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Kohler
Portable Generator
15CCO
Kohler 15CCO User Manual
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E
K
ohler
Co.,
2002.
Al
l
rights
reserved.
TP
-5606
6/02a
KOHLER
CO.
Kohler
,
Wisconsin
53044
Phone
920-565-3381,
Fax
920-459-1646
For
the
nearest
sales
/servic
e
out
let
in
t
he
US
and
Canada,
phone
1-800-544-2444
KohlerPowerSyst
ems.c
om
Kohler
P
ower
Sys
tems
Asia
Pac
ific
Headquarters
7
J
urong
Pier
Road
Singapore
619159
Phone
(65)264-
6422,
Fax
(65)
264-6455
139
Table of Contents
Table of Contents
3
Subject Page
4
Safety Precautions and Instructions
5
Routine Service Parts
10
Section 1. Specifications
11
Introduction
11
General Specifications
11
Engine
12
Generator
13
Generator Models 15/20 Kw
13
Section 2. Operation
21
Prestart Checklist
21
Exercising the Generator
21
Controller (Single Phase)
22
Controller (Three Phase)
22
Preheat Feature
23
Starting Procedure
23
Stopping Procedure
23
Fault Shutdowns
24
Low Oil Pressure Shutdown Switch
24
High Water Temperature Shutdown Switch
24
Circuit Protection
25
Accessories
26
Remote Panels (Optional)
27
Section 3. Scheduled Maintenance
31
General
31
Lubrication System
33
Oil Selection
33
Oil Check
33
Oil Change
34
Oil Filter
35
Fuel System
36
Specification
36
Fuel Filter
36
Bleeding the Fuel System
37
Fuel Solenoid
38
Air Cleaner Service
39
Governor
40
Cooling System
41
Cooling System Description
41
Cooling System Servicing
44
Clean Radiator Fins/Inspect Hoses
44
Change Coolant
44
Check Coolant Level
44
Battery Charging
45
Belt Tension
45
Battery
46
Cleaning
47
Checking Electrolyte Level
47
Checking Specific Gravity
48
Engine Cylinder Head
49
Valve Clearance
49
Head Bolt Torque
49
Wattage Requirements
50
Generator Service
51
General
51
Storage Procedure
51
Section 4. General Troubleshooting
53
Section 5. Controller Troubleshooting
69
Single-Phase Generator Sequence of Operation
69
Starting
69
Running
70
Stopping
71
Automatic Safety Shutdowns
72
Three-Phase Generator Sequence of Operation
73
Starting
73
Running
74
Stopping
75
Automatic Safety Shutdowns
76
Section 6. Generator/Controller Troubleshooting
77
Controller Circuit Board
77
Section 7. Component Testing and Adjustment
83
Separate Excitation
83
Powerboostä IIIE Voltage Regulator
86
Powerboostä IIIE Voltage Regulator Test Procedure
87
Powerboostä IIIE Voltage Regulator Adjustment
88
Powerboostä V Voltage Regulator
90
Powerboostä V Voltage Regulator Test Procedure
91
Powerboostä V Voltage Regulator Adjustment
92
Adjustment Procedure
93
Controller Circuit Board
94
Engine/Generator Components
96
Rotor
100
Single-Phase Rotor Tests
100
Three-Phase Rotor Tests
100
Stator
101
Checking Single-Phase Stator Continuity and Resistance
101
Checking Three-Phase Stator Continuity and Resistance
103
Exciter Field
104
Exciter Armature
105
Fuel Solenoid
107
Remote Start Panels (Optional)
108
Sender Tests
108
Panel Tests
108
Section 8. Disassembly/Reassembly
111
Single-Phase Generator Disassembly
111
Single-Phase Generator Brushes
115
Single-Phase Generator Slip Ring
115
Single-Phase Generator Reassembly
116
Three-Phase Generator Disassembly
117
Reassembly
121
Section 9. Wiring Diagrams
123
Twelve-Lead (Three-Phase) Generator Sets
127
Appendix A Abbreviations
131
Appendix B. Common Hardware Applications
133
Guidelines
133
Appendix C General Torque Specifications
134
Appendix D Common Hardware Identification
135
Appendix E Common Hardware List
136
4
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Kohler 15CCO Specifications
General
Brand
Kohler
Model
15CCO
Category
Portable Generator
Language
English
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