkilogram,kilograms
kg/cm2kilogramspersquarecentimeter
kgmkilogram meter(s)
kmkilometer,kilometers
kPakiloPascal,kiloPascals

TP-5648 8/93ii GlossaryofAbbreviations
Abbreviation Description
kph kilometersperhour
kVkilovolt
kVA kilovoltamperes
kWkilowatt, kilowatts
kWHkilowatt hour
Lliter,liters
LxWxHlengthxwidthxheight
LED,LEDslightemitting diode
lb., lbs.pound,pounds
L/hr.literperhour,litersperhour
L/min.liter(s)perminutes
LOPlowoil pressure
LPliquefied petroleum
LWTlow watertemperature
m meter,meters
m3cubicmeter,cubicmeters
max.maximum
MCMone thousand circularmils.
mi.mile,miles
mil one one-thousandth ofan inch
min.minimum
mJmillijoule,millijoules
MJmega joule,mega joules
mm millimeter,millimeters
m3/mincubicmetersperminute
MPamegaPascal
mph milesperhour
MSmilitary standard
mWmilliwatt, milliwatts
MWmegawatt, megawatts
N/Anotavailable
NEC NationalElectricalCode
NEMANationalElectrical
ManufacturersAssociation
NFPA NationalFireProtection Association
NmNewton meter,Newton meters
no., nos.number,numbers
NPTNationalStandardtaperpipe
thread pergeneraluse
Abbreviation Description
N/Rnotrequired
OCovercrank
ODoutside diameter
OEMoriginalequipmentmanufacturer
OSoverspeed,oversize
OVovervoltage
oz.ounce,ounces
PFpowerfactor
pot. potentiometer
ppmpartspermillion
psipoundspersquareinch
pt., pts.pint, pints
qt., qts.quart, quarts
qty.quantity
ref. reference
RFIradiofrequency interference
rmsrootmean square
rpmrevolutionsperinch
SAE SocietyofAutomotiveEngineers
sec.second,seconds
SCR silicon controlled rectifier
spec,specs specification
sq.square
sq.cmsquarecentimeters
sq.in.squareinch,squareinches
tachtachometer
TDC top dead center
temp. temperature
TIFtelephone influencefactor
turbo turbocharger
UNC Unified coarsethread (wasNC)
UNFUnified fine thread (wasNF)
ULUnderwriter’sLaboratories, Inc.
USundersize
Vvolt, volts
VACVoltsalternating current
VDC voltsdirectcurrent
Wwatt, watts

TP-5648 8/93 SafetyPrecautionsand Instructionsiii
Safety Precautions and Instructions
Ageneratorset, like anyotherelectro-mechanical
device,can pose potentialdangerstolife and limbif
improperlymaintained orimprudentlyoperated.The
bestwayto preventaccidentsisto be aware of the
potentialdangersand to always use good common
sense. Inthe interestofsafety,some general
precautionsrelating the to operating ofa generatorset
follow.Keep theseinmind.Thismanualcontains
severaltypesofsafetyprecautionswhich are explained
below.
DANGER
Dangerisusedtoindicatethepresenceofahazardthat
will causeseverepersonal injury,death,orsubstantial
propertydamage if the warning isignored.
WARNING
Warning isused toindicatethe presence ofa hazard
thatcan causeseverepersonal injury,death,or
substantialpropertydamage if the warning isignored.
CAUTION
Cautionisusedtoindicatethepresenceofahazardthat
will orcan causeminorpersonal injuryorproperty
damage if the warning isignored.
NOTE
Noteisusedtonotifypeople ofinstallation,operation,or
maintenanceinformation thatisimportantbutnot
hazard-related.
Safetydecalsare affixed tothe generatorsetin
prominentplacesto advisethe operatororservice
technician ofpotentiallyhazardous situations.The
decalsarereproduced heretoimprove operator
recognition and therebyincrease decaleffectiveness.
Forafurtherexplanationofdecalinformation,reference
theaccompanyingsafetyprecautions.Beforeoperating
orservicing the generatorset, be surethe message of
thesedecalsareunderstood.Replacedecalsifmissing
ordamaged.

