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General Motors Industrial Powertrain Vortec 5.7 L Engine

The General Motors Industrial Powertrain Vortec 5.7 L is a 5.7 L -8-cylinder turbocharged engine rated at 1800 rpm, producing up to 115 kW. It powers generator sets from Kohler and SDMO, including the 100ERESD, 100REZGD, 100RZGD and 60RCL. It holds 6.2 L (1.6 gal) of oil and 22.5 L (5.9 gal) of coolant.

Also known as: General Motors Industrial Powertrain Vortec 5.7 L

5.7 L

Displacement

-8

Cylinders

1800 rpm

Rated speed

115 kW

Gross power

On this pageSpecs Generator sets Maintenance FAQ Service intervals Torque & specs Fluids Fault codes Procedures Wiring

Engine specifications

Oil capacity	6.2 L
Coolant capacity	22.5 L
Displacement	5.7 L
Cylinders	-8
Aspiration	Turbocharged
Rated speed	1800 rpm
Gross power	115 kW

Generator sets powered by this engine

Shared across brands: Kohler, SDMO

Kohler 100ERESD Kohler 100REZGD Kohler 100RZGD Kohler 60RCL Kohler 70REZGT Kohler 80ERESD SDMO G60

Common problems

The generator set does not crank.
Cause: Battery weak or dead, Battery connections reversed or poor, Blown fuse(s)
Fix: Recharge or replace the battery, Check the connections, Replace the fuse. Contact an authorized Kohler distributor/dealer for service if fuse blows repeatedly
The generator set cranks but does not start, starts hard, lacks power, or operates erratically.
Cause: Air cleaner clogged, Battery weak or dead, Battery connection poor, Spark plug wire connection loose, Low oil pressure shutdown, Fuel pressure insufficient, Engine fuse blown, Engine malfunction
Fix: Clean and/or replace the air cleaner, Recharge or replace the battery, Clean and tighten the battery connections, Check the spark plug wires, Check for oil leaks. Check the oil level and add oil if necessary, Check the fuel supply and valves, Replace the fuse. If the fuse blows again, contact an authorized Kohler distributor/dealer, Contact an authorized Kohler distributor/dealer
Rough operation
Cause: Electromagnetic interference (EMI)
No AC output.
Cause: AC circuit breaker in the OFF position, AC circuit breaker tripping because of overload, AC circuit breaker tripping because of short circuit
Fix: Place the circuit breaker in the ON position, Reduce the load on the generator set, Contact an authorized Kohler distributor/dealer for service
Low output or excessive drop in voltage.
Cause: Generator set overloaded
Fix: Reduce the load
LCM relays do not operate.
Cause: Bad connections.
Fix: Check wiring and connections. Verify that cable size and length of run comply with the instructions in the Installation manual. Low or no battery voltage. Check battery connections.
Generator set stops suddenly.
Cause: Low oil pressure shutdown, Out of fuel, Overcrank shutdown
Fix: Check for oil leaks. Check the oil level and add oil if necessary, Check fuel supply, Reset the controller. If the overcrank fault occurs again, contact an authorized Kohler distributor/dealer
Generator set is OFF.
Fix: Press the RUN button to start the engine or press AUTO to allow remote starting
Date is flashing.
Cause: Controller power was disconnected and then reconnected.
Fix: Check battery connections. See Figure 5-1. Check utility power connection for the built-in battery charger. Reset the time, date, and exercise schedule. See Section 2.5.7, Setting the Exerciser at Power-Up.
Controller reset
Cause: Electromagnetic interference (EMI)
Fix: Inspect the distributor cap and rotor for specific features. Replace them if necessary with updated parts.
Controller LCD display is off.
Cause: Low or no battery voltage.
Fix: Check connections. Check generator set battery. See Figure 5-1.
Controller display backlight is off.
Cause: Backlight turns off after about 1 minute with no activity.
Fix: Backlight will turn on when a button is pressed or the generator set starts. Loss of communication to accessory modules: Bad connections. Check wiring and connections. Verify that cable size and length of run comply with the instructions in the Installation manual. Low or no battery voltage. Check battery connections.
Voltage reconnection
Fix: Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.
Unbalanced weight
Fix: Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.
Servicing the exhaust system. Hot parts
Fix: Do not touch hot engine parts.

Compiled from service & troubleshooting documentation across every generator set that uses the General Motors Industrial Powertrain Vortec 5.7 L.

