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General Motors Vortec DOHC Engine

The General Motors Vortec DOHC is a 1.6 L engine rated at 1800 rpm. It powers generator sets from Kohler, including the 100ERES, 15RES, 30RES and 50ERES.

Also known as: General Motors Vortec DOHC

Part of the General Motors Vortec engine family — 4 variants share parts & fitment.

1.6 L

Displacement

1800 rpm

Rated speed

On this pageSpecs Generator sets FAQ Torque & specs Fault codes Procedures Wiring

Engine specifications

Displacement	1.6 L
Rated speed	1800 rpm

Generator sets powered by this engine

Kohler 100ERES Kohler 15RES Kohler 30RES Kohler 50ERES Kohler 60ERES Kohler 80ERES

Common problems

Generator set stops suddenly
Cause: Low oil pressure shutdown
Fix: Check the oil level. Check for oil leaks.
The generator set cranks but does not start, starts hard, lacks power, or operates erratically
Cause: Air cleaner clogged
Fix: Clean and/or replace the air cleaner.
The generator set does not crank
Cause: Battery weak or dead
Fix: Recharge or replace the battery.
No AC output
Cause: AC circuit breaker in the OFF position
Fix: Place the circuit breaker in the ON position.
Controller LED display is off
Cause: No power to the controller: Controller powers down if the generator set has not run for 48 hours or longer
Fix: Controller display will automatically activate when a remote start command is received or the generator set master switch is moved to the RUN position.
Undervoltage shutdown — shutdown occurs if the voltage falls below 80% of the nominal system voltage for more than 10 seconds UU
Fix: Reduce the load and restart the generator set; contact an authorized Kohler distributor/dealer for service if problem continues.
Underfrequency shutdown — shutdown occurs when the governed frequency falls below 90% of the nominal system frequency for more than 5 seconds or below 59 Hz for more than 60 seconds; this protective becomes active 10 seconds after engine start (10 second inhibit) UF
Fix: Reduce the load and restart the generator set; contact an authorized Kohler distributor/dealer for service if problem continues.
Software Communication Fault 0 — indicates a software or communication problem within the ADC 2100 SCF0
Fix: Replace the controller.
Overvoltage shutdown — shutdown occurs if the voltage exceeds 120% of the system nominal voltage for more than 2 seconds OU
Fix: Contact an authorized Kohler distributor/dealer for service if problem continues.
Overspeed shutdown — shutdown occurs if the engine speed exceeds 115% of the normal running speed for more than 0.3 seconds OS
Fix: Contact an authorized Kohler distributor/dealer for service if problem continues.
Overfrequency shutdown — shutdown occurs when the governed frequency exceeds 110% of the system's frequency setpoint for more than 5 seconds; this protective becomes active 10 seconds after engine start (10 second inhibit) OF
Fix: Contact an authorized Kohler distributor/dealer for service if problem continues.
Overcrank shutdown — shutdown occurs after 3 unsuccessful starting attempts; the crank cycle is set for three starting attempts of 15 seconds cranking and 15 seconds rest; the generator set also shuts down if no engine rotation is sensed during cranking; shuts down 1 second after the fault is detected OC
Fix: Check the fuel supply, spark plug, and battery; check for loose connections; contact an authorized Kohler distributor/dealer for service if problem continues.
Low output or excessive drop in voltage
Cause: Generator set overloaded
Fix: Reduce the load.
Low oil pressure shutdown — shutdown occurs if a low oil pressure condition exists for more than 5 seconds; this protective becomes active 30 seconds after the engine has reached crank disconnect speed (30 second inhibit) LOP
Fix: Check for leaks in the lubrication system; check the oil level and add oil if the level is low.
Low coolant level — not used LCL

Compiled from service & troubleshooting documentation across every generator set that uses the General Motors Vortec DOHC.