TP-5648 8/93ivSafetyPrecautionsand Instructions
EXHAUSTSYSTEM
WARNING
Carbon monoxide.
Cancause severenausea,fainting,ordeath.
The exhaustsystem mustbe leakproofand
routinelyinspected.
Carbon monoxide cancause severenausea,
fainting,ordeath.Install exhaustsystemtail pipe so
discharged exhaustgaseswill notbe drawnintovehicle
interiorthrough windows,doors,airconditioners,etc.
Do notuseflexibletail piping sincethistype couldcrack
and allowlethalexhaust fumesto enterthe vehicle.
Carbon monoxide cancause severenausea,
fainting,ordeath.Neveroperatethe generatorset
inside a building unless the exhaustgasispiped safely
outside.Neveroperatein anyarea where exhaustgas
could accumulate and seep back inside an occupied
building orvehicle.Becarefulwhen parking the vehicle
to avoid obstructing the exhaustoutlet. The exhaust
gasesmustdischarge freely,otherwisecarbon
monoxide maydeflectintothe vehicle.Avoid breathing
exhaust fumeswhen working on ornearthe generator
set. Carbon monoxide isparticularlydangerous
becauseitisan odorless,colorless, tasteless,
nonirritatinggasthatcancausedeathifinhaledforeven
ashortperiod of time.
Carbon monoxide cancause severenausea,
fainting,ordeath.Dieselfumes can rapidlydestroy
coppertubing in dieselexhaustsystems.Do notuse
coppertubing in dieselexhaustsystems.Exhaust
sulphurwill causerapid deterioration and this could
resultin exhaustleakage.
ACCIDENTALSTARTING
WARNING
Accidentalstarting.
Cancause severeinjuryordeath.
Disconnectbattery cablesbeforeworking on
generatorset(negativelead firstand reconnectit
last).
Accidentalstarting cancause severeinjuryor
death.Disconnectbattery cables(remove negative
lead firstand reconnectitlast)to disable generatorset
beforeworking on anyequipmentconnected to
generator.The generatorsetcan be started byremote
start/stop switch unless thisprecaution isfollowed.

TP-5648 8/93 SafetyPrecautionsand Instructions v
MOVINGPARTS
WARNING
Hazardous voltage.
Do notoperate generatorsetwithoutall guards
and electricalenclosuresin place.
Moving rotor.
Cancause severeinjuryordeath.
WARNING
Rotating parts.
Cancause severeinjuryordeath.
Do notoperate generatorsetwithoutall guards,
screens,orcoversin place.
Exposedmoving parts cancause severeinjuryor
death.Keep hands, feet, hair,clothing,and testleads
awayfrombeltsand pulleys when unitisrunning.
Replace guards,covers,and screensbefore operating
generatorset.
Flying projectiles cancause severeinjuryordeath.
Retorque all crankshaft and rotorhardware after
servicing.When making adjustmentsorservicing
generatorset, do notloosen crankshaft hardware or
rotorthru-bolt. If rotating crankshaft manually,direction
shouldbeclockwise only.Turning crankshaft boltor
rotorthru-boltcounterclockwisecan loosen hardware
and resultinseriouspersonal injuryfromhardware or
pulleyflying off engine while unitisrunning.
ENGINEBACKFIRE/FLASHFIRE
WARNING
Fire.
Cancause severeinjuryordeath.
Do notsmoke orpermit flame orsparkto occur
nearfuelorfuelsystem.
Asuddenbackfire cancause severeinjuryordeath.
Do notoperatewith aircleaner removed.