Maintenance schedule

Item	Spec	Capacity	Part #	Interval
Oil filter	Cartridge		—
Oil		6.2 L	—	100 hr

Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.

Service intervals

Item	Action	Hours	Months	Notes
Engine oil level	Check	24 hr		Check the oil level in the crankcase every 24 hours of operation or before the engine is started each day
Air cleaner element	Inspect	100 hr
Change engine oil and filter	Change	100 hr
Check all bolts and nuts for tightness	Check	100 hr
Filter(s)	Replace	150 hr	3 mo	Service more frequently if operated in dusty areas
Oil	Change	150 hr	3 mo	Every 150 Hours or 3 Months
Blow dust out of alternator	Clean	300 hr		2 Yrs or 300 Hrs; service more frequently in dusty areas
Valve clearance	Adjust	500 hr		3 Yrs or 500 Hrs
Wire-cable insulation breakdown	Test	500 hr		3 Yrs or 500 Hrs
Air cleaner element	Replace	1000 hr
Belts and belt tension	Check	1000 hr
Coolant	Change	1500 hr		1500 Hours
Engine coolant	Replace	5000 hr	60 mo	When long-life coolant used
Alternator end bracket bearing	Replace	10000 hr		20--300 kW models; prime power applications
Check coolant level	Check		0 mo
Check engine oil level	Check		0 mo
Check for fluid leaks	Check		0 mo
Coolant temperature protection level	Check		6 mo	Six Months
Paralleling box	Inspect		12 mo	Annually by a Kohler authorized distributor/dealer, or when wear, damage, deterioration, or malfunction is evident or suspected.
Paralleling box internal components	Inspect		1 mo	Monthly or when a condition noticed during external inspection may have affected internal components; enclosure cover must be removed by trained personnel.
Safety and alarm operation	Check		6 mo	Six Months
Safety and alarm operation	Test		6 mo	Six Months
Tighten DC electrical connections	Check		6 mo	Six Months
Wheel lug nut torque	Check			First service — First 80/160 km (50/100 miles); then Quarterly or 3000 Miles

