Kohler 15/20CCO Instruction Manual

RV/MobileGeneratorSets
Models:
15/20CCO
15/20CCFO
15/20CCOZ
15/20CCFOZ
TP-5605 4/97a
Operation and
Installation

Engine exhaust fromthisproductcontains
chemicals knowntotheState ofCaliforniatocause
cancer,birth defects,orother reproductive harm.
WARNING
CaliforniaProposition 65

TP-5605 4/97 Table ofContents
Table of Contents
SUBJECTPAGE SUBJECTPAGE
SafetyPrecautions and InstructionsI.......
Introduction i.............................
Service Assistance i.......................
Routine ServicePartsii....................
Section 1.Specifications 1-1.................
Introduction 1-1...............................
GeneralSpecifications1-1..................
Engine 1-2................................
Generator1-3.............................
GeneratorModels15/20 kW1-4.............
Section 2. Operation 2-1.....................
PrestartChecklist2-1.........................
Exercising the Generator2-1................
Controller (Single-Phase)2-2...................
Controller (Three-Phase)2-3...................
PreheatFeature 2-4...........................
Starting Procedure 2-4........................
Stopping Procedure 2-4.......................
FaultShutdowns2-4..........................
LowOil Pressure
ShutdownSwitch 2-4.....................
High WaterTemperature
ShutdownSwitch 2-5.....................
CircuitProtection 2-5..........................
Section 3.ScheduledMaintenance 3-1........
General3-1..................................
Lubrication System3-3........................
Oil Selection 3-3...........................
Oil Check 3-3..............................
Oil Change 3-4............................
Oil Filter3-5...............................
FuelSystem3-6..............................
Specification 3-6...........................
FuelFilter3-6.............................
Bleeding the FuelSystem3-7...............
FuelSolenoid 3-8..........................
AirCleanerService 3-8........................
Governor3-9.................................
Cooling System3-10...........................
BeltTension 3-12..............................
BatteryCharging 3-12..........................
Battery3-13...................................
Cleaning 3-13..............................
Checking Electrolyte Level3-14...............
Checking SpecificGravity3-14...............
Gauge ConnectionsforSingle-PhaseModels3-15.
Wattage Requirements3-16.....................
GeneratorService 3-17.........................
General3-17...............................
Storage Procedure 3-17........................
Section 4.Troubleshooting 4-1...............
Engine 4-1.................................
ElectricalSystem4-4........................
Generator4-4...............................
Section 5.Wiring Diagrams 5-1...............
Voltage Reconnection 5-1......................
Voltage Reconnection Procedure 5-2...........
12-Lead (Three-Phase)GeneratorSets5-3.....
Section 6. Installation 6-1....................
Introduction 6-1...............................
Features6-1..............................
GeneratorSelection And
Wattage Requirements6-2...................
Installation Factors6-2.....................
ElectricalLoad 6-2.........................
Lighting Load 6-2..........................
MotorLoads6-3...........................
Appliance Loads6-4........................
Kilowatt Derating 6-4.......................
CompartmentSize 6-4......................
AirRequirements6-6.......................
RemoteRadiatorCooling System6-9.........
FuelSystem6-13..............................
FuelLines6-14.............................
ExhaustSystems6-15..........................
ElectricalSystems6-17.........................
BatteryAnd Connections6-17................
ACLoad Lead Connections6-19..............
RemoteSwitchConnection
(Single-PhaseModelsOnly)6-20............
Section 7. Installation Drawings 7-1...........
AppendixA. GlossaryofAbbreviationsA-1....
AppendixB. Operating HourService Log B-1. .

TP-5605 4/97 SafetyPrecautionsand InstructionsI
Safety Precautions and Instructions
Ageneratorset, like anyotherelectromechanical
device,can pose potentialdangerstolife and limbif
improperlymaintained oroperated.The bestwayto
preventaccidentsisto be aware ofpotentialdangers
and actsafely.Pleaseread and followthe safety
precautionsand instructionsbelowto preventharmto
yourselfandothers.Thismanualcontainsseveraltypes
ofsafetyprecautionsand instructionswhich are
explained below.SAVE THESE INSTRUCTIONS.
DANGER
Dangerindicatesthe presence ofa hazardthatwill
causeseverepersonal injury,death,orsubstantial
propertydamage.
WARNING
Warning indicatesthe presence ofa hazardthatcan
causeseverepersonal injury,death,orsubstantial
propertydamage.
CAUTION
Caution indicatesthe presence ofa hazardthatwill or
can causeminorpersonal injuryorpropertydamage.
NOTICE
Noticecommunicatesinstallation,operation,or
maintenanceinformation thatisimportantbutnot
hazardrelated.
Safetydecalsaffixed tothe generatorsetin prominent
placesadvisethe operatororservicetechnician of
potentialhazardsand howto actsafely.The decalsare
reproduced inthispublication toimprove operator
recognition.Replacemissing ordamaged decals.
AccidentalStarting
Accidentalstarting.
Cancause severeinjuryordeath.
Disconnectbattery cablesbeforeworking on
generatorset(disconnectnegativelead firstand
reconnectitlast).
WARNING
Disabling generatorset.Accidentalstarting can
cause severeinjuryordeath.Disconnectbattery
cables(remove negativelead firstand reconnectitlast)
todisablegeneratorsetbeforeworkingonthegenerator
setorconnected equipment. The generatorsetcan be
started bythe remotestart/stop switch unless this
precaution isfollowed.
Battery
Sulfuric acidin batteries.
Cancause severeinjuryordeath.
Use protective gogglesand clothes.Batteryacidcan
cause permanentdamage to eyes,burnskin,and eat
holesinclothing.
WARNING
Battery acid.Sulfuric acidin batteries cancause
severeinjuryordeath.Sulfuricacidin battery can
cause permanentdamage to eyes,burnskin,and eat
holesinclothing.Always wearsplash-proofsafety
goggleswhenworking nearthebattery. If batteryacidis
splashed inthe eyesoron skin,immediatelyflushthe
affected area for15 minuteswithlarge quantitiesof
clean water.Seekimmediatemedicalaidinthe case of
eyecontact. Neveraddacidtoabatteryafterplacingthe
batteryinservice,asthismayresultin hazardous
spattering ofbatteryacid.