Service specifications

Type	Item	Value	Unit	Condition
Torque	1-12 fastener	283.0 (209)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	1-8 fastener	259.0 (191)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	1/2-13 fastener	60.0 (44)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	1/2-20 fastener	66.0 (49)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	1/4-20 fastener	6.8 (60)	Nm (in. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	1/4-28 fastener	8.1 (72)	Nm (in. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	10-24 fastener	2.9 (26)	Nm (in. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	10-32 fastener	2.9 (26)	Nm (in. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	3/4-10 fastener	199.0 (147)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	3/4-16 fastener	222.0 (164)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	3/8-16 fastener	24.0 (18)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	3/8-24 fastener	27.0 (20)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	5/16-18 fastener	13.6 (120)	Nm (in. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	5/16-24 fastener	14.9 (132)	Nm (in. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	5/8-11 fastener	113.0 (83)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	5/8-18 fastener	128.0 (94)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	7/16-14 fastener	39.0 (29)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	7/16-20 fastener	43.0 (32)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	8-32 fastener	1.8 (16)	Nm (in. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	9/16-12 fastener	81.0 (60)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	9/16-18 fastener	91.0 (67)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 2 or 5
Torque	M10 x 1.25 fastener	31.0 (23)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M10 x 1.50 fastener	30.0 (22)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M12 x 1.50 fastener	56.0 (41)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M12 x 1.75 fastener	53.0 (39)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M14 x 1.50 fastener	87.0 (64)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M14 x 2.00 fastener	83.0 (61)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M16 x 1.50 fastener	132.0 (97)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M16 x 2.00 fastener	127.0 (94)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M18 x 1.50 fastener	189.0 (140)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M18 x 2.50 fastener	179.0 (132)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M6 x 1.00 fastener	6.2 (4.6)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M8 x 1.00 fastener	16.0 (11)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8
Torque	M8 x 1.25 fastener	15.0 (11)	Nm (ft. lb.)	Assembled into cast iron or steel, Grade 5.8 or 8.8

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
AF	Auxiliary fault	FMI 2, SPN 0x02BD
CC	Crank cycle
CO-3		Fault displayed if the CO parameter is set incorrectly	Shutdown
CO-6		Fault displayed if the CO parameter is set incorrectly	Shutdown
HB	High battery voltage	FMI 0, SPN 0x00A8
HE	High engine temp	FMI 0, SPN 0x006E
LB	Low battery voltage	FMI 1, SPN 0x00A8
LCL	Low coolant level	FMI 1, SPN 0x006F
LOC	Loss of coolant	FMI 1, SPN 0x006F
LOP	Low oil pressure	FMI 1, SPN 0x0064
OC	Overcrank	FMI 0, SPN 0x068B
OF	Overfrequency	FMI 0, SPN 0x0984
OS	Overspeed	FMI 0, SPN 0x00BE
OU	Overvoltage	FMI 0, SPN 0x0988
UF	Underfrequency	FMI 1, SPN 0x0984
UU	Undervoltage	FMI 1, SPN 0x0988

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

Procedures

ADC-RES Controller Configuration (Cn setting) adjustment

⚠ The controller automatically exits configuration mode without saving changes after about 1 minute if no buttons are pressed.

Enter the configuration mode while the engine is not running by following the Figure 26 sequence.
Step through the parameters to the communication setting Cn parameter.
Use the up and down arrow buttons to change the Cn setting to Cn01, if necessary.
Press to SAVE CHANGES (YES) before exiting the configuration mode.
Move the generator set master switch to OFF/RESET.

Controller Configuration adjustment

⚠ Be sure to save the new settings immediately before exiting the configuration mode; changes are lost if the controller times out (about 1 minute).

Hold the Select button and move the master switch to RUN to enter configuration mode.
Press the down arrow key then the up arrow key 3 times to enter configuration mode (password).
Set the voltage/frequency parameter Uu for the model.
Set the unit configuration parameter Uc (marine, standby, mobile).
Set the engine type parameter Ec.
Press the up arrow at the Adnc display to enter advanced configuration mode.
Set the engine data input type Ed.
Set the battery voltage Bt (12 or 24 VDC).
Set the communications parameter Cn.
Enter save mode and save your settings before exiting.

Output Voltage and Frequency Adjustment adjustment

⚠ The generator set must be running during these adjustments.

⚠ The engine speed (frequency) adjustment menus are not accessible on models with mechanical governors.

Tools: multimeter

Move the master switch to RUN; the engine starts and runtime hours display.
Hold the Select button about 5 seconds until the program version number displays.
Press the down arrow key then the up arrow key 3 times to enter adjustment mode.
1P: adjust voltage coarse in large increments (approximately 5-7 volts per step).
2P: adjust voltage fine in smaller increments (approximately 0.5-0.7 volts per step).
Adjust voltage stability (gain) coarse and fine.
3P: set volts/Hz (00=low, 09=high).
4P: adjust engine governor speed coarse and fine.
5P: adjust engine governor stability (gain) coarse and fine.
Enter SAVE mode and save settings before exiting the adjustment mode.