TP-5648 8/93viSafetyPrecautionsand Instructions
HAZARDOUS VOLTAGE/
ELECTRICALSHOCK
WARNING
Hazardous voltage.
Do notoperate generatorsetwithoutall guards
and electricalenclosuresin place.
Moving rotor.
Cancause severeinjuryordeath.
Do notconnect to anybuilding electricalsystem
withoutconnecting through an approved device
and afterbuilding mainswitchisopen.
WARNING
Hazardous voltage.
Backfeedto utility systemcancause severe
injury,death,orpropertydamage.
Hazardous voltage cancause severeinjuryor
death.The heatsinkof the voltage regulatorcontains
high voltage.Do not touchvoltage regulatorheatsink
when testing orelectricalshock will occur.
Hazardous voltage cancause severeinjuryor
death.Performelectricalservice onlyasprescribed in
equipmentmanual.Besurethatgeneratorisproperly
grounded.Nevertouch electrical leadsorappliances
withwethands,when standing inwater,oron wet
ground asthe chance ofelectrocution isespecially
prevalentundersuchconditions.Wiring should be
inspected at the intervalrecommended inthe service
schedule—replaceleadsthatarefrayed orin poor
condition.The function ofa generatorsetisto produce
electricityand whereverelectricityispresent, thereis
the hazard ofelectrocution.
Hazardous“backfeed”voltage cancause severe
injuryordeath.The generatormustnotbe used to
“backfeed”by connecting it to building/campground
electricalcircuits. Install atransferswitchinvehicle
generatorinstallationsto preventconnection ofvehicle
and othersourcesofpower.Electricalbackfeed into a
utilityelectricalsystemcancauseseriousinjuryordeath
to utilitypersonnelworking on transmission lines.
Hazardous voltage cancause severeinjuryor
death.Shortcircuits can cause bodilyinjuryand/or
equipmentdamage.Do notcontactelectrical
connectionswithtoolsorjewelrywhile adjustmentsare
made.Removewristwatch,rings,and jewelrythatcan
causeshortcircuits.

TP-5648 8/93 SafetyPrecautionsand Instructions vii
FUELSYSTEM
WARNING
Explosive fuelvapors.
Cancause severeinjuryordeath.
Useextremecarewhenhandling,storing,
and using fuels.
Explosive fuelvapors cancause severeinjuryor
death.All fuelsare highlyexplosivein a vaporstate.
Use extremecarewhen handling,storing,and using
fuels.Storefuel in a well-ventilated area awayfrom
spark-producing equipmentand outof the reach of
children.Neveradd fueltothe tankwhilethe engine is
running sincespilled fuelmayignite on contactwith hot
partsorfromignition spark.Do notsmoke orpermit
flame orsparkto occurnearpotentialsourcesofspilled
fuelorfuelvapors.Keepfuel linesandconnectionstight
and in good condition—don’treplaceflexiblefuel lines
withrigidlines.Flexiblesectionsare used to avoid
breakageduetovibration.Should anyfuelleakage,fuel
accumulation,orelectricalsparks be noted,DONOT
OPERATEGENERATORSET.Havesystemsrepaired
beforeresuming generatoroperation.
Explosive fuelvapors cancause severeinjuryor
death.Spilled fuelcan cause an explosion.Use a
containertocatchfuelwhen draining fuelsystem.Wipe
up all spilled fuelafterdraining system.
HAZARDOUSNOISE
CAUTION
Hazardousnoise.
Cancause loss ofhearing.
Neveroperate generatorwithoutamuffleror
withfaultyexhaustsystem.