II SafetyPrecautionsand InstructionsTP-5605 4/97
Batterygases.Explosion cancause severeinjury
ordeath.Batterygases can cause an explosion.Do
notsmoke orpermit flame orsparkto occurneara
batteryatanytime,particularlywhen itis charging.
Avoidtouching terminalswithtools,etc., to prevent
burnsand sparks thatcouldcause an explosion.
Removewristwatch,rings,and anyotherjewelrybefore
handling battery.Neverconnectnegative(--) battery
cableto positive(+)connection terminalofstarter
solenoid.Do not testbattery condition by shorting
terminalstogether.Sparkscouldignite batterygasesor
fuelvapors.Ventilate any compartmentcontaining
batteriesto preventaccumulation ofexplosive gases.
To avoidsparks,do notdisturb battery charger
connectionswhilebatteryisbeingcharged.Alwaysturn
battery chargeroff before disconnecting battery
connections.Removenegativeleadfirstandreconnect
itlastwhen disconnecting battery.
EngineBackfire/Flash Fire
WARNING
Fire.
Cancause severeinjuryordeath.
Do notsmoke orpermit flame orsparkto occur
nearfuelorfuelsystem.
Servicingfuelsystem.Aflashfirecancausesevere
injuryordeath.Donotsmokeorpermitflameorspark
to occurnearcarburetor, fuel line, fuelfilter, fuelpump,
orotherpotentialsourcesofspilled fuelorfuelvapors.
Catch all fuel inasuitablecontainerwhen removingfuel
line orcarburetor.
Servicing aircleaner.Asudden backfire cancause
severeinjuryordeath.Donotoperatewithaircleaner
removed.
Exhaust System
WARNING
Carbon monoxide.
Cancause severenausea,fainting,ordeath.
The exhaustsystem mustbe leakproofand
routinelyinspected.
Generatorsetoperation.Carbon monoxide can
cause severenausea,fainting,ordeath.Never
operatethe generatorsetinside a building unless the
exhaustgasispiped safelyoutside.Neveroperatein
anyarea where exhaustgas could accumulate and
seep back inside a potentiallyoccupied building or
vehicle.Becarefulwhen parking yourvehicleto avoid
obstructingthe exhaustoutlet. Theexhaustgasesmust
discharge freelyto preventcarbon monoxide from
deflecting intothe vehicle.Avoid breathing exhaust
fumeswhen working on ornearthe generatorset.
Carbonmonoxideisparticularlydangerousbecauseitis
an odorless,colorless, tasteless,nonirritating gasthat
can cause deathifinhaled foreven a shortperiod of
time.
Carbon monoxide symptoms.Carbon monoxide
cancauseseverenausea,fainting,ordeath.Carbon
monoxide isa poisonousgaswhichispresentin
exhaustgases.Carbonmonoxide poisoning symptoms
include butare notlimited tothe following:
DLight-headedness,dizziness
DPhysicalfatigue,weakness injointsand muscles
DSleepiness,mentalfatigue,inabilitytoconcentrate
orspeak clearly,blurred vision
DStomachache,vomiting,nausea
If experiencing anyof thesesymptomsand carbon
monoxide poisoning ispossible,affected persons
shouldseekfresh airimmediately.They shouldremain
active.Theyshould notsit,liedown,orfall asleep.Alert
otherstothe possibilityofcarbon monoxide poisoning.
If the condition ofaffected personsdoesnotimprove
withinminutesofbreathing fresh air, they shouldseek
medicalattention.
Coppertubing exhaustsystems.Carbonmonoxide
cancause severenausea,fainting,ordeath.Do not
usecoppertubing in dieselexhaustsystems.Sulfurin
dieselexhaustcausesrapid deterioration ofcopper
tubing exhaustsystemsresulting in exhaustleakage.