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

Type	Item	Value	Unit	Condition
Gap	Spark plug gap	0.51	mm (0.02 in.)
Gap	Spark plug gap	0.7--0.8	mm (0.028--0.030 in.)
Gap	Spark plug gap	0.76	mm (0.03 in.)
Gap	Spark plug gap	0.8--0.9	mm (0.03--0.04 in.)
Gap	Spark plug gap	0.89	mm (0.035 in.)
Gap	Spark plug gap	0.9--1.0	mm (0.036--0.04 in.)
Other	10 in. weld flange bolt circle diameter B	361.95	mm (14.25 in.)
Other	10 in. weld flange outside diameter C	406.4	mm (16.0 in.)
Other	10 in. weld flange quantity of bolts / bolt hole diameter D	12, 25.40	mm (1.00 in.)
Other	12 in. weld flange bolt circle diameter B	431.80	mm (17.00 in.)
Other	12 in. weld flange outside diameter C	482.6	mm (19.0 in.)
Other	12 in. weld flange quantity of bolts / bolt hole diameter D	12, 25.40	mm (1.00 in.)
Other	14 in. weld flange bolt circle diameter B	476.25	mm (18.75 in.)
Other	14 in. weld flange outside diameter C	533.4	mm (21.0 in.)
Other	14 in. weld flange quantity of bolts / bolt hole diameter D	12, 28.58	mm (1.13 in.)
Other	16 in. weld flange bolt circle diameter B	539.75	mm (21.25 in.)
Other	16 in. weld flange outside diameter C	596.9	mm (23.5 in.)
Other	16 in. weld flange quantity of bolts / bolt hole diameter D	16, 28.58	mm (1.13 in.)
Other	18 in. weld flange bolt circle diameter B	577.85	mm (22.75 in.)
Other	18 in. weld flange outside diameter C	635.0	mm (25.0 in.)
Other	18 in. weld flange quantity of bolts / bolt hole diameter D	16, 31.75	mm (1.25 in.)
Other	20 in. weld flange bolt circle diameter B	635.00	mm (25.00 in.)
Other	20 in. weld flange outside diameter C	698.5	mm (27.5 in.)
Other	20 in. weld flange quantity of bolts / bolt hole diameter D	20, 31.75	mm (1.25 in.)
Other	5 in. weld flange bolt circle diameter B	215.90	mm (8.50 in.)
Other	5 in. weld flange outside diameter C	241.30	mm (9.50 in.)
Other	5 in. weld flange quantity of bolts / bolt hole diameter D	8, 22.23	mm (0.88 in.)
Other	6 in. weld flange bolt circle diameter B	254.0	mm (10.0 in.)
Other	6 in. weld flange outside diameter C	279.4	mm (11.0 in.)
Other	6 in. weld flange quantity of bolts / bolt hole diameter D	8, 22.23	mm (0.88 in.)
Other	8 in. weld flange bolt circle diameter B	298.45	mm (11.75 in.)
Other	8 in. weld flange outside diameter C	342.9	mm (13.5 in.)
Other	8 in. weld flange quantity of bolts / bolt hole diameter D	8, 22.23	mm (0.88 in.)
Other	Alternator protection current/time limits	200%: 40 seconds; 300%: 10 seconds; 425%: 5 seconds; 950%: 1 second		rated current percentage
Other	Battery specific gravity (charge threshold)	1.215	specific gravity	at 26.7 C (80 F); charge if below
Other	Battery specific gravity (fully charged)	1.260	specific gravity	at 26.7 C (80 F) electrolyte temperature
Other	Battery wrap length	1067 (42)	mm (in.)
Other	Battery wrap length	864 (34)	mm (in.)
Other	Controller operating temperature range	--40 to 70 C (--40 to 158 F)
Other	Controller power drain	400 milliamps at 12V; 200 milliamps at 24V
Other	Engine speed adjustment	50		default setting; settings between 40 and 60 acceptable; 52 increases speed by 2 RPM, 49 decreases by 1 RPM
Other	Gaseous fuel tank maximum safe fill level	80	% of total fuel tank volume
Other	Generator to bus phase angle	-10 to 10	degrees	verify with contactor closed
Other	Heater wrap rating	50	Watts
Other	Heater wrap rating	65	Watts
Other	LP gas fuel system leak test pressure	6--8 ounces per square inch (10--14 inches water column)	oz/in2 (in. water column)	test pressurized
Other	Plug cord length	75 (3)	mm (in.)
Other	Power cord length	1677 (66)	mm (in.)
Other	Power cord length	1830 (72)	mm (in.)
Other	Power cord length	483 (19)	mm (in.)
Other	Reactive droop	1	%	default setting; range 0.5 - 2%
Other	Weld flange angle A (10, 12, 14 in. nominal pipe size)	30	deg.
Other	Weld flange angle A (16, 18, 20 in. nominal pipe size)	22.5	deg.
Other	Weld flange angle A (5, 6, 8 in. nominal pipe size)	45	deg.
Other	Wheel stud size	1/2-20
Pressure	Fuel tank pressure relief valve (close)	1937--2130	kPa (281--309 psi)
Pressure	Fuel tank pressure relief valve (open)	2151	kPa (312 psi) min
Pressure	Tire inflation pressure @ rated load	552 (80 psi)	kPa (psi)
Speed	Overfrequency default setting	110% of nominal	%
Speed	Overfrequency setting range	102%--140% of nominal	%

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

Fluid	Grade	Standard	Ambient	Capacity	Notes
Coolant	50% ethylene glycol			0.6 L	Provides freezing protection to --37_C (--34_F) and overheating protection to 129_C (265_F). Do not use alcohol or methanol antifreeze. Coolant added after block heater installation is approximately 0.6 L (0.2 gal).
Coolant	Long-life coolant				Change interval 5000 hours or 5 years when long-life coolant used; do not mix coolant types
Engine oil	SAE 5W-30	API Starburst (for gasoline engines)	below -18°C	4.7 L	For below -18C (0F)
Engine oil	SAE 10W-30	API Starburst (for gasoline engines)	above -18°C	4.7 L	For -18C (0F) and above; CC/CD classification and straight-weight industrial/stationary oils not acceptable
Grease	Lithium complex				Axle bearing grease type
Grease	Multipurpose grease				Lubricate trailer hitch/coupler contact points
Grease	Petroleum jelly, silicon grease, or other nonconductive grease				Coat battery terminals after reconnecting
Grease	White lithium grease				Apply a small amount behind the brake shoe where it rubs against the backing plate