Network Bridge Diagnostics diagnostic

Check the network LEDs on the RJ45 connector for Ethernet network communication.
Check the STAT LED; if not lit, check connections and the engine starting battery.
Check the TX and RX LEDs for CAN data transmission and reception.
If neither the TX nor the RX LED flashes, check bridge power, connections, and settings.
If only one of the TX or RX LEDs flashes, check the connected devices on the generator set (CAN) side.

15/30RES and 15/30RYG Bridge Installation (GM62630-KP2) installation

Remove the junction box panel to gain access to the inside of the junction box.
Drill two 4.8 mm (3/16 in.) mounting holes in the top of the junction box.
Install network bridge GM58703 inside the junction box using two screws M7985A-0410-20, washers M125A-04-80, and nuts M934-04-50.
Proceed to Section 6, Network Bridge Connection.

15/30RESA and 15/30REYG Bridge Installation (GM62630-KP4) installation

Remove the junction box panel to gain access to the inside of the junction box.
Drill two 4.8 mm (3/16 in.) mounting holes in the top of the junction box.
Install network bridge GM58703 inside the junction box using two screws M7985A-0410-20, washers M125A-04-80, and nuts M934-04-50.
Proceed to Section 6, Network Bridge Connection.

17/18RES Bridge Installation (GM62630-KP1) installation

Open the enclosure and remove the front panel to access the controller junction box. Cover internal components.
Drill a hole for the customer-supplied Ethernet cable at the location shown.
Drill a 38.1 mm (1.5 in.) hole in the bottom of the junction box. Insert bushing X-634-28.
Route connector P21 of Y-harness GM62626 through this opening.
Drill two 4.8 mm (3/16 in.) mounting holes in the front panel at the locations shown.
Use two screws M7985A-04010-20, washers X-6278-8, and nuts M934-04-50 to mount network bridge GM58703.
Proceed to Section 6, Network Bridge Connection.

8.5/12RES Bridge Installation (GM62630-KP3) installation

Remove existing junction box panel GM60625. Save the hardware and seal for reuse.
Mount network bridge GM58703 onto the new panel using two screws X-51-15, washers M125A-04-80, and nuts M934-04-50.
Install new J-box panel GM66795 as shown. Use the existing hardware and seal X-6422-31.
Affix decal GM54820 in the location shown.
Proceed to Section 6, Network Bridge Connection.

Assign Bridge IP Address installation

Tools: DeviceInstaller software

Launch DeviceInstaller from the Windows Start button.
In the DeviceInstaller menu, click View then Details.
Click the Search button on the toolbar.
Find the device whose hardware address matches the MAC address printed on the network bridge label.
Click the Assign IP button in the toolbar.
If no IP address is assigned, enter the bridge's hardware (MAC) address and click Next.
Select Assign a Specific IP Address and click Next.
Type the bridge IP address, subnet mask, and default gateway in dotted decimal notation. Click Next.
Click the Assign button to assign the IP settings.
Click the Finish button to close the Wizard.

Common Hardware Application installation

Determine entry hole type: round or slotted.
Determine exit hole type: fixed female thread (weld nut), round, or slotted.
For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter.
Hardware greater than 1/2 inch in diameter uses a standard nut and SAE washer.
Hardware 1/2 inch or less in diameter can use a properly torqued whiz nut or spiralock nut.
Always use a washer between hardware and a slot.
Always use a washer under a nut.
Use a washer under a bolt when the female thread is fixed (weld nut).

Controller Replacement installation

⚠ Disconnect the battery cables before working on the generator set; remove the negative lead first and reconnect it last.

Tools: multimeter, personal computer with Program Loader Software

Record generator set information required for configuration: model, market, voltage, frequency, phases, battery voltage.
Place the generator set master switch in the OFF position.
Disconnect power to the battery charger, if equipped.
Disconnect the engine starting battery(ies), negative lead first.
Open the junction box; disconnect the controller at P1, J15, and J16.
Models ECD/EFCD, EGD/EFGD, EGZD only: disconnect the CO sensor harness at the 4-pin connector.
Remove four controller mounting screws and remove the old controller.
ECD/EFCD, EGD/EFGD, EGZD only: install CO sensor module assembly GM46362 on the back of the new controller GM47982.
Install the new controller and secure with the mounting screws.
Reconnect the P1, J15, and J16 connectors; connect the CO sensor harness on applicable models.
Models 10/13/15EG, 10/13/15ERG, 15/30RES, 15/30RYG with S/N before 2053692: cut a 1-in. section of the gray/orange lead entering pin 9 at the ECM connector.
Check that the generator set master switch is in the OFF position.
Reconnect the engine starting battery, negative lead last.
Reconnect power to the battery charger, if equipped.
Check the controller application software version and load the latest application code if necessary.