TP-5605 4/97 SafetyPrecautionsand InstructionsIII
Installing exhaust tail pipe.Carbon monoxide can
cause severenausea,fainting,ordeath.Install
exhaustsystemtail pipe so discharged exhaustgases
will notbe drawnintovehicleinteriorthrough windows,
doors,airconditioners,etc.Do notuseflexibletail
piping becauseitcouldcrack and allowlethalexhaust
fumesto enterthe vehicle.
Inspecting exhaustsystem.Carbon monoxide can
cause severenausea,fainting,ordeath.In addition
toroutine exhaustsysteminspection,install acarbon
monoxide detector.Consultyourcoach builderor
dealerforapproved detectorinstallation. Inspectyour
detectorbefore each generatorsetuse.
FuelSystem
Explosive fuelvapors.
Cancause severeinjuryordeath.
Useextremecarewhen handling,storing,
and using fuels.
WARNING
Fuelsystem.Explosive fuelvapors cancause
severeinjuryordeath.Allfuelsarehighlyexplosivein
avaporstate.Use extremecarewhen handling and
storing fuels.Storefuel in a well-ventilated area away
fromspark-producingequipmentandoutofthe reachof
children.Neveradd fueltothe tankwhilethe engine is
running sincespilled fuelmayignite on contactwith hot
partsorfromignition spark.Do notsmoke orpermit
flame orsparkto occurnearsourcesofspilled fuelor
fuelvapors.Keepfuel linesandconnectionstightandin
good condition.Do notreplaceflexiblefuel lineswith
rigidlines.Useflexiblesectionsto avoid breakage
causedby vibration.Donotoperategeneratorsetinthe
presence of fuel leaks, fuelaccumulation,orsparks.
Repairsystemsbeforeresuming generatorset
operation
Draining fuelsystem.Explosive fuelvapors can
cause severeinjuryordeath.Spilled fuelcan cause
an explosion.Use a containertocatchfuelwhen
draining fuelsystem.Wipe up all spilled fuelafter
draining system.
HazardousNoise
Hazardousnoise.
Cancause loss ofhearing.
Neveroperate generatorsetwithoutamuffleror
withafaultyexhaustsystem.
CAUTION
HazardousVoltage/
ElectricalShock
WARNING
Hazardous voltage.Moving rotor.
Cancause severeinjuryordeath.
Operate generatorsetonlywith all guardsand
electricalenclosuresin place.
WARNING
Hazardous voltage.
Backfeedto utility systemcancause severe
injury,death,orpropertydamage.
Connectgeneratorsetto building electricalsystem
onlythroughanapproveddeviceand afterbuilding
mainswitchisopen.
Grounding generatorset.Hazardous voltage can
cause severeinjuryordeath.Electrocution is
possiblewheneverelectricityispresent. Open main
circuitbreakersofall powersourcesbeforeservicing
equipment. Configurethe installation to electrically
ground the generatorsetand electricalcircuitswhen in
use.Nevercontactelectrical leadsorapplianceswhen
standing inwateroron wetground,asthe chance of
electrocution isincreased undersuchconditions.

IV SafetyPrecautionsand InstructionsTP-5605 4/97
Shortcircuits.Hazardousvoltage cancausesevere
injuryordeath.Shortcircuits can cause bodilyinjury
and/orequipmentdamage.Do notcontactelectrical
connectionswithtoolsorjewelrywhile adjustmentsare
made.Removewristwatch,rings,and jewelrybefore
servicing equipment.
Engineblock heater.Hazardous voltage cancause
severeinjuryordeath.Engineblockheatercancause
electricalshock.Removeengineblockheaterplugfrom
electricaloutletbeforeworkingonblockheaterelectrical
connections.
Electricalbackfeedto utility.Hazardousbackfeed
voltage cancause severeinjuryordeath.Connect
generatorset to building/campground electricalsystem
onlythrough an approved device and after
building/campground mainswitchisopen.Backfeed
connections can causeseriousinjuryordeathto utility
personnelworking on powerlinesand/orpersonnel in
thevicinityoftheworkarea.Unauthorizedconnectionto
utilityelectricalsystem maybe unlawful insomestates
and/orlocalities. Install atransferswitchto prevent
interconnection ofgeneratorsetpowerand other
sourcesofpower.
Heavy Equipment
Unbalancedweight.
Improperlift cancause severeinjuryordeath
and/orequipmentdamage.
Do notuselifting eyes.
Useslingsunderskidto balance and lift generator
set.
WARNING
HotParts
WARNING
Hotcoolantand steam.
Cancause severeinjuryordeath.
Beforeremoving pressurecap,stop generatorset
and allowit tocool.Then loosen pressurecap to
relieve pressure.
WARNING
Hotengine and exhaustsystem.
Cancause severeinjuryordeath.
Do notworkon generatorsetuntil itisallowed to
cool.
Checking coolantlevel. Hotcoolantcancause
severeinjuryordeath.Allowengine tocool.Release
pressurefromcooling systembefore opening pressure
cap.Torelease pressure,coverthe pressurecap witha
thick cloth; then slowlyturnitcounterclockwisetothe
firststop.Removecap afterpressure hasbeen
completelyreleased and the engine has cooled.Check
coolantlevelat tankifgeneratorsetisequipped with a
coolantrecoverytank.
Servicing exhaustsystem.Hotparts cancause
severeinjuryordeath.Do not touch hotengine parts.
An engine becomeshotwhilerunning and exhaust
systemcomponentsbecome extremelyhot.
Combustiblematerials.Fire cancause severe
injuryordeath.Hotexhaustsystemcan ignite
adjacentcombustiblematerials.Donotlocate electrical
wiring, fuel lines,orcombustiblematerialabovethe
exhaustmuffler.Exercisecaution when parking your
vehicleto preventexhaustsystemand hotexhaust
gasesfromstarting grass fires.

