Professional Documents
Culture Documents
Kohler Diesel PDF
Kohler Diesel PDF
Installation Manual
RV/Mobile Generator Sets
Models:
7CCO
7CCFO
7CCOZ
7CCFOZ
10CCO
10CCFO
10CCOZ
10CCFOZ
TP-5594 5/95
Table of Contents
SUBJECT PAGE SUBJECT PAGE
Safety Precautions and Instructions . . . . . . I Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . i Checking Electrolyte Level . . . . . . . . . . . . . . . . . 3-14
Service Assistance . . . . . . . . . . . . . . . . . . . . . . i Checking Specific Gravity . . . . . . . . . . . . . . . . . 3-14
Routine Service Parts . . . . . . . . . . . . . . . . . . . ii Gauge Connections . . . . . . . . . . . . . . . . . . . . . . 3-15
Wattage Requirements . . . . . . . . . . . . . . . . . . . . 3-17
Section 1. Specifications . . . . . . . . . . . . . . . . 1-1 Generator Service . . . . . . . . . . . . . . . . . . . . . . . . 3-18
General Specifications . . . . . . . . . . . . . . . . . . . . 1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . 3-18
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Generator Models 7/10 kW . . . . . . . . . . . . . . . . 1-4 Section 4. Troubleshooting . . . . . . . . . . . . . . 4-1
Service View Components Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remote-Radiator Model . . . . . . . . . . . . . . . . . 1-6 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Service View Components Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Inline-Radiator Model . . . . . . . . . . . . . . . . . . . 1-8
Section 5. Wiring Diagrams . . . . . . . . . . . . . . 5-1
Section 2. Operation . . . . . . . . . . . . . . . . . . . . 2-1
Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section 6. Installation . . . . . . . . . . . . . . . . . . . 6-1
Exercising the Generator . . . . . . . . . . . . . . . . . . 2-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Controller (Single Phase) . . . . . . . . . . . . . . . . . . 2-2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Controller (Three Phase) . . . . . . . . . . . . . . . . . . 2-2 Generator Selection And
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 2-3 Wattage Requirements . . . . . . . . . . . . . . . . . . 6-2
Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . 2-3 Installation Factors . . . . . . . . . . . . . . . . . . . . . . . 6-2
Fault Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Electrical Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Low Oil Pressure Shutdown Switch . . . . . . . . . 2-4 Lighting Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
High Water Temperature Shutdown Switch . . . 2-4 Motor Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Appliance Loads . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Kilowatt Derating . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Section 3. Scheduled Maintenance . . . . . . . 3-1 Compartment Size . . . . . . . . . . . . . . . . . . . . . . . . 6-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 3-3 Remote Radiator Cooling System . . . . . . . . . . . 6-13
Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Battery And Connections . . . . . . . . . . . . . . . . . . 6-21
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 AC Load Lead Connections . . . . . . . . . . . . . . . . 6-23
Fuel Filter (Metal Spin-On Type) . . . . . . . . . . . . 3-6 Remote Switch Connection
Fuel Filter (Plastic In-Line Type (Single-Phase Models Only) . . . . . . . . . . . . . . 6-24
Supplied Loose) . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Bleeding the Fuel System . . . . . . . . . . . . . . . . . 3-7 Section 7. Installation Drawings . . . . . . . . . . 7-1
Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . 3-8
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Appendix A. Glossary of Abbreviations . . . A-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Appendix B. . Operating Hour
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Hazardous noise.
Explosive fuel vapors. Can cause loss of hearing.
Can cause severe injury or death.
Never operate generator set without a muffler or
Use extreme care when handling, storing, with a faulty exhaust system.
and using fuels.
Hazardous voltage.
Backfeed to utility system can cause severe
injury, death, or property damage.
Do not connect to any building electrical system
without connecting through an approved device
and after building main switch is open.
WARNING WARNING
Do not work on generator set until it is allowed to Do not operate generator set without all guards,
cool. screens, and covers in place.