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Fault codes

Code	Name	Meaning	Severity	Action
AC Sens Lost	AC Sensing Lost	In Auto mode, generator output AC sensing is lost; starts 10 seconds after crank disconnect. Warning after 1 second if no output detected after crank disconnect; shutdown after 3 seconds if voltage was present and then lost.	Warning	Contact an authorized distributor/dealer for service.
AC Sensing Lost			Warning
ATS Com Error	ATS Communication Error	Warning is displayed if RXT interface connection is lost.	Warning	Check communication wiring between transfer switch interface board and generator set.
ATS PhaseRot	ATS Phase Rotation Mismatch	Transfer switch phase rotation does not match; ATS will not transfer.	Warning	Correct the ATS connection per the ATS Installation manual, wiring diagrams, and labels on the transfer switch.
Accy PwrOver	Accessory Power Overload	Over current fault on the accessory controller power output	Warning
Accy PwrOver Warning	Accessory Power Overload	An over current fault (short circuit) on the accessory controller power output.	Warning	Contact an authorized distributor/dealer for service.
Alt Protect Shtdwn	Alternator Protection Shutdown	High generator current detected; shuts down to protect alternator windings from overheating (38RCL only).	Shutdown	Reduce the load.
Alternator Protection			Shutdown
Aux Input	Auxiliary Input	An optional customer-connected input is closed (digital input from optional PIM).	Shutdown	Check customer-supplied equipment.
Auxiliary Input			Warning
Avg Current	High		Warning
Avg Gen Voltage L-L	Low		Warning
Batt Chg Flt	Battery Charger Fault	Input to PIM from an external battery charger (not the built-in charger).	Warning	Check external battery charger.
Battery Charger Fault			Warning
Battery Voltage High	Battery Voltage High	Engine starting battery voltage rises above 125% of the battery voltage setting for more than 10 seconds; inhibited during crank cycle.	Warning	Check the battery rating and condition; check the battery charger operation.
Battery Voltage Low	Battery Voltage Low	Engine starting battery voltage falls below the battery voltage setting (typically 12.5 volts) for more than 90 seconds when engine not running; inhibited during crank cycle.	Warning	Check the battery rating and condition; check the battery charger operation; charge or replace the battery.
CAN comm fault	CAN Communications Fault	Engine CAN communications fault.	Shutdown	Check wiring to ECM; check power to ECM.
Cabinet Intrusion Alarm			Warning
Coolant Pressure	Low		Warning
Cranking Voltage	Low		Warning
ECM Communication Loss			Shutdown
ECM Model Mismatch			Shutdown
Electrical Metering Communication Loss			Shutdown
Emergency Stop			Shutdown
Engine Coolant Level	Low		Shutdown
Engine Coolant Temperature	Low		Warning
Engine Coolant Temperature High	Engine Coolant Temperature High	Engine coolant temperature exceeds the maximum temperature for more than 5 seconds; active after crank disconnect.	Shutdown	Check for blocked air inlets and exhaust outlets.
Engine Derate Active			Warning
Engine Fuel Level	Low		Warning
Engine Oil Level	Low		Warning
Engine Oil Pressure	Shorted High		Warning
Engine Oil Pressure Low	Engine Oil Pressure Low	The engine ECM indicates low oil pressure for more than 5 seconds	Shutdown	Check for leaks in the lubrication system; check the oil level and add oil if low.
