Kohler 7CCO Specification sheet

Operation and
Installation Manual
RV/MobileGenerator Sets
Models:
7CCO
7CCFO
7CCOZ
7CCFOZ
10CCO
10CCFO
10CCOZ
10CCFOZ
TP-5594 5/95

TT-5594 5/95 Table ofContents
TableofContents
SUBJECTPAGE SUBJECTPAGE
SafetyPrecautions and InstructionsI......
Introduction i............................
Service Assistance i......................
RoutineService Partsii...................
Section 1.Specifications 1-1................
GeneralSpecifications1-1....................
Engine 1-2..................................
Generator1-3...............................
Generator Models7/10 kW1-4................
ServiceView Components
Remote-Radiator Model1-6.................
ServiceView Components
Inline-Radiator Model1-8...................
Section 2. Operation 2-1....................
PrestartChecklist2-1........................
Exercising the Generator2-1..................
Controller (SinglePhase)2-2..................
Controller (Three Phase)2-2..................
Starting Procedure 2-3.......................
Stopping Procedure 2-3......................
FaultShutdowns2-4.........................
LowOil PressureShutdownSwitch 2-4.........
High WaterTemperatureShutdownSwitch 2-4...
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.............................
FuelFilter (MetalSpin-OnType)3-6............
FuelFilter (PlasticIn-Line Type
Supplied Loose)3-7........................
Bleeding the FuelSystem3-7.................
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 Connections3-15......................
Wattage Requirements3-17....................
GeneratorService 3-18........................
General3-18.................................
Storage Procedure 3-18.......................
Section 4.Troubleshooting 4-1..............
Engine 4-1..................................
ElectricalSystem4-5.........................
Generator4-6...............................
Section 5.Wiring Diagrams 5-1..............
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 System6-13...........
FuelSystem6-17.............................
FuelLines6-18...............................
ExhaustSystems6-19.........................
ElectricalSystems6-21........................
BatteryAnd Connections6-21..................
ACLoad Lead Connections6-23................
RemoteSwitchConnection
(Single-PhaseModelsOnly)6-24..............
Section 7. Installation Drawings 7-1..........
AppendixA. GlossaryofAbbreviationsA-1...
AppendixB..Operating Hour
Service Log B-1...........................

TP-5594 5/95 SafetyPrecautionsand InstructionsI
Safety Precautions and Instructions
Ageneratorset, like anyotherelectromechanical
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 tothe operation ofa generatorset
follow.Belowaresome generalprecautionsrelating to
the operation ofa generatorset. SAVE THESE
INSTRUCTIONS.
DANGER
Dangerindicatesthe presence ofa hazardthatwill
causeseverepersonal injury,death,orsubstantial
propertydamage if the dangerisignored.
WARNING
Warning indicatesthe presence ofa hazardthatcan
causeseverepersonal injury,death,orsubstantial
propertydamage if the warning isignored.
CAUTION
Caution indicatesthe presence ofa hazardthatwill or
can causeminorpersonal injuryorpropertydamage if
the caution isignored.
NOTE
Notecommunicatesinstallation,operation,or
maintenanceinformation thatisimportantbutnot
hazardrelated.
Safetydecalsare affixed tothe generatorsetin
prominentplacesto advisethe operatororservice
technician ofpotentialhazards.The decalsare
reproduced heretoimprove operator recognition.Fora
furtherexplanation ofdecal information,refertothe
safetyprecautionsthroughout thismanual.Before
operating orservicing the generatorset, be sureyou
understand the messagesof these decals.Replace
decalsifmissing ordamaged.