TP-5648 8/93viii SafetyPrecautionsand Instructions
BATTERY
WARNING
Sulfuric acidin batteries.
Cancause severeinjuryordeath.
Use protective gogglesand clothes.Can cause
permanentdamage to eyes,burnskin,and eatholes
inclothing.
Sulfuric acidin batteries cancause severeinjuryor
death.Sulfuricacidin battery can cause permanent
damage to eyes,burnskin,and eatholesinclothing.
Alwayswearsplash-proofsafetygoggleswhenworking
around the battery. If batteryelectrolyteis splashed in
the eyesoron skin,immediatelyflushthe affected area
for15minuteswithlargequantitiesofcleanwater. Inthe
caseofeyecontact,seekimmediatemedicalaid.Never
addacidtoabatteryoncethebatteryhasbeenplacedin
service.Doing somayresultin hazardous spattering of
electrolyte.
Explosion cancause severeinjuryordeath.Battery
gases can cause an explosion.Do notsmoke orpermit
flame orsparkto occurneara batteryatanytime,
particularlywhen itisbeing charged.Avoidcontacting
terminalswithtools,etc.topreventburnsandtoprevent
sparks thatcouldcause an explosion.Remove
wristwatch,rings,andanyotherjewelrybeforehandling
battery.Neverconnectnegative(--) battery cableto
positive(+)connection terminalofstartersolenoid.Do
not testbattery condition by shorting terminalstogether
orsparks couldignite batterygasesorfuelvapors.Any
compartmentcontaining batteriesmustbe well
ventilated to preventaccumulation ofexplosive gases.
To avoidsparks,do notdisturb battery charger
connectionswhile batteryisbeing charged and always
turnchargeroff before disconnecting battery
connections.When disconnecting battery,remove
negativelead firstand reconnectitlast.

TP-5648 8/93 SafetyPrecautionsand Instructionsix
HOTPARTS
WARNING
Hotcoolantand steam.
Cancause severeinjuryordeath.
Beforeremoving pressurecap stop generator,
allowtocooland loosen pressurecap torelieve
pressure.
WARNING
Hotengine and exhaustsystem.
Cancause severeinjuryordeath.
Donotworkongeneratorsetuntilunitisallowedto
cool.
Fire cancause severeinjuryordeath.Hotexhaust
systemcan ignite adjacentcombustiblematerials.Do
notlocate electricalwiring, fuel lines,orcombustible
materialabovethe exhaustmuffler.Becarefulwhen
parking the vehicleto preventgrass fires started by
exhaustsystemand hotexhaustgases.
Fire cancause severeinjuryordeath.Hotgenerator
can ignite debrisincompartment. Keep the
compartmentandgeneratorsetclean and free ofdebris
and combustiblematerialstominimizechancesof fire.
Do notblock fuel/oil drain opening in generator
mounting tray. If sub-flooring isused,cuta
correspondingholeinthe sub-flooringfordrainopening.
Hotparts cancause severeinjuryordeath.Do not
touchhotengineparts.Anenginegetshotwhilerunning
and exhaustsystemcomponentsgetextremelyhot.
Hotcoolantcancause severeinjuryordeath.Allow
engine tocooland release pressurefromcooling
systembefore opening pressurecap.Torelease
pressure,coverthe pressurecap with a thick cloththen
turnitslowly counterclockwisetothe firststop.After
pressure hasbeen completelyreleased and the engine
has cooled,removecap. If generatorsetisequipped
withacoolantrecoverytank,checkcoolantlevelattank.

TP-5648 8/93xSafetyPrecautionsand Instructions
NOTES NOTE
Thisgeneratorsetdoes notcomplywithUnited
States CoastGuard(U.S.C.G.)requirements and
mustnotbeusedformarine applications.Use only
generatorsets specified formarine useinmarine
installations.U.S.C.G.Regulation 33CFR183 requires
a generatorset to be “ignitionprotected” whenused ina
gasoline-fueled environment.
NOTE
Do not“tee”intofuel injected fuelsystems.Use a two
diptube arrangement forfuelsupply.Consultan
authorized Kohlerservice dealerforfurtherfuelsystem
installation information.
NOTE
Wipe up all spilled dieselfuelafterbleeding system.
Wash handsafterany contactwithfueloil.
NOTE
ENGINEDAMAGE!Failureto bleed airfromcooling
system may cause overheating and subsequent
damage to engine.
NOTE
Specialattention should be given when checking for
propercoolantlevel.Afterthe coolanthasbeen
drained,itnormallyrequiressometimebeforecomplete
refill of the engine waterjacket takesplace.