TP-5605 4/97 SafetyPrecautionsand InstructionsV
Combustiblematerials.Fire cancause severe
injuryordeath.Hotgeneratorsetcan ignite debrisin
compartment. Keep the compartmentand generator
setcleanandfreeofdebrisandcombustiblematerialsto
minimize possibilityof fire.Do notblock fuel/oil drain
opening in generatorsetmounting tray.Cuta
corresponding holeinthe subfloorfordrain opening if
subfloorisused.
Moving Parts
WARNING
Hazardous voltage.Moving rotor.
Cancause severeinjuryordeath.
Operate generatorsetonlywith all guardsand
electricalenclosuresin place.
WARNING
Rotating parts.
Cancause severeinjuryordeath.
Do notoperate generatorsetwithoutall guards,
screens,and coversin place.
Tightening hardware.Flying projectiles cancause
severeinjuryordeath.Retorque all crankshaft and
rotorhardwareafterservicing.Donotloosencrankshaft
hardware or rotorthruboltwhen making adjustmentsor
servicinggeneratorset. Rotatecrankshaftmanuallyina
clockwisedirectiononly.Turningcrankshaftboltorrotor
thruboltcounterclockwisecan loosen hardware.Loose
hardwarecan cause hardware orpulleytoreleasefrom
engine ofgeneratorsetand can cause personal injury.
Servicing generatorsetwhen operating.Exposed
moving parts cancause severeinjuryordeath.
Keep hands, feet, hair,clothing,and testleadsaway
frombeltsand pulleys when generatorsetisrunning.
Replace guards,screens,and coversbefore operating
generatorset.
Notice
NOTICE
Thisgeneratorsethas beenrewiredfromits
nameplate voltageto:
246242
NOTICE
Voltagereconnection!Affixnoticeto generatorset
after reconnecting to a voltage different than the
nameplate.Ordervoltage reconnection decal246242
fromauthorized service distributors/dealers.
NOTICE
Hardwaredamage!Engineand generatorsetmayuse
bothAmerican Standard and metrichardware.Usethe
correctsizetoolsto preventrounding ofboltheadsand
nuts.
NOTICE
Whenreplacing hardware,do notsubstitutewith
inferiorgradehardware.Screwsand nutsare
availablein differenthardness ratings.American
Standard hardware usesaseriesofmarkingsand
metrichardware usesa numeric systemtoindicate
hardness.Check markingson bolthead and nutsfor
identification.
NOTICE
Canadianinstallationsonly:
Forstandbyserviceconnectoutputofgeneratorsettoa
suitablyrated transferswitchin accordancewith
Canadian ElectricalCode,Part1.
NOTICE
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 tobeignition protected when used in a
gasoline-fueled environment.

VISafetyPrecautionsand InstructionsTP-5605 4/97
Notes

TP-5605 4/97 Introduction i
Introduction
All information inthispublication representsdata
available at time ofprinting.KohlerCo.reservesthe
right tochange thisliterature and the products
represented withoutincurring obligation.
Read through thismanualand carefullyfollowall
proceduresand safetyprecautionsto ensure proper
equipmentoperation and to avoid bodilyinjury.Read
and followthe SafetyPrecautionsand Instructions
section at the beginning of thismanual.Keep this
manualwith equipment forfuturereference.
Equipmentservicerequirementsareminimalbutare
veryimportant tosafe and efficientoperation; therefore,
inspectpartsoften and performrequired service at the
prescribed intervals.An authorized service
distributor/dealershould performrequired serviceto
keep equipmentintop condition.
Service Assistance
Forsalesand serviceinthe U.S.A.and Canada check
the yellowpagesof the telephone directoryunderthe
headingGENERATORS—ELECTRICforanauthorized
service distributor/dealerorcall 1-800-544-2444.
Forsalesand service outside the U.S.A.and Canada,
contactyourlocaldistributor.
Forfurtherinformation orquestions,contact the
companydirectlyat the following address ornumber:
KOHLER CO., Kohler,Wisconsin 53044 U.S.A.
Phone:[phone]
Fax:[phone] (U.S.A.Sales)
414-459-1614 (International)
To ensuresupplyofcorrectpartsorinformation,make
note of the following identification numbersinthe
spacesprovided:
G
E
N
E
R
A
T
O
R
S
E
T
ModelNo.
Specification No.
SerialNo.
MODEL,SPEC,andSERIALnumbersarefoundonthe
nameplate attached tothe generatorset.
AccessoryNos.
G
E
N
E
R
A
T
O
R
S
E
T
A
C
C
E
S
S
O
R
I
E
S
An alternate nameplateinside the junction box
identifiesfactory-installed generatorsetaccessories.
E
N
G
I
N
E
Engine SerialNo.
The engine serialnumberisfound on the engine
nameplate.