Hot coolant can cause severe injury or death. Allow Flying projectiles can cause severe injury or death.
engine to cool and release pressure from cooling Retorque all crankshaft and rotor hardware after
system before opening pressure cap. To release servicing. Do not loosen crankshaft hardware or rotor
pressure, cover the pressure cap with a thick cloth; then thrubolt when making adjustments or servicing
slowly turn it counterclockwise to the first stop. Remove generator set. Rotate crankshaft manually in a
cap after pressure has been completely released and clockwise direction only. Loose hardware can result
the engine has cooled. Check coolant level at tank if from turning crankshaft bolt or rotor thrubolt
generator set is equipped with a coolant recovery tank. counterclockwise. Personal injury can occur from loose
hardware causing hardware or pulley to come off engine
Hot parts can cause severe injury or death. Do not
when generator set is running.
touch hot engine parts. An engine gets hot while running
and exhaust system components get extremely hot. Exposed moving parts can cause severe injury or
death. Keep hands, feet, hair, clothing, and test leads
Fire can cause severe injury or death. Hot exhaust
away from belts and pulleys when generator set is
system can ignite adjacent combustible materials. Do
running. Replace guards, screens, and covers before
not locate electrical wiring, fuel lines, or combustible
operating generator set.
material above the exhaust muffler. Exercise caution
when parking your vehicle to prevent grass fires started
by exhaust system and hot exhaust gases.
NOTE
Do not turn on block heater before filling cooling system.
Run engine until warm and refill radiator to purge air
from the system before energizing block heater. Block
heater failure occurs if heater element is not immersed
in water.
Service Assistance
For sales and service in the U.S.A. and Canada check GENERATOR SET ACCESSORIES
the yellow pages of the telephone directory under the
heading GENERATORS— ELECTRIC for an authorized An alternate nameplate inside the junction box identifies
service distributor/dealer or call 1-800-544-2444. factory-installed generator set accessories.
For sales and service outside the U.S.A. and Canada,
Accessory Nos.
contact your local distributor.
For further information or questions, contact the
company directly at:
KOHLER CO., Kohler, Wisconsin 53044 U.S.A.
Phone: 414-565-3381
Fax: 414-459-1646 (North American Sales)
414-459-1614 (International)
To ensure supply of correct parts or information, make
note of the following identification numbers in the
spaces provided:
GENERATOR SET
DERATION: All units are rated 1.0 power factor. The kilowatts of the generator set will decrease 3.5% for each 1,000
feet (305 meters) above 500 feet (152 meters) above sea level and 1% for each 10_F (5.5_C) above 85_F (30_C).
7 kW 10 kW
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D905BG-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V1305BG-2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle diesel engine
Number Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22:1
Displacement cu. in. (cm3) . . . . . . . . . . . . . . . . . . . 54.86 (898) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.46 (1335)
Rated Horsepower (60 Hz) . . . . . . . . . . . . . . . . . . . . . 12.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.6
RPM (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800
Bore in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.83 (72) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.99 (76)
Stroke in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.90 (73.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.90 (73.6)
Combustion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect injection
Valve Clearance— cold in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0057--0.0072 (0.145--0.185)