II SafetyPrecautionsand InstructionsTP-5594 5/95
AccidentalStarting
Accidentalstarting.
Cancause severeinjuryordeath.
Disconnectbattery cablesbeforeworking on
generatorset(negativelead firstand reconnectit
last).
WARNING
Accidentalstarting cancause severeinjuryor
death.Disconnectbattery cables(remove negative
lead firstand reconnectitlast)to disable generatorset
beforeworking on anyequipmentconnected to
generatorset. The generatorsetcan be started bythe
remotestart/stop switch unless thisprecaution is
followed.
Battery
Sulfuric acidin batteries.
Cancause severeinjuryordeath.
Use protective gogglesand clothes.Batteryacidcan
cause permanentdamage to eyes,burnskin,and eat
holesinclothing.
WARNING
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.Seek
immediatemedicalaidinthecaseofeyecontact. Never
addacidtoabatteryoncethebatteryhasbeenplacedin
service.Thismayresultin hazardous spattering of
electrolyte.
Explosioncancausesevereinjuryordeath.Battery
gases can cause an explosion.Do notsmoke orpermit
flame orsparkto occurneara batteryatanytime,
particularlywhen itisbeing charged.Avoidcontacting
terminalswithtools,etc., to preventburnsand sparks
thatcouldcause an explosion.Removewristwatch,
rings,and anyotherjewelrybefore handling battery.
Neverconnectnegative(--) battery cableto positive(+)
connection terminalofstartersolenoid.Do not test
batterycondition by shorting terminalstogether.Sparks
couldignite batterygasesorfuelvapors.Ventilate any
compartmentcontaining batteriesto prevent
accumulation ofexplosive gases.To avoidsparks,do
notdisturb battery chargerconnectionswhile batteryis
being changed.Always turn battery chargeroff before
disconnecting battery connections.Remove negative
lead firstand reconnectitlastwhen disconnecting
battery.
EngineBackfire/Flash Fire
WARNING
Fire.
Cancause severeinjuryordeath.
Do notsmoke orpermit flame orsparkto occur
nearfuelorfuelsystem.
Aflashfire cancause severeinjuryordeath.Do
notsmoke orpermit flame orsparkto occurnear
carburetor, fuel line, fuelfilter, fuelpump,orother
potentialsourcesofspilled fuelorfuelvapors.Use a
suitablecontainertocatch all fuelwhen removing fuel
line orcarburetor.
Asuddenbackfirecancausesevereinjuryordeath.
Do notoperatewith aircleaner removed.

TP-5594 5/95 SafetyPrecautionsand InstructionsIII
ExhaustSystem
WARNING
Carbon monoxide.
Cancause severenausea,fainting,ordeath.
The exhaustsystem mustbe leakproofand
routinelyinspected.
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 your
vehicleto avoid obstructing the exhaustoutlet. The
exhaustgasesmustdischarge freelyto preventcarbon
monoxide fromdeflecting intothe vehicle.Avoid
breathing exhaust fumeswhen working on ornearthe
generatorset. Carbon monoxide isparticularly
dangerousbecauseitisan odorless,colorless,
tasteless,nonirritating gasthatcan cause deathif
inhaled forevenashortperiod of time.
Carbon monoxide cancause severenausea,
fainting,ordeath.Carbon monoxide isa poisonous
gaswhichispresentin exhaustgases.Carbon
monoxide poisoning symptomsinclude butare not
limited tothe following:
DLight-headedness,dizziness
DPhysicalfatigue,weakness injointsand muscles
DSleepiness,mentalfatigue,inabilitytoconcentrate
orspeak clearly,blurred vision
DStomachache,vomiting,nausea
If anyof thesesymptomsisexperienced and carbon
monoxide poisoning ispossible,affected persons
shouldseekfresh airimmediately.They shouldremain
active.They should notbe permitted tosit, lie down,or
fall asleep.Alertotherstothe situation. If the condition
ofaffected personsdoesnotimprovewithinminutesof
breathing fresh air, they shouldseekmedicalattention.
Carbon monoxide cancause severenausea,
fainting,ordeath.Do notusecoppertubing in diesel
exhaustsystems.Dieselfumes can rapidlydestroy
coppertubingindieselexhaustsystems.Exhaustsulfur
causesrapid deterioration ofcoppertubing resulting in
exhaustleakage.
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.In addition toroutine inspection of
theexhaustsystem,installacarbonmonoxidedetector.
Consultyourcoach builderordealerforinstallation of
approved detectors. Inspectyourdetectorbefore each
generatorsetuse.