EngineSpeed High	Engine Speed High	Engine speed exceeds 115% of normal running speed for more than 0.3 seconds.	Shutdown	Contact an authorized distributor/dealer for service.
EngineSpeed Low	Engine Speed Low	Engine speed drops below 85% of normal running speed for more than 3 seconds.	Shutdown	Reduce the load; contact an authorized distributor/dealer for service.
Exer Not Sch	Exercise Not Scheduled	No exercise has been scheduled on the RDC2 controller.	Warning	See exerciser setup instructions.
Failure To Synchronize			Warning
Fuel Pressure	Low		Warning
Fuel Tank Leak			Warning
Fuel Temperature	High		Warning
Gen Battery Voltage	Low		Warning
Generator Frequency	Low		Warning
Generator Frequency High	Generator Frequency High	Governed frequency exceeds 110% of the system's frequency setpoint for more than 10 seconds; active 10 seconds after engine start.	Shutdown	Contact an authorized distributor/dealer for service.
Generator Frequency Low	Generator Frequency Low	Governed frequency falls below 90% of system frequency setting for more than 10 seconds, or 1 Hz below setting for more than 60 seconds; active 10 seconds after engine start.	Shutdown	Reduce the load and restart the generator set; contact an authorized distributor/dealer for service.
Generator Voltage L1-L2	Low		Shutdown
Generator VoltageL1-L2 High	Generator Voltage High	Output voltage exceeds 120% of the system nominal voltage for more than 2 seconds.	Shutdown	Contact an authorized distributor/dealer for service.
Generator VoltageL1-L2 Low	Generator Voltage Low	Output voltage falls below 80% of the nominal system voltage for more than 10 seconds.	Shutdown	Reduce the load and restart the generator set; contact an authorized distributor/dealer for service.
Ground Fault Input			Warning
Injector Wiring Fault			Warning
Intake Air Temperature	High		Warning
Lo Crank Vlt	Low Cranking Voltage	Battery voltage falls below 60% of system battery voltage for more than 6 seconds while the starter is engaged.	Warning	Charge or replace the battery.
Locked Rotor	Locked Rotor	No engine rotation is sensed during cranking; shuts down 3 seconds after the fault is detected.	Shutdown	Check the battery; check for loose connections; contact an authorized distributor/dealer for service.
MainPwrOverL Shutdown	Main Power Overload	An over current fault on the controller power output (short circuit).	Shutdown	Contact an authorized distributor/dealer for service.
Maximum Alternator Current	Low		Shutdown
Not In Auto			Warning
Not in Auto	Not in Automatic Mode	The generator set is not in Automatic (standby) mode; remote start/stop commands from a transfer switch or remote switch will be ignored.	Warning	Press AUTO to place the generator set in Automatic mode, when appropriate.
Over Crank	Over Crank	Three unsuccessful starting attempts.	Shutdown	Check the fuel supply, spark plug, and battery; check for loose connections; contact an authorized distributor/dealer for service.
Reserve Oil Empty			Warning
Run Relay Coil Overload			Shutdown
Speed Sensor Fault	Speed Sensor Fault	Engine speed sensor has failed or engine stalled.	Warning	Contact an authorized distributor/dealer for service.
Starter Relay Coil Overload			Shutdown
System Frequency	High		Warning
System Voltage	High		Warning
Total Power (Generator Total Real Power)	Low		Warning
Total Power High ShtDwn	Total Power High Shutdown	Measured load is greater than 102% of the generator set power rating for more than 1 minute (38RCL only).	Shutdown	Reduce the load.
Total Reactive Power	Low		Warning
Water In Fuel			Warning