ii Introduction TP-5605 4/97
RoutineService Parts
Kohlergeneratordistributor/dealershaveacomplete
listing ofpartsforeach generatorset. Contact the local
Kohlergeneratordistributor/dealerforservice.
PartDecsription KohlerPartNo.
Aircleanerelement258646
Oil filter229841
Fuelfilter225010
AlternatorV-belt225626
Black spraypaint221292

TP-5605 4/97 Specifications1-1
Section 1. Specifications
Introduction
Yourvehicleisequipped with a dependableKohler
alternating-currentRV/MobileGeneratorSet. Service
requirementsof the generatorsetareminimal,butitis
importantthattherequiredservicesbeperformed atthe
prescribed intervals.Pleasetake a fewmomentsto
read through thismanual; then carefullyfollowall
servicerecommendationstokeep yoursetintop
condition. Inthe space provided,recordthe MODEL,
SPECIFICATION,SERIAL and ENGINE SPEC.
numbersasfoundonthenameplateattachedtothebelt
guard of the engine for remote-radiatormodelsand on
the radiatorbracket forin-line radiatormodels(see
Section8“ServiceOrdering Instructions”).This
information will enableyourKohlerGeneratorService
Dealer/Distributortosupplythe correctpartordatafor
yourparticularversion.Keepthismanualinyourvehicle
forfuturereference.The illustrationsinthismanualare
representative ofmostunits.Yourgeneratorsetmay
differslightlyfromthoseshown.
GeneralSpecifications
15 kW(60Hz)20 kW(60Hz)
DimensionsLxWxHin.(mm):
RemoteRadiator (SinglePhase)39.57 x20.89 x25.61 39.57 x20.89 x27.25.......................... ........
(1005 x531 x650) (1005 x531 x692)
RemoteRadiator (SinglePhase)Airbag Mounted 39.57 x22.00 x25.61 39.57 x22.00 x28.51............ ........
(1005 x559 x650) (1005 x559 x724)
In-line Radiator (SinglePhase)45.02 x20.99 x28.00 45.02 x20.99 x28.00........................... ........
(1144 x533 x711) (1144 x533 x711)
In-line Radiator (Three Phase)46.62 x20.99 x28.00 46.62 x20.99 x28.00............................ ........
(1184 x533 x711) (1184 x533 x711)
Weight—dry,lbs.(kg):
RemoteRadiator (SinglePhase)684 (310)695 (315)............................... ..................
RemoteRadiator (SinglePhase)Airbag Mounted N/AN/A.................... ........................
In-line Radiator (SinglePhase)719 (326)730 (331)................................ ..................
In-line Radiator (Three Phase)719 (326)730 (331)................................. ..................
AirRequirementsCFM(M3/min):
Combustion.70 (2)70 (2).................................................. ......................
Cooling 1930 (55)1930 (55).................................................... ..................
FuelInletSizein.(mm)1/4-18 N.P.S.F1/4-18 N.P.S.F......................................... ..............
FuelReturnSizein.(mm)1/4-18 N.P.S.F1/4-18 N.P.S.F....................................... ..............
FuelConsumption gph (Lph):
Load 25%50%75%100%
15 kW0.6(2.3)0.8(3.0)1.1(4.2)1.4(5.3)
20 kW0.9(3.4)1.2(4.5)1.5(5.7)1.9(7.2)
DERATION:All unitsarerated 1.0 powerfactor.The kilowattsof the generatorsetwill decrease 3.5%foreach 1,000 feet(305 meters)above
500 feet(152 meters)abovesea leveland 1%foreach 10_F(5.5_C)above 85_F(30_C).