IV SafetyPrecautionsand InstructionsTP-5594 5/95
FuelSystem
Explosive fuelvapors.
Cancause severeinjuryordeath.
Useextremecarewhen handling,storing,
and using fuels.
WARNING
Explosive fuelvapors cancause severeinjuryor
death.All fuelsare highlyexplosivein a vaporstate.
Use extremecarewhen handling and storing fuels.
Storefuel inawell-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.Keepfuellinesandconnectionstight
and in good condition.Do notreplaceflexiblefuel lines
withrigidlines.Flexiblesectionsare used to avoid
breakage due tovibration. If anyfuel leakage, fuel
accumulation,orelectricalsparks are noted,DONOT
OPERATEGENERATORSET.Repairsystemsbefore
resuming generatorsetoperation
Explosive fuelvapors cancause severeinjuryor
death.Spilled fuelcan cause an explosion.Use a
containertocatchfuelwhendraining fuelsystem.Wipe
up all spilled fuelafterdraining system.
HazardousNoise
Hazardousnoise.
Cancause loss ofhearing.
Neveroperate generatorsetwithoutamuffleror
withafaultyexhaustsystem.
CAUTION
HazardousVoltage/
ElectricalShock
WARNING
Hazardous voltage.Moving rotor.
Cancause severeinjuryordeath.
Do notoperate generatorsetwithoutall guardsand
electricalenclosuresin place.
WARNING
Hazardous voltage.
Backfeedto utility systemcancause severe
injury,death,orpropertydamage.
Do notconnect to anybuilding electricalsystem
withoutconnecting through an approved device
and afterbuilding mainswitchisopen.

TP-5594 5/95 SafetyPrecautionsand InstructionsV
Hazardous voltage cancause severeinjuryor
death.Wheneverelectricityispresent, thereisthe
hazardofelectrocution.Openmaincircuitbreakeronall
powersourcesbeforeservicing equipment. Electrically
ground the generatorsetand electricalcircuitswhen in
use.Nevercomeintocontactwith electrical leadsor
applianceswhen standing inwateroron wetground,as
the chance ofelectrocution isincreased undersuch
conditions.
Hazardous voltage cancause severeinjuryor
death.Shortcircuits can cause bodilyinjuryand/or
equipmentdamage.Do notcontactelectrical
connectionswithtoolsorjewelrywhile adjustmentsare
made.Removewristwatch,rings,and jewelrythatcan
causeshortcircuits.
Hazardous voltage cancause severeinjuryor
death.High voltage ispresentat the heatsinkof the
voltage regulator.Do not touchvoltage regulatorheat
sinkwhen testing orelectricalshock will occur.
(PowerBoostt,PowerBoosttIII, and PowerBoosttV
voltage regulatormodelsonly.)
Hazardous voltage cancause severeinjuryor
death.Engine block heatercan cause electricalshock.
Remove engine block heaterplug fromelectricaloutlet
beforeworking on block heaterelectricalconnections.
Hazardousbackfeedvoltage cancause severe
injuryordeath.Do notconnectgeneratorset to any
building/campground electricalsystemwithout
connecting through an approved device and after
building/campground mainswitchisopen.Backfeed
connections can causeseriousinjuryordeathto utility
personnelworking torepaira poweroutage and/or
personnel inthe vicinity.Unauthorized connection to
utilityelectricalsystem maybe unlawful insomestates
and/orlocalities.Atransferswitchmustbe installed to
preventinterconnection ofgeneratorsetpowerand
othersourcesofpower.
Heavy Equipment
WARNING
Unbalancedweight.
Improperlift cancause severeinjuryordeath
orequipmentdamage.
Do notuselifting eyes.
Useasling underskidtolift generatorset.