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

Calibration adjustment

⚠ Copying personality profiles from one controller to another can overwrite calibration coefficients and requires re-calibration.

Tools: Calibrated multimeter with recent calibration verification

Use a calibrated multimeter to measure the generator voltage and enter the correct value in the CONTROLLER CONFIG -> CALIBRATION screen.
Use a calibrated multimeter to measure the bus voltage and enter the correct value in the CONTROLLER CONFIG -> CALIBRATION screen.

Electric Brake Adjustment adjustment

⚠ Never use compressed air to clean brake components; some components may contain asbestos.

Tools: Adjustment tool or large slotted screwdriver, Jack stands

Raise the trailer with wheels off the ground and block safely with jack stands; remove the wheel.
Remove the rubber plug from the backing plate slot.
Insert an adjustment tool or large slotted screwdriver in the slot and rotate the star wheel to expand the shoe against the drum.
Expand the shoe until the drum can't be turned by hand to center each shoe.
Back off the adjustment in the other direction until the drum turns freely with slight resistance.
Replace the rubber plug in the backing plate slot.
Repeat procedure for remaining wheels.

RDC2 Voltage Calibration Using SiteTech adjustment

Tools: digital voltmeter, personal computer, SiteTech software

Connect PC to controller via USB
With generator off, connect multimeter across L1/L2 (AC volts)
Start generator set
Compare voltmeter reading to controller display
Calculate new Genset Calibration Factor Voltage using (Vmeter / Vcontrol) x Fold = Fnew
Enter new value into SiteTech and click Apply Changes
Verify voltmeter matches controller display
Repeat for L2-L3 and L3-L1 if three-phase
Press OFF to stop generator set

RDC2 Voltage Calibration Using the Controller Keypad adjustment

Tools: digital voltmeter

With generator off, connect digital multimeter across L1 and L2, set to AC volts
Start generator set with RUN button
Navigate to Generator Metering menu, press Select; Volts L1-L2 displayed
Press Select; voltage number flashes
Use up/down arrows to match voltmeter reading
Press Select to confirm
Step to Return screen
Press OFF to stop generator set

VSC Current (Load) Calibration Using the Controller Keypad adjustment

Tools: clamp-on DC current probe or DC current meter

Connect DC current probe/clamp meter to measure generator current
Start generator with RUN button
Adjust system voltage to obtain rated current output with battery bank attached (or use load bank)
Trip output breaker
Navigate to Generator Metering menu, select Generator Load
Press and hold Select for No-Load Calibration; verify breaker open, confirm Yes
Close output breaker; verify rated output current, confirm Yes
Verify displayed load is correct; recalibrate if necessary
Press OFF to stop generator set

Procedure to Reset the Controller after a Fault Shutdown diagnostic

⚠ Always identify and correct the cause of a fault shutdown before resetting the controller.

Press the Select button to go to the Overview menu.
Press Select again to display the active fault.
Press Select; Confirm Clear Fault: NO is displayed.
Press the Up arrow button; Confirm Clear Fault: YES is displayed.
Press the Select button to enter YES and clear the fault.
Press the Select button to return to the overview menu.
Press AUTO to put the generator set into automatic mode.

Verify Generator Operation diagnostic

⚠ Generators must all operate at the same frequency, voltage, and phase connection in order to parallel.

Tools: SiteTech software

Ensure the load is not connected or is drawing less power than a single generator can provide.
Navigate to CONTROLLER CONFIG -> COMMUNICATION SETUP and verify PGEN Nodes Online indicates the correct number of nodes.
Verify alternator connection (voltage selector switch position), system voltage, and voltage regulator target on each generator.
Start a single generator by pressing the Run button; the paralleling box contactor should close and the Generator Connected to Bus indicator should light.
Verify bus and generator voltages match and generator to bus phase angle is between -10 and 10 degrees.
Verify the load bus is energized and available at the load.
Stop the generator by pressing the OFF button; the contactor should open.
Repeat for each generator in the paralleling system.

Verify Paralleling and Load Sharing diagnostic

Tools: Load bank (optional)

Place all generators in automatic mode by pressing the Auto button; verify the red shutdown indicator is not illuminated.
Provide a local start request by holding AUTO, pressing RUN, releasing RUN, then releasing AUTO.
Verify all generators start, one generator closes its contactor, and the others synchronize and close their contactors.
Verify that the % of rated power of the generators matches, showing the generators are sharing load equally.
If a load bank is available, test the system under load.

Control Harness Connections installation

⚠ The control harness connections for GEN 1 and GEN 2 must correspond to the source camlock cable connections.

Connect the control harness from the generator set connected to the GEN 1 camlock connectors to GEN 1 CONTROL.
Connect the control harness from the generator set connected to the GEN 2 camlock connectors to GEN 2 CONTROL.
When not used, store the control harnesses on the storage rack inside the enclosure.

Grounding installation

⚠ Grounding electrical equipment: hazardous voltage can cause severe injury or death. Turn off the main circuit breakers of all power sources before servicing.

Connect the ground lug on the paralleling box to earth ground according to applicable state and local codes.
Follow NEC guidelines for grounding electrical equipment.
The neutral is bonded to ground inside the paralleling box; if required, remove the bonding bus to disconnect neutral from ground.

Install the block heater installation

⚠ Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater.

⚠ Do not add coolant to a hot engine. Wait until the engine has cooled.

⚠ Hot coolant and steam. Stop the generator set and allow it to cool before removing the pressure cap.