DeviceInstaller Software Installation Procedure installation

Tools: OnCue software CD-ROM

Insert the OnCue software CD-ROM into your PC's CD drive and wait for the opening window.
Click on DeviceInstaller Software. A new window will open.
Click on the Installer.msi file. The DeviceInstaller Setup Wizard will start.
Read the information on the screen and click Next.
Choose the installation directory, normally C:\Program Files. Click Next.
Choose Everyone or Just me for multiple PC users. Click Next.
Continue to follow the on-screen instructions to install DeviceInstaller software.

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
100 VAC	1	1Ph, 2W		Uu00; 60 Hz
100 VAC	1	1Ph, 3W		Uu00; 60 Hz
100/200 VAC	1	1Ph, 3W		Uu08; 60 Hz
110 VAC	1	1Ph, 2W		Uu05; 50 Hz
110 VAC	1	1Ph, 3W		Uu05; 50 Hz
110/190 VAC	3	Wye		Uu17; 50 Hz
110/220 VAC	1	1Ph, 3W		Uu07; 50 Hz
110/220 VAC	1	Dogleg		Uu07; 50 Hz
110/220 VAC	3	Delta		Uu15; 50 Hz
115 VAC	1	1Ph, 2W		Uu05; 50 Hz
115/200 VAC	3	Wye		Uu23; 50 Hz
115/230 VAC	1	1Ph, 3W		Uu02; 50 Hz
115/230 VAC	1	Dogleg		Uu06; 50 Hz
115/230 VAC	3	Delta		Uu14; 50 Hz
120 VAC	1	1Ph, 2W		Uu00; 60 Hz
120 VAC	1	1Ph, 3W		Uu00; 60 Hz
120/208 VAC	3	Wye		Uu11; 60 Hz
120/240 VAC	1	1Ph, 3W		Uu01; 60 Hz
120/240 VAC	1	Dogleg		Uu01; 60 Hz
120/240 VAC	3	Delta		Uu10; 60 Hz
127/220 VAC	3	Wye		Uu16; 60 Hz
139/240 VAC	3	Wye		Uu10; 60 Hz
220 VAC	1	1Ph, 2W		Uu12; 50 Hz
220/380 VAC	3	Wye		Uu19; 60 Hz
230 VAC	1	1Ph, 2W		Uu02; 50 Hz
230/400 VAC	3	Wye		Uu03; 50 Hz
240 VAC	1	1Ph, 2W		Uu13; 50 Hz
240/416 VAC	3	Wye		Uu20; 60 Hz
277/480 VAC	3	Wye		Uu04; 60 Hz

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

Parts cataloged across the General Motors Vortec family

Part #	Description	Category
0A4637	Air Cleaner	Air filter
GM16944	Element, air cleaner	Air filter
NGE012014	Charge Air Cooler Bolts	Bolt
058665	BATTERY 12VDC 90-AH 27F	Service part / kit
GM36247	Exhaust pipe	Service part / kit
GM58703	Assy, J1939/ModBus/Ethernet Converter (network bridge)	Service part / kit
GM71612-MA1	X-612-25	Service part / kit

Parts cataloged across all variants of this engine family — verify the exact part fits your specific variant and serial number before ordering.

Common questions

What is the displacement of the General Motors Vortec DOHC?

The General Motors Vortec DOHC has a displacement of 1.6 liters.

Which generators use the General Motors Vortec DOHC engine?

The General Motors Vortec DOHC powers 6 generator set(s), including Kohler 100ERES, Kohler 15RES, Kohler 30RES, Kohler 50ERES, Kohler 60ERES.

What is a common problem with the General Motors Vortec DOHC engine?

A commonly reported issue on generators using the General Motors Vortec DOHC is: Generator set stops suddenly. Cause: Low oil pressure shutdown. Fix: Check the oil level. Check for oil leaks..