TP-5648 8/93 Introduction 1-1
Section 1. Introduction
Servicerequirementsareminimal,butarevery
important tothe safe and efficientoperation of the
generatorset.
Pleasetakeafewmomentstoread thismanual, then
carefullyfollowallservicerecommendationstokeepthe
generatorsetintop condition.See Figure 1-1for
identification and location ofcomponents.
All information inthe publication isbased on data
available at time ofprinting.KohlerCo.reservesthe
right tomakechangestothisliterature and theproducts
represented atanytimewithoutnotice orincurring
obligation.
Keepthismanual inthe vehicleforfuturereference.
The illustrationsinthe manualarerepresentative of
mostunits.Thisgeneratorsetmaydifferslightlyfrom
thatshown.
Specifications
Generator
ModelVoltage
Series CodeVoltageAmps kW/kVA
PH
10CCOZ61 61/67 120/240 83.4/41.7 10/10
1
NOTE
DERATING:All unitsarerated 1.0 powerfactor.The
kilowattsof the generatorsetwill decrease 3.5%per
1000 ft. (305 m)above 500 ft. (152 m)abovesea level.
Derate 1%forevery10°F(5.5°C)above 85°F(30°C).
Engine
The 10CCOZispowered byaKubotaV1305BG-2
four-cylinder, four-cycle dieselengine.
Service Guidelines
In any communicationsregarding the generatorset,
pleaseinclude the MODEL,SPECIFICATION,SERIAL
and ENGINE SPEC.numbersasfound on the
nameplate attached tothe generator’sframe orengine
block.The authorized service dealer/distributorwill
need these numbersto provide the correctpartsand
information forthe generatorset. Do notattempt to
replace anything thatcallsforspecialtoolsor
procedures--havethisdone onlybyqualified Kohler
generatorspecialists.Check the yellowpagesof the
telephone directoryunderthe heading
GENERATORS-ELECTRICforKohlergenerator
service dealers/distributors.
KOHLER CO., Kohler,Wisconsin 53044
Phone [phone]
Fax[phone] (NorthAmerican Sales)
Fax[phone] (International)
ForSales& ServiceinU.S.A.&Canada
Phone [phone]

TP-5648 8/931-2Introduction
CV-250000
1
2
3
4
5678 9 10
11
12 13
14
15
16
18 17
19
20
21
22
23
24
25
26 27 28 29 30
31
32
Figure 1-1.Service View-Typical(10CCOZ).

TP-5648 8/93 Introduction 1-3
Service Views
1.Controller
2.Voltage Regulator
3.High WaterTemperatureShutdownSwitch
4.FuelReturnConnection Point
5. IntakeManifold
6. Injectors
7. InjectorPump
8.Oil Fill
9.PressureCap/InitialCoolantFill
10.Lifting Eye
11.GeneratorNameplate
12.Oil Fill
13.Low CoolantLevelShutdownSwitch
14.Governor
15. Inline Radiator
16.CoolantDrain
17.Oil Filter
18.Oil Drain
19.FuelFilter
20.EquipmentGround Location
21.FuelPump
22.FuelInletConnection Point
23.GlowPlug Relay
24.Oil LevelCheck
25.FuelSolenoid
26.LowOil PressureShutdownSwitch and Sender
27.BatteryCharging Alternator
28.WaterTemperatureSender
29.ExhaustOutlet
30.Lifting Eye
31.Starter
32.BeltGuard