VISafetyPrecautionsand InstructionsTP-5594 5/95
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.
Hotcoolantcancause severeinjuryordeath.Allow
engine tocooland release pressurefromcooling
systembefore opening pressurecap.Torelease
pressure,coverthepressurecapwithathickcloth;then
slowlyturnitcounterclockwisetothefirststop.Remove
cap afterpressure hasbeen completelyreleased and
the engine has cooled.Check coolantlevelat tankif
generatorsetisequipped with a coolantrecoverytank.
Hotparts cancause severeinjuryordeath.Do not
touchhotengineparts.Anenginegetshotwhilerunning
and exhaustsystemcomponentsgetextremelyhot.
Fire cancause severeinjuryordeath.Hotexhaust
systemcan ignite adjacentcombustiblematerials.Do
notlocate electricalwiring, fuel lines,orcombustible
materialabovethe exhaustmuffler.Exercisecaution
when parking yourvehicleto preventgrass fires started
byexhaustsystemand hotexhaustgases.
Fire cancause severeinjuryordeath.Hotgenerator
setcan ignite debrisincompartment. Keep the
compartmentandgeneratorsetclean and free ofdebris
and combustiblematerialstominimizechancesof fire.
Do notblock fuel/oil drain opening in generatorset
mounting tray.Cutacorresponding holeinthe
subflooring fordrain opening ifsubflooring isused.
Moving Parts
WARNING
Hazardous voltage.Moving rotor.
Cancause severeinjuryordeath.
Do notoperate generatorsetwithoutall guardsand
electricalenclosuresin place.
WARNING
Rotating parts.
Cancause severeinjuryordeath.
Do notoperate generatorsetwithoutall guards,
screens,and coversin place.
Flying projectiles cancause severeinjuryordeath.
Retorque all crankshaft and rotorhardware after
servicing.Do notloosen crankshaft hardware or rotor
thruboltwhen making adjustmentsorservicing
generatorset. Rotatecrankshaft manuallyin a
clockwise direction only.Loose hardwarecan result
fromturning crankshaft boltor rotorthrubolt
counterclockwise.Personalinjurycanoccurfromloose
hardwarecausinghardwareorpulleytocome offengine
when generatorsetisrunning.
Exposedmoving parts cancause severeinjuryor
death.Keep hands, feet, hair,clothing,and testleads
awayfrombeltsand pulleys when generatorsetis
running.Replace guards,screens,and coversbefore
operating generatorset.

TP-5594 5/95 SafetyPrecautionsand InstructionsVII
Notes
NOTICE
Thisgeneratorsethas beenrewiredfromits
nameplate voltageto:
246242
NOTICE
Thisisapositive terminalonly.
Do notattach negative lead!
NOTE
Affixnoticeto generatorsetafter reconnecting to a
voltage different than the nameplate.Ordervoltage
reconnection decal246242 fromauthorized service
distributors/dealers.
NOTE
Wipe up all spilled dieselfuelafterbleeding system.
Wash handsafterany contactwithfueloil.
NOTE
Pay specialattention tothe coolantlevel.Afterthe
coolanthasbeen drained,sometimeisrequired before
completerefill of the engine waterjacket takesplace.
NOTE
EngineDamage!Failureto bleed airfromcooling
system may cause overheating and subsequent
damage to engine.
NOTE
Donot turnonblock heaterbeforefillingcoolingsystem.
Run engine until warmand refill radiatorto purge air
fromthe systembefore energizing block heater.Block
heaterfailure occursifheaterelementisnotimmersed
inwater.
NOTE
HardwareDamage!Engine and generatorsetmay
usebothAmericanStandard and metrichardware.Use
the correctsizetoolsto preventrounding ofboltheads
and nuts.
NOTE
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.
NOTE
Forstandbyserviceconnectoutputofgeneratorsettoa
suitablyrated transferswitchin accordancewith
Canadian ElectricalCode,Part1.
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 tobeignition protected when used in a
gasoline-fueled environment.
NOTE
Do not tee intofuel injected fuelsystems.Use a two dip
tubearrangementforfuelsupply.Consultanauthorized
service dealerforfurtherfuelsysteminstallation
information.

TP-5594 5/95 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.Keep
thismanualwith equipment forfuturereference.
Equipmentservicerequirementsareminimalbutare
veryimportant tosafe and efficientoperation; therefore,
inspectpartsoften and performrequired servicesat the
prescribed intervals.An authorized service
distributor/dealershould performrequired servicing to
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:
KOHLER CO., Kohler,Wisconsin 53044 U.S.A.
Phone:[phone]
Fax:[phone] (NorthAmerican Sales)
414-459-1614 (International)
To ensuresupplyofcorrectpartsorinformation,make
note of the following identification numbersinthe
spacesprovided:
GENERATORSET
MODEL,SPEC,and SERIAL numbersarefound on the
nameplate attached tothe generatorset.
ModelNo.
Specification No.
SerialNo.
GENERATORSETACCESSORIES
Analternate nameplateinside the junction boxidentifies
factory-installed generatorsetaccessories.
AccessoryNos.
ENGINE
The engine serialnumberisfound on the engine
nameplate.
Engine SerialNo.

