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.
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, 100RZG 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
| 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 |
Shared across brands: Kohler, SDMO
Compiled from service & troubleshooting documentation across every generator set that uses the General Motors Industrial Powertrain Vortec 5.7 L.
| 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.
| 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 | ||
| Air cleaner element | Replace | 1000 hr | ||
| Belts and belt tension | Check | 1000 hr | ||
| Engine coolant | Replace | 5000 hr | 60 mo | When long-life coolant used |
| Check coolant level | Check | 0 mo | ||
| Check engine oil level | Check | 0 mo | ||
| Check for fluid leaks | Check | 0 mo | ||
| 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. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| 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 | Engine speed adjustment | 50 | default setting; settings between 40 and 60 acceptable; 52 increases speed by 2 RPM, 49 decreases by 1 RPM | |
| Other | Generator to bus phase angle | -10 to 10 | degrees | verify with contactor closed |
| 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. | |
| Temperature | Block heater thermostat cut-off temperature | 27--38 | °C | coolant temperature |
| Temperature | Block heater thermostat cut-off temperature | 80--100 | °F | coolant temperature |
| Torque | PGEN terminal block connections | 0.5 | Nm | |
| Torque | PGEN terminal block connections | 4.4 | in. lbs. | |
| Torque | Spark plug torque | 15 | Nm (11 ft. lb.) | |
| Torque | Spark plug torque | 18 | Nm (13.3 ft. lb.) | |
| Torque | Spark plug torque | 24.4--29.8 | Nm (18--22 ft. lb.) | |
| Torque | Spark plug torque | 25 | Nm (18 ft. lb.) | |
| Voltage | Controller measurement accuracy | 2 | % | without calibration; requires a calibrated multimeter for calibration |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| 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 |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| 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. |
| 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. |
| Aux Input | Auxiliary Input | An optional customer-connected input is closed (digital input from optional PIM). | Shutdown | Check customer-supplied equipment. |
| 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 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. |
| 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 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. |
| 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 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. |
| 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. |
| 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. |
| Speed Sensor Fault | Speed Sensor Fault | Engine speed sensor has failed or engine stalled. | Shutdown | Contact an authorized distributor/dealer for service. |
| 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. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
⚠ Copying personality profiles from one controller to another can overwrite calibration coefficients and requires re-calibration.
Tools: Calibrated multimeter with recent calibration verification
Tools: digital voltmeter, personal computer, SiteTech software
Tools: digital voltmeter
Tools: clamp-on DC current probe or DC current meter
⚠ Always identify and correct the cause of a fault shutdown before resetting the controller.
⚠ Generators must all operate at the same frequency, voltage, and phase connection in order to parallel.
Tools: SiteTech software
Tools: Load bank (optional)
⚠ The control harness connections for GEN 1 and GEN 2 must correspond to the source camlock cable connections.
⚠ Grounding electrical equipment: hazardous voltage can cause severe injury or death. Turn off the main circuit breakers of all power sources before servicing.
⚠ 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
⚠ Multiple power sources can automatically energize the distribution bus. Disconnect all power sources before connecting to the distribution bus.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Voltage | Phase | Connection | Leads | Notes |
|---|---|---|---|---|
| 12-Lead | Alternator Reconnections diagram ADV-5875B-M (page 16) | |||
| 4-Lead | Alternator Reconnections diagram ADV-5875A-M (page 15) | |||
| Alternator Reconnection drawing ADV-5875U--1 | 4 | 4--Lead | ||
| 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 | Wye | ||
| 120/240 | 1 | Single | ||
| 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 | Wye |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
The General Motors Industrial Powertrain Vortec 5.7 L engine has an oil capacity of 6.2 liters.
The General Motors Industrial Powertrain Vortec 5.7 L has a displacement of 5.7 liters with -8 cylinders.
The General Motors Industrial Powertrain Vortec 5.7 L powers 7 generator set(s), including Kohler 100ERESD, Kohler 100REZGD, Kohler 100RZG, Kohler 60RCL, Kohler 70REZGT.
The General Motors Industrial Powertrain Vortec 5.7 L oil change interval is every 100 hours.
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.