Cylinder Block Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast iron
Cylinder Head Tightening Torque ft. lbs (Nm) . . . . . . . . . . . . . . . . . . . . . 47.0--50.6 (63.7--68.6)
Cylinder Head Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast iron
Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forged carbon steel
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 compression/1 oil
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replaceable sleeve
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure
Oil Capacity (with filter) qts. (L) . . . . . . . . . . . . . . . . 5.4 (5.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 (6.0)
Oil Type (API) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIL-L-2104C, or API classification CC, CD, or CE
Oil Pressure psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36--64 (248--441)
Fuel Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel fuel no. 2-D (ASTM D975)
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch MD
Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative
Battery Recommendation (min.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625 cold cranking amps
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear-reduction type
Cooling System Capacity qts. (L)
Inline Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . 2.44 (2.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 (4.8)
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry paper element
Cold Weather Starting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow plugs
60 Hz Models: 60 Hz Models:
7CCO 61 120/240 3 29.2 7.0 1 10CCO 61 120/240 3 41.7 10.0 1
7CCO 101 100/200 3 35.0 7.0 1 10CCO 101 100/200 3 50.0 10.0 1
7CCO 11 100 2 70.0 7.0 1 10CCOZ 01 120/240 4 30.1 10.0 3
7CCOZ 01 120/240 4 21.0 7.0 3 10CCOZ 51 139/240 4 30.1 10.0 3
7CCOZ 51 139/240 4 21.0 7.0 3 10CCOZ 51 127/220 4 32.8 10.0 3
7CCOZ 51 127/220 4 23.0 7.0 3 10CCOZ 71 227/480 4 15.0 10.0 3
7CCOZ 71 227/480 4 10.5 7.0 3 10CCOZ 71 240/416 4 17.3 10.0 3
7CCOZ 71 240/416 4 12.1 7.0 3 10CCOZ 81 120/208 4 34.7 10.0 3
7CCOZ 81 120/208 4 24.3 7.0 3
50 Hz Models:
50 Hz Models: 10CCFO 101 120/240 3 34.7 8.3 1
7CCFO 101 120/240 3 24.3 5.8 1 10CCFO 61 110/220 3 37.9 8.3 1
7CCFO 61 110/220 3 26.5 5.8 1 10CCFO 11 100/200 3 41.7 8.3 1
7CCFO 11 100/200 3 29.2 5.8 1 10CCFO 41 220 2 37.9 8.3 1
7CCFO 41 220 2 26.5 5.8 1 10CCFOZ 51 110/190 4 31.7 8.3 3
7CCFOZ 51 110/190 4 22.2 5.8 3 10CCFOZ 51 115/200 4 30.1 8.3 3
7CCFOZ 51 115/200 4 21.0 5.8 3 10CCFOZ 71 220/380 4 15.8 8.3 3
7CCFOZ 71 220/380 4 11.1 5.8 3 10CCFOZ 71 230/400 4 15.0 8.3 3
7CCFOZ 71 230/400 4 10.5 5.8 3 10CCFOZ 71 240/416 4 14.5 8.3 3
7CCFOZ 71 240/416 4 10.1 5.8 3 10CCFOZ 81 120/208 4 28.9 8.3 3
7CCFOZ 81 120/208 4 20.2 5.8 3 10CCFOZ 81 110/220 4 27.3 8.3 3
7CCFOZ 81 110/220 4 19.1 5.8 3
10 kW:
Stator Resistance (ohms)** Leads:
1-2, 3-4, 33-44 . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12
55-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
B1-B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07
** Most ohmmeters will not give accurate readings when measuring less than 1 ohm. The stator can be considered
good if a low resistance reading (continuity) is obtained and there is no evidence of shorted windings
(discoloration). Do not confuse a low resistance reading with a reading indicating a shorted winding.
4
15
3
16
2 17
27
18
19
20
26 25 23
24 22 21
28
29
30
31
32
33
ADV-5831-A
4
16
17
3
2 18
19
30
20
29
27
26
28 21
22
25 24 23
31
32
33
34
ADV-5831-C
Ambient
Temperature Preheating Time
Limit of
Continuous use 20 Seconds
NOTE
If the engine starts and then stops, allow the engine to
come to a complete stop before making a restart
attempt. If the flywheel ring gear is still rotating when the
starter pinion gear is engaged, the pinion gear will clash
which may damage the ring gear teeth.