TP-5594 5/95ii Introduction
RoutineService Parts
YourKohlergeneratordealer/distributorhasacomplete
listing ofpartsforyourgeneratorset. Contactyour
dealer/distributorforservice.
PartDescription KohlerPartNo.
AirCleanerElement258646
Oil Filter322422
Metal-Type FuelFilter
Element322536
Plastic-Type FuelFilter
(Supplied Loose)322056
AlternatorV-belt322456
Black spraypaint221292

TP-5594 5/95 Specifications1-1
Section 1.Specifications
GeneralSpecifications
7 kW(60Hz)10 kW(60Hz)
DimensionsLxWxHin.(mm):
RemoteRadiator (SinglePhase)30.49 x18.43 x25.09 35.37 x20.22 x25.60................... .....
(774 x468 x637) (898 x514 x650)
Inline Radiator (SinglePhase/Suction Fan)34.68 x18.68 x25.09 40.29 x20.72 x25.60.......... .....
(881 x475 x637) (1023 x526 x650)
Inline Radiator (Three Phase/Suction Fan)35.68 x18.68 x25.09 41.29 x20.72 x25.60.......... .....
(906 x475 x637) (1049 x526 x650)
Inline Radiator (SinglePhase/PusherFan)35.82 x21.18 x26.56 40.99 x21.18 x27.68........... .....
(910 x538 x675) (1041 x538 x703)
Inline Radiator (Three Phase/PusherFan)36.82 x21.18 x26.56 41.99 x21.18 x27.68........... .....
(935 x538 x675) (1067 x538 x703)
Weight—dry,lbs.(kg):
RemoteRadiator (SinglePhase)472 (214)576 (261)........................ ................
Inline Radiator (SinglePhase/Suction Fan)482 (219)586 (266)............... ................
Inline Radiator (Three Phase/Suction Fan)496 (225)606 (275)............... ................
Inline Radiator (SinglePhase/PusherFan)482 (219)586 (266)................ ................
Inline Radiator (Three Phase/PusherFan)496 (225)606 (275)................ ................
AirRequirements(Suction Fan)CFM(M3/min):
Combustion.25 (0.71)36 (1.02).......................................... ................
Cooling 1050 (29.7)1300 (36.8).............................................. ..............
AirRequirements(PusherFan)CFM(M3/min):
Combustion 25 (0.71)36 (1.02)........................................... ................
Cooling 1000 (28.3)1800 (51.0).............................................. ..............
FuelInletSizein.(mm)5/16 (8)5/16 (8)..................................... .................
FuelReturnSizein.(mm)3/16 (5)3/16 (5)................................... .................
FuelConsumption gph (Lph):
Model:25%Load 50%Load 75%Load 100%Load
7 kW0.34 (1.3)0.44 (1.7)0.57 (2.2)0.79 (3.0)
10 kW0.46 (1.7)0.60 (2.3)0.80 (3.0)1.07 (4.0)
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-5594 5/951-2Specifications
Engine
Some generalengine specificationsarelisted below.Refertotheappropriateservicesection and the engine service
manualforspecific service details.
7 kW10 kW
ManufacturerKubota.......................................................
ModelD905BG-2V1305BG-2..................................... ................................
Type Water-cooled,4-cycle dieselengine..................................................
NumberCylinders3 4.............................. ........................................
Firing Order1-2-3 1-3-4-2.................................. ....................................
Compression Ratio 22:1...................................................
Displacementcu.in.(cm3)54.86 (898)81.46 (1335)................... ..............................
Rated Horsepower (60 Hz)12.6 18.6..................... ......................................
RPM(60 Hz)1800.........................................................
Borein.(mm)2.83 (72)2.99 (76)............................... .................................
Strokein.(mm)2.90 (73.6)2.90 (73.6)............................. ................................
Combustion SystemIndirectinjection.............................................
ValveClearance—coldin.(mm)0.0057--0.0072 (0.145--0.185).............................
CylinderBlock MaterialCastiron..............................................
CylinderHead Tightening Torque ft. lbs(Nm)47.0--50.6(63.7--68.6).....................
CylinderHead MaterialCastiron..............................................
Connecting Rod Forged carbon steel...............................................
Piston Rings2compression/1 oil..................................................
MainBearingsReplaceablesleeve................................................
GovernorMechanical.........................................................
Lubrication SystemPressure.................................................
Oil Capacity(withfilter) qts.(L)5.4(5.1)6.3(6.0)................ ..................................
Oil Type (API)MIL-L-2104C,orAPIclassification CC,CD,orCE....................................
Oil Pressure psi(kPa)36--64 (248--441)...........................................
FuelRecommendation Dieselfuelno.2-D(ASTMD975)...................................
FuelInjection PumpBoschMD................................................
BatteryVoltage 12........................................................
BatteryGround Negative.....................................................
BatteryRecommendation (min.)625 coldcranking amps...............................
StarterMotorGear-reduction type.................................................
Cooling SystemCapacityqts.(L)
Inline Radiator2.44 (2.3)5.1(4.8).......................... .................................
AirCleanerDrypaperelement....................................................
ColdWeatherStarting AidsGlowplugs.........................................