TP-5605 4/971-2Specifications
Engine
Some generalengine specificationsarelisted below.
Refertothe appropriateservicesection and the engine
servicemanualforspecific service details.15 kW20 kW
ManufacturerYanmar..............................................................
Model4TN84E-RK4TN84TE-TK.......................................... ...................................
Type Water-cooled,4-cycle dieselengine..........................................................
NumberCylinders4.............................................................
Firing Order1-3-4-2 1-3-4-2....................................... .......................................
Compression Ratio 17.79:1 16.99:1................................ .......................................
Displacementcu.in.(cm3)116 (1910)..................................................
Rated Horsepower (60 Hz)27.4 36.3........................... ..........................................
RPM(60 Hz)1800................................................................
Borein.(mm)3.307 (84).............................................................
Strokein.(mm)3.386 (86)............................................................
Combustion SystemDirect Injection.....................................................
ValveClearancein.(mm)
Intake 0.0079 (0.2)..............................................................
Exhaust0.0079 (0.2)............................................................
CylinderBlock MaterialCast Iron.....................................................
CylinderHead 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).........................................................
CylinderHead MaterialCast Iron.....................................................
Connecting Rod Forged Carbon Steel......................................................
Piston Rings2Compression/1Oil..........................................................
MainBearings,Numberand Type 4,ReplaceableSleeves......................................
GovernorMechanical................................................................
Lubrication SystemFull Pressure.......................................................
Oil Capacity(withfilter) qts.(L)6.1(5.8)...............................................
Oil Type (API)CC orCD.............................................................
Oil Pressure psi(kPa)42.66--56.88 (294--392)................................................
FuelRecommendation Diesel—ASTMD975 No.2-D(Cetane No.>45).....................................
Aspiration NaturalAspiration Turbocharged................................... ................................
FuelInjection PumpYanmarYPES......................................................
BatteryVoltage 12...............................................................
BatteryGround Negative.............................................................
BatteryRecommendation (min.)625 ColdCranking Amps100 AmpHr..................................
StarterMotorBendixAutomotiveType........................................................
Cooling SystemCapacityqts.(L)
RemoteRadiator (Engine WaterJacket)2.85 (2.7)..................................
In-line Radiator4 qts.16 oz.(4.26)...................................................
Timing 16_±1_12_±1_.......................................... .....................................
AirCleanerDryPaperElement...........................................................

TP-5605 4/97 Specifications1-3
Generator
Models 15CCO/CCFO/CCOZ/CCFOZ
ModelVoltageAmps/
Series CodeVoltageWirePole kW PH
60 HzModels:
15CCO61 120/240 3 62.5 15.0 1
15CCO101 100/200 3 75.0 15.0 1
15CCOZ01 120/240 4 45.1 15.0 3
15CCOZ51 139/240 4 45.1 15.0 3
15CCOZ51 127/220 4 49.2 15.0 3
15CCOZ71 227/480 4 22.6 15.0 3
15CCOZ71 240/416 4 26.0 15.0 3
15CCOZ81 120/208 4 52.0 15.0 3
50 HzModels:
15CCFO101 120/240 3 52.1 12.5 1
15CCFO61 110/220 3 56.8 12.5 1
15CCFO11 100/200 3 62.5 12.5 1
15CCFO41 220 2 56.8 12.5 1
15CCFOZ51 110/190 4 47.5 12.5 3
15CCFOZ51 115/200 4 45.1 12.5 3
15CCFOZ71 220/380 4 23.7 12.5 3
15CCFOZ71 230/400 4 22.6 12.5 3
15CCFOZ71 240/416 4 21.7 12.5 3
15CCFOZ81 120/208 4 43.4 12.5 3
15CCFOZ81 110/220 4 41.0 12.5 3
Models 20CCO/CCFO/CCOZ/CCFOZ
ModelVoltageAmps/
Series CodeVoltageWirePole kW PH
60 HzModels:
20CCO61 120/240 3 83.3 20.0 1
20CCO101 100/200 3 100.0 20.0 1
20CCOZ01 120/240 4 60.1 20.0 3
20CCOZ51 139/240 4 60.1 20.0 3
20CCOZ51 127/220 4 65.6 20.0 3
20CCOZ71 227/480 4 30.1 20.0 3
20CCOZ71 240/416 4 34.7 20.0 3
20CCOZ81 120/208 4 69.4 20.0 3
50 HzModels:
20CCFO101 120/240 3 69.4 16.5 1
20CCFO61 110/220 3 75.8 16.5 1
20CCFO11 100/200 3 83.3 16.5 1
20CCFO41 220 2 75.8 16.5 1
20CCFOZ51 110/190 4 63.3 16.5 3
20CCFOZ51 115/200 4 60.1 16.5 3
20CCFOZ71 220/380 4 31.7 16.5 3
20CCFOZ71 230/400 4 30.1 16.5 3
20CCFOZ71 240/416 4 28.9 16.5 3
20CCFOZ81 120/208 4 57.8 16.5 3
20CCFOZ81 110/220 4 54.7 16.5 3