1-933
1 1-933
1 2
1 2 4
4 3
Single-Phase Three-Phase
1-933
FUEL SYSTEM
Check the fuel level . . . . . . . . . . . . . . . . . . . . . . . . X
Fill fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Check fuel pipes and clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Remove sediment from fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Replace the fuel filter element (metal spin-on type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Check governor operation and adjust
as necessary** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Check the nozzle injection pressure** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
(1000 Hrs)
Check and/or replace fuel filter (plastic in-line type supplied loose) . . . . . . . X
LUBRICATION SYSTEM
Check the oil level in crankcase . . . . . . . . . . . . . . X
Replace the oil in crankcase* . . . . . . . . . . . . . . . . . . . . . . . . . . . X . . . . . . . . . X
(Break-in Period)
Replace the oil filter element* . . . . . . . . . . . . . . . . . . . . . . . . . . . X . . . . . . . . . X
(Break-in Period)
COOLING SYSTEM
Check coolant level . . . . . . . . . . . . . . . . . . . . . . . . X
Check water pipes and clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Adjust the tension of water pump V-belt . . . . . . . . . . . . . . . . . . X . . . . . . . . . X
(Break-in Period)
Change coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Clean radiator fins, inspect hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
AIR CLEANER, ETC.
Replace the air cleaner element* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
(300 Hrs)
Clean the breather pipe* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
ELECTRICAL SYSTEM
Verify proper operation of gauges (if equipped) . X
Check the electrolyte level in the battery . . . . . . X
Check the electrical connections . . . . . . . . . . . . . . . . . . . . . . . . X
Check the battery specific gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Adjust battery charging alternator V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
CYLINDER HEAD, ETC.
Check for leakage of water and oil . . . . . . . . . . . . X . . . . . . . . X
Retighten all major nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
(Break-in Period)
Check mounting bolts and vibro mounts
for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Retighten the cylinder head bolts** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Adjust intake exhaust valve clearance** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
(800 Hrs)
GENERATOR
Blow dust out of generator* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
Clean slip rings and inspect brushes (single-phase models only)** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
SAE 30 or
10W-30
77_F
(25_C)
SAE 20 or
10W-30
32_F 1-932
(0_C) 1. MAX Level
2. MIN Level
Figure 3-2. Oil Level Check
SAE 10W or
10W-30 NOTE
Do not check oil level when the set is in operation. The
engine must be stopped and on a level surface when
checking oil. Most accurate oil reading is obtained by
shutting down the generator and waiting several
minutes before checking oil.
Figure 3-1. Engine Oil Selection
OIL CAPACITY
(with Filter)
qts. (L) 1-932
1. Oil Fill
7 kW . . . . . . . . . . . . . . . . . . . . . . . 5.4 (5.1) Figure 3-4. Oil Fill Locations
10 kW . . . . . . . . . . . . . . . . . . . . . 6.3 (6.0)
Figure 3-3.
ADV-5831
1. Oil Filter
Figure 3-5. Oil Filter Location
Never store diesel fuel in galvanized containers; diesel 4. See Bleeding section following.
fuel and the galvanized coating react chemically to
1
produce flaking which quickly clogs filters or causes
failure of the fuel pump or injectors. Do not run the
generator set out of fuel; air will be drawn into the fuel
lines and the entire system will have to be bled before
the unit can be restarted.
NOTE
Avoid storing fuel over long periods of time. Take special
precautions to keep all dirt, water, and other
contaminants out of the fuel. Storage tanks containing
diesel fuel contaminated with water may cause the
growth of microbes. The presence of microbes will form
a slime which clogs fuel filters and lines.
1-932
1. Fuel Filter
Figure 3-6. Fuel Filter Location
4 3
1-932
6
5 4 3
1-932
1. Eyebolt/Clamp
2. Base
3. Cover
4. Element
5. Threaded Rod
6. Wing Nut
Figure 3-8. Air Cleaner Components
ADV-5831-A
ADV-5831-C
1
Hazardous voltage. Moving rotor.
Can cause severe injury or death.
Do not operate generator set without all guards and
electrical enclosures in place.