TP-5594 5/95 Specifications1-3
Generator
Models 7CCO/CCFO/CCOZ/CCFOZ
ModelVoltageAmps/
Series CodeVoltageWirePole kWPH
60 HzModels:
7CCO61 120/240 3 29.2 7.0 1
7CCO101 100/200 3 35.0 7.0 1
7CCO11 100 2 70.0 7.0 1
7CCOZ01 120/240 4 21.0 7.0 3
7CCOZ51 139/240 4 21.0 7.0 3
7CCOZ51 127/220 4 23.0 7.0 3
7CCOZ71 227/480 4 10.5 7.0 3
7CCOZ71 240/416 4 12.1 7.0 3
7CCOZ81 120/208 4 24.3 7.0 3
50 HzModels:
7CCFO101 120/240 3 24.3 5.8 1
7CCFO61 110/220 3 26.5 5.8 1
7CCFO11 100/200 3 29.2 5.8 1
7CCFO41 220 2 26.5 5.8 1
7CCFOZ51 110/190 4 22.2 5.8 3
7CCFOZ51 115/200 4 21.0 5.8 3
7CCFOZ71 220/380 4 11.1 5.8 3
7CCFOZ71 230/400 4 10.5 5.8 3
7CCFOZ71 240/416 4 10.1 5.8 3
7CCFOZ81 120/208 4 20.2 5.8 3
7CCFOZ81 110/220 4 19.1 5.8 3
Models 10CCO/CCFO/CCOZ/CCFOZ
ModelVoltageAmps/
Series CodeVoltageWirePole kWPH
60 HzModels:
10CCO61 120/240 3 41.7 10.0 1
10CCO101 100/200 3 50.0 10.0 1
10CCOZ01 120/240 4 30.1 10.0 3
10CCOZ51 139/240 4 30.1 10.0 3
10CCOZ51 127/220 4 32.8 10.0 3
10CCOZ71 227/480 4 15.0 10.0 3
10CCOZ71 240/416 4 17.3 10.0 3
10CCOZ81 120/208 4 34.7 10.0 3
50 HzModels:
10CCFO101 120/240 3 34.7 8.3 1
10CCFO61 110/220 3 37.9 8.3 1
10CCFO11 100/200 3 41.7 8.3 1
10CCFO41 220 2 37.9 8.3 1
10CCFOZ51 110/190 4 31.7 8.3 3
10CCFOZ51 115/200 4 30.1 8.3 3
10CCFOZ71 220/380 4 15.8 8.3 3
10CCFOZ71 230/400 4 15.0 8.3 3
10CCFOZ71 240/416 4 14.5 8.3 3
10CCFOZ81 120/208 4 28.9 8.3 3
10CCFOZ81 110/220 4 27.3 8.3 3