TP-5605 4/971-4Specifications
GeneratorModels 15/20 kW
Single-Phase ModelsThree-Phase Models
RPM(60-HzModels)1800 1800.............................. ..........................................
RPM(50-HzModels)1500 1500.............................. ..........................................
15 kW:
StatorResistance(ohms)** Leads:
1-2,3-4,33-44 0.07 N/A............................... ...........................................
55-33 1.3N/A....................................... ...........................................
B1-B2 0.06 N/A....................................... ...........................................
RotorResistance(ohms)3.0N/A.......................... ...........................................
20 kW:
StatorResistance(ohms)** Leads:
1-2,3-4,33-44 0.07 N/A............................... ...........................................
55-33 1.3N/A....................................... ...........................................
B1-B2 0.06 N/A....................................... ...........................................
RotorResistance(ohms)3.0N/A.......................... ...........................................
Excitation Method StaticExcited Rotating Exciter............................ .................................
OverboltTorque 25 ft. lbs.(300 in.lbs.)..................................................
Voltage RegulatorType PowerBoostäIIIE PowerBoostäV...................... ...............................
Insulation (Rotorand Stator) Class 155,Epoxy Varnish,VacuumImpregnated...........................
Winding MaterialCopper.......................................................
Bearing (Numberand Type)1,ReplaceableBall.........................................
CircuitProtection:
Controller10-AmpFuse 10-AmpCircuitBreaker................................ ..............................
OptionalACOutputManual-ResetCircuitBreaker........................................
Voltage Regulator10-AmpFuseN/A......................... .......................................
FuelSolenoid 10-AmpFuse....................................................
** Mostohmmeterswill notgive accuratereadingswhen measuring less than 1 ohm.The statorcan be considered
good ifalowresistancereading (continuity)isobtained and thereisno evidence ofshorted windings
(discoloration).Do notconfusealowresistancereading withareading indicatingashorted winding.

TP-5605 4/97 Specifications1-5
1-933
1
2
3
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10 11 12 13 14
15 16 17
18
19
20
21
22
2324
25
26
27
28
29
30
31 32
33
34
1.OptionalACcircuitbreaker
2.Voltage regulatorfuse
3.Start-stop/preheatswitch
4.Fuelsolenoidfuse
5.Controllerfuse
6.Hourmeter
7.Controller
8.Remoteconnection (atrearofcontroller)
9.Aircleaner
10.Lifting eye
11. Intake heater
12.Fuelsolenoid
13.Oil fill
14.Lifting eye
15.High watertemperatureshutdown
16.Coolantinlet
17.Oil fill
18.Generatornameplate
19.Mechanicalgovernor
20.Oil filter
21.Fuelfilter
22.Ground connection
23.Oil drain
24.Fuelpump
25.Fuel inletconnection point
26.Fuelreturnconnection point
27.Oil check
28.Heatercoil relay
29.Lowoil pressureshutdown
30.Voltage regulator
(inside junction/circuitbreakerbox)
31.Coolantoutlet
32.Exhaustoutlet
33.Battery charging alternator (behind guard)
34.Starter
Figure 1-1.Service Viewof20CCORVwithRemoteRadiator(Typical)

TP-5605 4/971-6Specifications
1-933
1
2
3
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10 11 12 13 14 15 16
17
18
19
20
21
22
23
24
25
26
27
28
2930
31
32
33
34
35
1.OptionalACcircuitbreaker
2.Voltage regulatorfuse
3.Start-stop/preheatswitch
4.Fuelsolenoidfuse
5.Controllerfuse
6.Hourmeter
7.Controller
8.Remoteconnection (atrearofcontroller)
9.Aircleaner
10.Lifting eye
11. Intake heater
12.Fuelsolenoid
13.Oil fill
14.Lifting eye
15.High watertemperatureshutdown
16.Pressurecap/initialcoolant fill
17.Generatornameplate
18.Oil fill
19. In-line radiator
20.Mechanicalgovernor
21.Oil filter
22.Coolantdrain
23.Ground connection
24.Oil drain
25.Fuel inletconnection point
26.Fuelpump
27.Fuelreturnconnection point
28.Oil check
29.Fuelfilter
30.Heatercoil relay
31.Lowoil pressureshutdown
32.Voltage regulator
(inside junction/circuitbreakerbox)
33.Exhaustoutlet
34.Batterychargingalternator(behindguardonnon-servicesideof
unit)
35.Starter (on non-serviceside ofunit)
Figure 1-2.Service Viewof20CCORVIn-lineRadiator(Typical)