Battery Charging
Your generator is equipped with a 20-amp, belt-driven
battery charging alternator. See Figure 3-13. It is
attached to the engine block by a bracket and serves to
keep the battery constantly charged. Be sure to observe
3 2
battery polarity when connecting the battery to the
generator set. The alternator requires no maintenance
1-932 other than maintaining belt tension. To adjust the
alternator belt tension, see Belt Tension.
1. Adjusting Screw
2. Pivot Screw
3. Fan Belt 1
Figure 3-12. Belt Tension
1. Disconnect battery, negative lead first.
2. Loosen pivot and adjusting screws.
3. While prying battery-charging alternator outward,
tighten adjusting screw.
4. Tighten pivot screw.
5. Recheck and adjust as necessary.
6. Reconnect battery, negative lead last.
NOTE
Check fan belt for cracks or tears and replace if
necessary.
1-932
32.2 90 + .004
21.1 70 -- .004
Hydrometer Reading 1.235
--. 006
-- .014
Add .008 Sp. Gravity
Corrected Sp. Gravity is 1.243
4.4 40 -- .016
-- .018
-- 1.1 30 -- .020
1-046
-- .022
-- 6.7 20 -- .024
Figure 3-14. Battery Electrolyte Level -- .026
-- 12.2 10 -- .028
See DETAIL A
2
4
DETAIL A
CV-250000-G
P4-10 P3-6
11 11 Light Blue
S +
11 J4-10 J3-3
Violet (53)
Oil J3-4
B+ To
Pressure
Controller
Sender
P3-2
Violet (53)
P4-13 P3-3
10 10 Tan
S +
10 J4-13 J3-2
Water
Temperature
Gauge
Water
Temperature
Sender
Storage Procedure
If your generator set is to be out of service for a 3. Check the engine coolant protection. See Section
considerable length of time (2 months or more), perform 3, Cooling System for additional information.
the following steps to preserve the set before placing it in 4. Disconnect battery (negative lead first) and place
storage. in storage.
1. Drain the oil (while hot) from the crankcase then 5. Seal all openings in the engine with non-absorbent
refill with regular grade oil. See Section 3, Oil adhesive tape. Mask off all areas to be used for
Selection in this manual. electrical contact.
2. Drain the fuel from the fuel tank to prevent 6. Clean exterior surface of the generator. Spread a
accumulated moisture from mixing with the fuel. light film of oil over unpainted metallic surfaces
which could rust or corrode.
Water, dirt in fuel system Drain, flush fuel system and replace fuel
Engine runs Vent in fuel tank cap obstructed Clean cap in solvent, blow dry
irregularly or
stalls frequently Clogged fuel filter Replace fuel filter element
Water, dirt, or air in fuel system Drain, flush, fill, and bleed air in
fuel system
High water temperature (HWT) Check engine coolant level, loose fan
shutdown* belt, radiator obstructions, etc.
Low oil pressure (LOP) shutdown* Check engine lube oil level
Vent in fuel tank cover obstructed Clean cap in solvent; blow dry
Radiator clogged with dirt or oil Clean with water soluble grease
remover and flush cooling system
Low lube oil Low lube oil level Add lube oil
pressure
Improper lube oil viscosity Drain, fill with proper viscosity oil
High lube oil Too light viscosity oil Use proper viscosity oil
consumption
Oil leaks Check for leaks in lines, around
gaskets, and drain plug
Electrical System
Problem Possible Cause Corrective Action
Battery will Loose or corroded connections Clean and tighten connection
not charge
Sulfated or worn-out battery Check electrolyte level and specific
gravity (batteries with filler caps only)
Starter does not Loose or corroded connections Clean and tighten connection
work properly
Low battery output Check electrolyte level and specific
gravity (batteries with filler caps only)
Starter cranks Low battery output Check electrolyte level and specific
slowly gravity (batteries with filler caps only)
Low output Engine speed too low Contact authorized service dealer/
or excessive distributor for repairs
drop in
voltage Generator overloaded Reduce load
Accidental starting can cause severe injury or Hazardous voltage can cause severe injury or
death. Disconnect battery cables (remove negative death. Whenever electricity is present, there is the
lead first and reconnect it last) to disable generator set hazard of electrocution. Open main circuit breaker on all
before working on any equipment connected to power sources before servicing equipment. Electrically
generator set. The generator set can be started by the ground the generator set and electrical circuits when in
remote start/stop switch unless this precaution is use. Never come into contact with electrical leads or
followed. appliances when standing in water or on wet ground, as
the chance of electrocution is increased under such
conditions.