TP-5594 5/951-4Specifications
GeneratorModels 7/10 kW
Single-Phase ModelsThree-Phase Models
RPM(60-HzModels)1800..............................................
RPM(50-HzModels)1500..............................................
7 kW:
StatorResistance(ohms)** Leads:
1-2,3-4,33-44 0.13..........................
55-33 1.60..................................
B1-B2 0.08..................................
1-4,2-5,3-6,7-10,8-11,9-12 0.1.........................................................
B1-B2 0.1.............................................................................
V0-V7,V0-V8,V0-V9 0.1................................................................
55-66 2.3.............................................................................
RotorResistance(ohms)3.9 5.1...................... ......................................
10 kW:
StatorResistance(ohms)** Leads:
1-2,3-4,33-44 0.12..........................
55-33 1.50..................................
B1-B2 0.07..................................
1-4,2-5,3-6,7-10,8-11,9-12 0.1.........................................................
B1-B2 0.1.............................................................................
V0-V7,V0-V8,V0-V9 0.1................................................................
55-66 2.0.............................................................................
RotorResistance(ohms)4.3 3.9...................... ......................................
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,replaceable ball..................................
CircuitProtection:
Controller10-ampfuse 10-ampcircuitbreaker........................... ..........................
OptionalACOutputManual-resetcircuitbreaker.................................
Voltage Regulator10-ampfuse 8-ampfuse.................... ...............................
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-5594 5/95 Specifications1-5
Notes

TP-5594 5/951-6Specifications
Service ViewComponents
Remote-RadiatorModel(See Figure 1-1)
1.OptionalAC CircuitBreaker
2.Voltage RegulatorFuse
3.Start/Stop-PreheatSwitch
4.FuelSolenoidFuse
5.ControllerFuse
6.Hourmeter
7.Controller
8.RemoteConnection (atrearofcontroller)
9.AirCleaner
10.Lifting Eye
11.High WaterTemperatureShutdown
12.FuelSolenoid
13.Oil Fill
14.Lifting Eye
15.Oil Fill
16.GeneratorNameplate
17.MechanicalGovernor
18.Oil Filter
19.FuelFilter
20.Ground Connection
21.Oil Drain
22.FuelPump
23.Oil Check
24.FuelInletConnection Point
25.FuelReturnConnection Point
26.GlowPlug Relay
27.Voltage Regulator
(inside junction/circuitbreakerbox)
28.BatteryCharging Alternator (behind guard)
29.LowOil PressureShutdown
30.ExhaustOutlet
31.CoolantOutlet
32.Coolant Inlet
33.Starter

TP-5594 5/95 Specifications1-7
ADV-5831-A
1
2
3
4
568
79
10 11 12 13
32
14
15
17
18
31
19
20
22
23 21
24
25
26
30
27
28
33
29
16
Figure 1-1.Service Viewof7CCO-RVRemoteRadiator(Typical)

TP-5594 5/951-8Specifications
Service ViewComponents
Inline-RadiatorModel(See Figure 1-2)
1.OptionalAC CircuitBreaker
2.Voltage RegulatorFuse
3.Start/Stop-PreheatSwitch
4.FuelSolenoidFuse
5.ControllerFuse
6.Hourmeter
7.Controller
8.RemoteConnection (atrearofcontroller)
9.AirCleaner
10.Lifting Eye
11.High WaterTemperatureShutdown
12.FuelSolenoid
13.Oil Fill
14.CoolantFill (Initial)
15.Lifting Eye
16. Inline Radiator
17.Oil Fill
18.GeneratorNameplate
19.MechanicalGovernor
20.Oil Filter
21.CoolantDrain
22.FuelFilter
23.Oil Drain
24.Ground Connection
25.FuelPump
26.Oil Check
27.FuelInletConnection Point
28.FuelReturnConnection Point
29.GlowPlug Relay
30.Voltage Regulator
(inside junction/circuitbreakerbox)
31.ExhaustOutlet
32.BatteryCharging Alternator (behind guard)
33.LowOil PressureShutdown
34.Starter

TP-5594 5/95 Specifications1-9
ADV-5831-C
1
2
3
4
56789
10 11 12 13 14 15
16
17
18
20
21
22
24
25
26
23
27
28
29
33
30
31
32
34
19
Figure 1-2.Service Viewof7CCO-RVInlineRadiator(Typical)