TP-5648 8/93 Operation 2-1
Section 2. Operation
Toinsurecontinued satisfactoryoperation, the following
items shouldbechecked before eachstartup.
PrestartChecklist
OIL LEVEL:Should be atornearfull mark(notover).
AIRINLETS:Mustbe clearand unobstructed.
COMPARTMENT:Interiormustbe clean.Check the
condition of fuelsystem,exhaustpiping,hoses,and
muffler. If fuel leaks, fumes,exhaustgases,orelectrical
sparks are noted,contacta qualified servicetechnician
before operating generatorset.
AIR CLEANER:Mustbe clean and properlyinstalled to
preventunfiltered airfromentering the engine.
ELECTRICAL:All connections(including battery)must
be tight.
FUEL LEVELS:Makesurethe fueltank(s)arefull and
the fuelsystemprimed foroperation.
COOLING:If the cooling systemisequipped with a
coolantrecoverytank,check coolantlevel(and refill
coolantasnecessary)at tank.Maintainlevelaccording
tomarkingson the tank.Coolantlevelshould be just
belowthefillerneck[approx.3/4to11/2in.(19.38 mm)]
when the engine is cold.
BATTERY:Check connectionsand levelofbattery
electrolyte.
DRIVEBELTS:Checkradiatorfan,waterpump,andthe
battery charging belt tomakesureitisproperly
tensioned and in good condition.Exhaustgasmustbe
vented safelyoutside.
OPERATINGAREA:Makesurethere are no
obstructionsthatcould block the flowofcooling air.
Makesuretheareais clean.Rags, tools,ordebrismust
notbe left on ornearthe generatorset.
EXHAUSTSYSTEM:Exhaustoutletmustbe clear;
silencerand piping mustbe tightand in good condition.
Exhaustgasmustbe vented safelyoutside.
Exercising theGenerator
Run the generatorsetonce a weekforone hour (under
load).The operatorshould be in attendance during this
period.Besuretomake all “PrestartChecks”before
starting the exercise procedure.Start the generatorset
according tothe procedure given forthe generator
controller.

2-2Operation TP-5648 8/93
Manual ControllerOperation
The manualcontrollerisdesigned forprime power
applicationsand isused on the 10CCOZ-Mobile
dieselgenerator.Foridentification ofmanual
controllercomponentsand an explanation of their
function,refertoFigure 2-1 and the following
descriptions.
A-225296
1 2 3
5
6
7
89
10
11
12
13
4
Figure 2-1.Controller

TP-5648 8/93 Operation 2-3
Features
1.Frequency Metermeasuresfrequency (Hz)of
generatoroutputvoltage.
2.AC Voltmetermeasures voltage across output
leadsindicated bythe voltage toggleswitch.
3.AC Ammeter(L1Amps)measuresamperage
fromoutputlead L1.
4.AC Ammeter(L2Amps)measuresamperage
fromoutputlead L2.
5.Start-Stop/PreheatSwitchisused tostart, stop,
and preheat the generatorset. The
start-stop/preheatswitchservesadualfunctionof
generatoroperationandgeneratorpreheat.When
pressed tothe “preheat”position, the preheat
switch aidsincold-weatherstarting.Referto
“Starting”procedurefollowing.
6.FaultLampilluminatesduringengine shutdownif
the engine has shutdown due to high engine
temperature,lowoilpressure,lowwaterlevel,low
fuel level,oroverspeed faults.See “Fault
Shutdowns”following foradditionalshutdown
information.(Faultlampwill notstaylitafterunit
shutsdown.Faultlampwill onlylightasfault
occurs.Faultlampwillalsolightforanemergency
stop.)
7.VoltageToggleSwitchselectsthe Line 1 (L1)or
Line2(L2)outputvoltagestobemeasured.
8.10 Amp.Fuse protectsthe controllercircuitry
fromshortcircuitsand overloads.
9.Emergency Stop Switchinstantly shutsdown
the generatorsetin emergency situations.Reset
the switch afterthe shutdown byrotating the
switchclockwise.THE EMERGENCY STOP
SWITCH ISINTENDEDFOREMERGENCY
SHUTDOWNSONLY.Usethe generatorstop
switchtostop the setundernormal
circumstances.
10.WaterTemperatureindicatesengine coolant
temperature.
11.Oil Pressureindicatesengine oil pressure.
12.Hourmeterrecordsgeneratorset totaloperating
hoursfor referenceinscheduling maintenance.
13.DC Voltmeterindicates voltage ofbattery(ies).