NOTE
Tape to insulate
When connecting a generator set to a voltage different from ground
than nameplate voltage, place a notice on the unit
indicating this change. A decal (part no. 246242) is Line
available to indicate reconnected voltage from Side
authorized Kohler dealers/distributors.
Single-Pole
Circuit
120/240-Volt (or 110/220-Volt, Load Breaker
100/200-Volt) Configurations— Figure 5-1 Side
Circuit breaker must be a circuit breaker manufacturer L1
two-pole circuit breaker. Two single-pole circuit Ground
breakers do not conform to NEC requirements when GRD.
supplying a 240-volt (or 220-volt) load. This is true even LO
LO (Neutral)
if they are mechanically attached together. Leads L1
and L2 are different phases and must never be
connected together. Figure 5-2.
Leads 60 Hz 50 Hz
L0-L1 Not used 200-240 volt
LO (Neutral)
LO
GRD.
Ground
L2
Load L1
Side
Factory
Two-Pole
Circuit
Line Breaker
Side
4 3 2 1
Stator Leads
Figure 5-1.
Leads 60 Hz 50 Hz
L0-L1 120 volt 110 volt
L0-L2 120 volt 110 volt
L1-L2 240 volt 220 volt
10 L0 2
9 1
12 4
7 5
5 11
L1 L3
6 3 12 9
2 8
L2
L3
Introduction
Use this section as a guide when installing a generator Features
set in the vehicle, then refer to the operation section for
specific service instructions. When installing an These generator sets feature Kubota D905BG-2 or
RV/Mobile generator set, the installation must comply V1305BG-2 diesel engines, rotating-field,
with the Kohler detailed installation instructions. Any alternating-current generator, and relay controller. The
additional requirements can also be found in the generator is directly connected to the engine for
following sources: (1) ANSI A 119.2/NFPA 501 C, (2) permanent alignment. Each controller includes a
article 551 of ANSI/NFPA 70, National Electrical Code, Start/Stop-Preheat switch for test operating the set at
(3) C.S.A. (Canadian Standards Association) standard the controller. The single-phase controller also has a
C22.2 #100, and (4) C.E.C. (Canadian Electrical Code) keyed connector for connecting a wiring harness to a
C22.1. Generator set installation must also comply with remote start/stop switch (usually located on the
state and local requirements. dashboard of the vehicle). After the set is attached to
the frame of the vehicle and the coach supplied radiator
NOTE and hose connections are installed, all that is usually
This generator set does not comply with United required to make it operational is the following:
States Coast Guard (U.S.C.G.) requirements and
must not be used for marine applications. Use only D Attach exhaust system.
generator sets specified for marine use in marine D Add proper amount of radiator coolant. Mount the
installations. U.S.C.G. Regulation 33CFR183 requires coolant recovery tank.
a generator set to be ignition protected when used in a D Add oil to crankcase until dipstick reads to MAX
gasoline-fueled environment. level.
D Connect fuel lines (inlet and return), remote switch,
load leads, and battery terminals.
Will Operate
Wattage Air Conditioner(s) Power To Spare
Kohler Model Capacity of Sizes Indicated for Lighting, Appliance, Tools, etc.