Tools: pipe sealant, cable tie

Secure the block heater to the block heater mounting bracket (GM78546) using 4 screws (M933-06020-60), 4 washers (M125A-06-80), and 4 hex nuts (M6923-06-80).
Secure the mounting bracket with block heater to the skid using 2 screws (M933-06016-60) and 2 hex nuts (M6923-06-80).
Locate the 2 shutoff valves on opposite sides of the engine block and verify they are closed.
Remove the pipe plug from each shutoff valve and discard the plugs.
Apply pipe sealant to the threads of hose connectors X-391-19 and X-582-1.
Install the 90 degree hose connector (X-391-19) in the shutoff valve closest to the block heater.
Install the straight connector (X-582-1) in the shutoff valve on the opposite side of the engine.
Hold the molded hose (276206 or GM103656) in place and cut to fit if necessary.
Install the shorter heat shield (GM17809) over the molded hose and secure with a cable tie.
Connect the molded hose to the hose connector and secure with a hose clamp (X-426-12 or GM103203).
Connect the other end of the hose to the block heater outlet and secure with a hose clamp (X-426-12 or GM103203).
Install the longer heat shield (GM23718) over the inlet hose (X-312-53 or X-312-47) and secure with a cable tie.
Connect the hose to the block heater inlet with a hose clamp (X-426-12); route the hose under the engine.
Secure the hang tag (279047) to the power cord.
Open the two block heater shutoff valves and, after the block heater is full, add approximately 0.6 L (0.2 gal) coolant to the cooling system.

Load Connections installation

⚠ Multiple power sources can automatically energize the distribution bus. Disconnect all power sources before connecting to the distribution bus.

Remove the camlock security guard from one row of connectors for each generator and store the guard.
Connect the load side ground (green) camlock cables to the distribution bus and then to the paralleling box.
Connect the load side neutral (white) camlock cables to the distribution bus and then to the paralleling box.
Connect the load side L1 (black), L2 (red), and L3 (blue) camlock cables to the distribution bus and then to the paralleling box.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

Voltage	Phase	Connection	Leads	Notes
		Alternator Reconnection drawing ADV-5875U--1	4	4--Lead
	1	Camlocks (left to right)	Green=GND; White=L0; Black=L1; Red=L2	Single-phase uses four camlocks
	3	Camlocks (left to right)	Green=GND; White=L0; Black=L1; Red=L2; Blue=L3	Three-phase uses all five camlocks
100/200	1	Single
100/200	3	Delta
110/220	1	Single
110/220	3	Delta
115/230	1	Single
120	1	Single		Genset System Voltage/Frequency/Phase table for controller setup
120/208	3	Low wye	L0-L1: 120; L1-L2: 208; L1-L3: 208; L2-L3: 208	Voltage selector switch position Low wye; selector switch factory set Pos. 2 Volts 120/208, 60 Hz, Three Phase Wye
120/208	3	Wye
120/240	1	Single
120/240	1	Single-phase	L0-L1: 120; L1-L2: 240	Voltage selector switch position Single-phase; selector switch factory set Pos. 3 Volts 120/240, 60 Hz, Single Phase Dogleg (3-position switch only)
120/240	3	Delta
127/220	3	Wye
220	1	Single
220/380	3	Wye
230	1	Single
230/400	3	Wye
240	1	Single
240/416	3	Wye
277/480	3	High wye	L0-L1: 277; L1-L2: 480; L1-L3: 480; L2-L3: 480	Voltage selector switch position High wye; selector switch factory set Pos. 1 Volts 277/480, 60 Hz, Three Phase Wye
277/480	3	Wye

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

What is the oil capacity of the General Motors Industrial Powertrain Vortec 5.7 L?

The General Motors Industrial Powertrain Vortec 5.7 L engine has an oil capacity of 6.2 liters.

What is the displacement of the General Motors Industrial Powertrain Vortec 5.7 L?

The General Motors Industrial Powertrain Vortec 5.7 L has a displacement of 5.7 liters with -8 cylinders.

Which generators use the General Motors Industrial Powertrain Vortec 5.7 L engine?

The General Motors Industrial Powertrain Vortec 5.7 L powers 7 generator set(s), including Kohler 100ERESD, Kohler 100REZGD, Kohler 100RZGD, Kohler 60RCL, Kohler 70REZGT.

How often should you change the oil in the General Motors Industrial Powertrain Vortec 5.7 L?

The General Motors Industrial Powertrain Vortec 5.7 L oil change interval is every 100 hours.

What is a common problem with the General Motors Industrial Powertrain Vortec 5.7 L engine?

A commonly reported issue on generators using the General Motors Industrial Powertrain Vortec 5.7 L is: The generator set does not crank.. Cause: Battery weak or dead, Battery connections reversed or poor, Blown fuse(s). Fix: Recharge or replace the battery, Check the connections, Replace the fuse. Contact an authorized Kohler distributor/dealer for service if fuse blows repeatedly.