2-4Operation TP-5648 8/93
Starting Procedure
The generatorisequippedwith a preheat feature.Place
controllerstartswitch(Figure 2-2)inSTOP/PREHEAT
position forthe amountof timeshowninFigure 2-3
before attempting tostart the generatorset. Thisaction
preheatsthe glowplugs.Do notenergize preheat
featureformorethan20secondsordamagemayoccur.
Movethe START-STOPswitch(Figure 2-2)intothe
STARTposition and holdinthisposition until the engine
isrunning, then release.Do notcrank engine
continuouslyformorethan10 seconds atatime.A
60-second cooldown period mustbe allowed between
cranking attemptsif the engine doesnotstart. If the unit
failstostartafterthree attempts contactan authorized
service dealer/distributorfor repair.Failuretofollow
these guidelinesmayresultin damage tothe starter
motor.
NOTE
Do notuse etheroranyotherstarting fluidto assistin
startingtheunitundercoldconditions.Thisisan indirect
fuel-injectedengineand severeenginedamage islikely.
A-225296
1
1.PreheatSwitch
Figure 2-2.PreheatSwitch Location
Ambient
TemperaturePreheating Time
Above 23_F(--5_C)Approx.5Seconds
Below23_F(--5_C)Approx.10 Seconds
LimitofContinuousUse 20 Seconds
Figure 2-3.Preheating Time
NOTE
If the engine startsand then stops,allowthe engine to
cometoacompletestop beforemaking a restart
attempt.Iftheflywheelringgearisstillrotatingwhenthe
starterpinion gearisengaged, the pinion gearwill clash
damaging the ring gearteeth.
Stopping Procedure
Wheneverpossible,allowa briefcooling period by
running the setatloworno load forafewminutesjust
priortoshutdown.Tostop,pushthe switchintothe
STOP/PREHEATposition. If the generatorsetshuts
down automatically,identifyand correct the problem
before attempting torestart.
NOTE
Do notplaceStart-Stop/PreheatSwitchin
STOP/PREHEATposition formorethan 20 secondsor
damage mayoccurtothe preheat feature.

TP-5648 8/93 Operation 2-5
CoolantSystemFilling
The low-profilecoolantsystemof the 10CCOZ-Mobile
generatorsetrequiresacoolantrecovery systemto
ensurethat the cooling systemremainsfull ofcoolant.
The systemalsorequiresthat the unitbe filled using
specialprecautionsto ensurethatitdoes,infact, get
filled withfluid beforethe unitisplaced intoservice.To
protectagainstoperation withlowcoolant, the unit
includesa Low CoolantLevel(LCL)switch.
Due tothe configuration of the systemand itsextremely
lowprofile,itisnecessarytofill the systemwithcoolant
VERY SLOWLYto allowairto escape fullyfromthe
radiatorand the engine block.Oncethe coolantsystem
seemstobefull,someairmay still remaintrapped inthe
system.Often,when the unithas started and runsfor
approximately10-15 minutesafterfilling,ashutdown
will be experienced orthe unitmay continue torun but
will notstartat the nextattempt. If eitherof these
conditionsoccur, the shutdownmaybe due tolow
coolantlevel inthe radiator.Asaremedyforthis,add
one totwocupsofcoolant tothe radiator.Besureto
connect the coolantrecoverytanktothe system,asitis
an integraland required partof the cooling system.
Oncethe radiatoristopped off, the coolantrecovery
systemwill replacethe lastsmall amountsofair,which
remaintrapped inthe cooling system,withcoolant.
Oftenalowcoolantleveloralowfuellevel isoverlooked
aspossiblecausesforashutdown.Anytimeaunitshuts
down,and no othercausecan be found,check foralow
fuelorlowcoolantlevelcondition.Removethe radiator
pressurecap fromthe engine very slowly. If the unitis
hot, itwill releasecoolantintothe recoverytank.
Atscheduled maintenanceintervals,check the coolant
whileitis coldinthe coolantrecoverytank,aswell asat
the pressurecap priortostarting the unit forits
maintenance.Ifitisnotcompletelyfull,add coolantat
therecoverytankandthe pressurecaptobringthelevel
toitsappropriatemark.