7 kW 7,000 Two 13,500 Btu 2800 Watts
10 kW 10,000 Two 13,500 Btu N/A
AIR AIR
INLET OUTLET Figure 6-8. Inlet Screen
Remote and inline radiator generator sets with suction
7 kW Remote Radiator 140 (903) 167 (1077)
fans will require an air outlet in the compartment floor,
7 kW Inline Radiator and an air inlet in the generator-end wall. Inline radiator
(Suction) 421 (2716) 319 (2058) generator sets with pusher fans require an outlet and
inlet in the compartment floor, and an air inlet in the
7 kW Inline Radiator generator-end wall. An additional 3 in. (7.62 cm)
(Pusher) 239 (1542) 474 (3058) diameter hole is required in the compartment so
combustion air from the outside of the compartment can
10 kW Remote Radiator 140 (903) 195 (1258)
be brought into the air cleaner using a 2 in. (5 cm) I.D.
hose.
10 kW Inline Radiator
(Suction) 446 (2877) 309 (1995) NOTE
10 kW Inline Radiator The air inlet perimeters, at the engine radiator and
(Pusher) 242 (1562) 502 (3241) generator end bracket must be sealed against the
compartment wall. This is to make sure that only
exterior air is drawn into the generator compartment.
Figure 6-7. Min. Air Requirements
sq. in. (sq. cm.) NOTE
Kubota’s allowable air intake restriction limit is:
8 in. (200 mm) of water at installation.
25 in. (635 mm) of water after use.
17 in.
(432 mm)
Seal Radiator
to Compartment Wall
Radiator
End
Generator
End Bottom Discharge in. (mm)
Outlet A Outlet B
7 kW:
Length 8 (203) 18.83 (479)
Width 19 (483) 8.88 (226)
10 kW:
Length 6 (152) 22 (559)
Width 19 (483) 8.88 (226)
18.45 in.
(469 mm)
Seal Radiator
to Compartment
Wall
Radiator
End
Generator
End Bottom Discharge in. (mm)
Inlet Outlet
7 kW:
Length 16.62 (422) 18.83 (478)
Width 5.95 (151) 8.88 (225)
10 kW:
Length 16.62 (422) 22 (559)
Width 6.15 (156) 8.88 (225)
10 kW Inline-Radiator Model
ADV-5832A-C
Figure 6-11. Air Flow Requirements for Inline-Radiator Models (with Suction Fan)
10 kW Inline-Radiator Model
ADV-5968A-A
Figure 6-12. Air Flow Requirements for Inline-Radiator Models (with Pusher Fan)
Figure 6-13. 7CCO/CCOZ Inline Radiator (Pusher Fan) Single- and Three-Phase Models
Optional Cooling without Cutouts in Compartment Floor
Figure 6-14. 10CCO/CCOZ Inline Radiator (Pusher Fan) Single- and Three-Phase Models
Optional Cooling without Cutouts in Compartment Floor
Maintain tight
seal around radiator Discharge Chute
through floor
Air
Inlet
Air Flow
Generator
End
NOTE:
The dimensions shown
are compartment inside
measurements. The
compartment must allow
1 1/2 in.(38 mm) clearance
on all sides of generator.
Generator
End
Figure 6-16. Typical Cooling System Installation (Compartment Minimum Sizes) for
Remote Radiator Mounted Outside the Generator Compartment
To Radiator Inlet
2
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and
routinely inspected.
Battery NOTE
Vehicle Battery Negative
Positive
Frame to Vehicle Frame A ground connection is required between the generator
and the vehicle frame even if the battery used to start the
Figure 6-21. Battery Connection Details generator is not the same as the vehicle.
L0 L0
N N N N N N
120-V 240-V
Outside Outside
Power L1 Power L1
Gen. Gen.
Set Set
L2 L2
NOTE
For standby service connect output of generator to
suitably rated transfer switch in accordance with
Canadian Electrical Code, Part 1.
1-933
1. Remote Connection
Figure 6-23. Controller Remote Connection
ON Lamp
53
Oil Pressure
Gauge (if equipped)
11
Water Temperature
Gauge (if equipped)
10
6 4 2
Start 11 3 53
3 5 3 1
2 10 4
Stop-Preheat
2
Ground
4
P3
ADV-5968A-A