TP-5605 4/97 Operation 2-1
Section 2. Operation
To ensurecontinued satisfactoryoperation,check the
following itemsbefore eachstartup and atregular
intervals.
PrestartChecklist
AirCleaner.Keep aircleanerelementclean. Install
element tokeep unfiltered airfromentering engine.
AirShrouding.Keep tightand in position.
AirInlets.Keep clean and unobstructed.
Battery.Ensuretightbattery connections.Maintainfull
batteryelectrolytelevel.
CoolantLevel. Forcooling systemsequipped with a
coolantrecoverytank,check coolantlevelat tankafter
the engine has cooled.
Maintaincoolantlevel justbelowthe fillerneck,
approximately3/4to11/2in.(19 to33mm).
Acoolantsolution of50%ethylene glycolprovides
freezing protection of--34°F(--37°C)and overheating
protectionto265°F(129°C).Acoolantsolutionwithless
than 50%ethylene glycolmaynotprovide adequate
freezing and overheating protection.Acoolantsolution
withmorethan50%ethyleneglycolcancauseengineor
componentdamage.Do notuse alcoholormethanol
antifreeze ormixthemwiththe specified coolant.
Consulttheengine manufacturer’soperationmanualfor
engine coolantspecifications.
Donotaddcoolanttoahotengine.Waituntilenginehas
cooled.Adding coolant to a hotengine can causethe
cylinderblock orcylinderhead tocrack.
NOTE
Do notenergize block heaterbeforefilling cooling
system.Beforeenergizingblockheater,runengineuntil
itiswarmandrefillradiatortopurgeairfromthesystem.
Immerse heaterelementincoolant to preventblock
heaterfailure.
Drive Belts.Check beltcondition and tension of
radiatorfan,waterpump,and battery charging
alternatorbelt(s).
ExhaustSystem.Keep exhaustoutletclear.Keep
mufflerand piping tightand in good condition.
FuelLevel. Keep tank(s)full to ensure adequatefuel
supply.
Oil Level. Maintain oil levelatornearfull markon
dipstickbutnotover.Keeptheoillevelinthemechanical
governor (ifequipped)atornearthe full level.
Operating Area.Check forobstructionsthatcould
block the flowofcooling air.Keep the airintake area
clean.Do notleaverags, tools,ordebrison ornearthe
generatorset.
Exercising theGenerator
Run the generatorsetunderload once eachweekfor
one hourwith an operatorpresent.
Operatorshould performall prestartchecks before
startingtheexerciseprocedure.Whilethegeneratorset
isrunning,listen forasmooth-running engine and
visuallyinspect the generatorset to ensurethere areno
fluid orexhaustleaks.
Start the generatorsetaccording tothe starting
procedureinthe controllersection of thismanual.

TP-5605 4/972-2Operation
Controller(Single-Phase)
Depending on application, the Kohler relay controller
maybelocatedatthesetoratalocationremotefromthe
generator.Remote harnessesforthe controllerare
availablein 7.5-and 15-foot(2.3-and 4.6-meter)
lengths. If the generatorsethasautomatically stopped
because ofhigh watertemperature(230_F/110_C)or
lowoil pressure(6.8 psi/46.9kPa orless),correct the
cause beforerestarting the set.
RefertoFigure 2-1 orFigure 2-2 and the following
descriptionstoidentify controllercomponents.
GeneratorStartand Stop/PreheatSwitch.Switch
servesthe dualfunction ofgeneratoroperation and
generatorpreheat. When pressed tothe preheat
position, the preheatswitch aidsincoldweather
starting.RefertoStart/Stopand Preheatingprocedures
following.
FuelSolenoid Fuse.10-ampfuse protectsfuel
solenoidcircuitry.
ControllerFuse.10-ampfuse protects controller
circuitryagainstdamage ifashortdevelopsinthe
engine wiring systemorthe wiring tothe remote
start/stop switch.
RemoteSwitchConnection (located atrearof
controller).Connect the remotestart/stop switchto
operatethe generatorsetatalocation remotefromthe
set. Controllerconnectionsaremade through the plug
connectorat the rearof the unit.
Hourmeter.Meterrecordstotalgeneratorsetoperating
hoursfor referenceinmaintenanceschedule.
DC CircuitBreaker.Circuitbreakershutsdownthe
generatorsetautomaticallyafterfault. See Circuit
Protection following.
AC CircuitBreaker(optional).Circuitbreakertrips
when a faultisdetected inthe outputcircuit. Used to
disconnectgeneratorsetduring maintenance on
vehiclewiring.Toclosecircuitbreaker(s),placebreaker
inONposition.
1-932
1 2 3 45
1.Generatorstartand stop/preheatswitch
2.Fuelsolenoidfuse
3.Controllerfuse
4.Remoteswitchconnection
5.Hourmeter
Figure 2-1.Single-Phase Controller
1
2 3 4
A-229301-L
5
1.Generatorstartand stop/preheatswitch
2.Hourmeter
3.DC circuitbreaker
4.Remoteswitchconnection
5.ACcircuitbreaker
Figure 2-2.Single-Phase Controller
(spec PA-135322)

TP-5605 4/97 Operation 2-3
Controller(Three-Phase)
Foridentification of three-phasecontroller,see
Figure 2-3.
1-932
1
2345
1.Generatorstartand stop preheatswitch
2.DC circuitbreaker
3.Hourmeter
4.ACcircuitbreaker
5.Fuelsolenoidfuse
Figure 2-3.Three-Phase Controller
GeneratorStartand Stop PreheatSwitchservesthe
dualfunction ofgeneratoroperation and generator
preheat. When pressed tothe preheatposition, the
preheatswitch aidsincoldweatherstarting.Referto
Start/Stop and Preheating proceduresfollowing.
DC CircuitBreakertripswhen a faultisdetected inthe
DC circuitry.The generatorsetshutsdown
automaticallyafterfault. See CircuitProtection
following.
Hourmeterrecordstotalgeneratorsetoperating hours
for referenceinmaintenanceschedule.
AC CircuitBreaker(optional)tripswhen a faultis
detected inthe outputcircuit. Used to disconnect
generatorsetduring maintenance ofvehiclewiring.To
closecircuitbreaker(s),placeinONposition.
FuelSolenoid Fuse (located inside the controller).
10-ampfuse protectsfuelsolenoidcircuitry.