Kohler CH 440 Engine

Tools: digital voltmeter, personal computer, SiteTech software

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

Tools: digital voltmeter

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

1. From Overview menu, step down to Genset Run Time menu.
2. Press Select button and step down to Next Maintenance screen.
3. Press Select button.
4. Press Up arrow button so 'Reset Maint Timer? Yes' is displayed.
5. Press Select button.
6. Wait about two minutes for new maintenance interval and date to display.

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

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

1. Disable set: press OFF button, disconnect battery charger power, remove battery cables, negative (--) lead first.
2. Loosen the cover retaining knob(s) or release the retaining clips and remove the cover.
3. Remove and discard the old air cleaner element and precleaner (if equipped).
4. Install the precleaner over the new air cleaner element.
5. Install the paper element onto the air cleaner base, making sure it is flat and properly seated.
6. Reinstall the element cover, element cover nut, and the air cleaner cover; secure with the knob(s) or clips.
7. 15RES/30RES and RCL models: wipe cover and housing with a clean rag and make sure sealing surfaces fit correctly.
8. Reconnect the battery cable, negative (--) lead last.

⚠ Do not wash paper element or clean with pressurized air

1. Press OFF button on generator set controller.
2. Disconnect utility power.
3. Disconnect engine starting battery, negative lead first.
4. Loosen cover retaining knob and remove cover.
5. Remove element cover nut, element cover, and paper element.
6. Replace element if dirty, bent, or damaged.
7. Check air cleaner base for security and damage.
8. Check element cover for damage and fit.
9. Remove any loose dirt or debris from air cleaner base.
10. Wipe base carefully so no dirt enters intake throat.
11. Check condition of rubber seal on air cleaner stud.
12. Reinstall paper element, element cover, element cover nut, and air cleaner cover.
13. Secure cover with cover retaining knob.
14. Reconnect utility power.
15. Reconnect engine starting battery, negative lead last.

⚠ Do not wash paper element or use pressurized air

1. Loosen two cover retaining knobs and remove cover.
2. Remove paper element.
3. Replace dirty, bent, or damaged element.
4. Handle new elements carefully; do not use if sealing surfaces are damaged.
5. When servicing, check air cleaner base is secured and not damaged.
6. Check element cover for damage or improper fit.
7. Remove any loose dirt or debris from air cleaner base.
8. Reinstall paper element onto air cleaner base ensuring flat and properly seated.
9. Install air cleaner cover and secure with two retaining knobs.
10. Order genuine Kohler parts for element replacement.

⚠ Do not load RDC2.4 firmware onto a red- or green-board controller

Tools: personal computer, USB cable, SiteTech software

1. Download latest firmware file (.bin) from Kohler Power Resource Center or dealer portal
2. Connect controller to PC via USB cable
3. Start SiteTech; program recognizes connected device
4. Click Update Firmware
5. Browse to and select firmware file, click Open
6. Verify current/new version and file name, click Update Firmware
7. Wait for 'Firmware Updated Successfully' message, click Close

⚠ Drain oil while warm

⚠ Dispose of waste materials safely

Tools: Oil filter wrench, Oil collection container

1. Press OFF button on generator set controller.
2. Disconnect utility power to generator set.
3. Disconnect engine starting battery, negative lead first.
4. Remove housing side panel.
5. Clean area around dipstick and oil fill cap.
6. Remove oil drain hose from retaining clip and lower into collection container.
7. Open oil drain valve on engine.
8. Remove dipstick and oil fill cap; allow oil to drain completely.
9. Close oil drain valve and replace cap on drain hose.
10. Replace oil filter by rotating counterclockwise with wrench.
11. Clean gasket sealing surface of oil filter adapter.
12. Apply light coat of clean oil to rubber seal of new filter.
13. Install new oil filter per filter instructions.
14. Add recommended oil through oil fill port.
15. Use dipstick to check oil level before adding final quart.

⚠ Hot engine oil can cause severe injury or death. Avoid skin contact with hot oil.

⚠ Do not work on the generator set until it cools.

⚠ Accidental starting can cause severe injury or death. Remove the negative (--) lead first when disconnecting the battery.

Tools: Funnel, Drain tube (3/8 in. inside diameter), Catch basin / drain pan

1. Disable set: press OFF button, disconnect battery charger power, remove battery cables, negative (--) lead first.
2. Drain the oil while it is warm. On most models a drain plug is on the service side, opposite the starter.
3. For most models remove one oil drain plug and the oil fill cap/dipstick; aim the drain tube into a catch basin.
4. For most models open the valve near the oil sump and allow ample time for complete drainage.
5. Close the valve and place the tube back in the clip on the bulkhead wall.
6. For 8/10/12RESV(L), cover the alternator with rags near the oil drain valve and oil filter.
7. For 8/10/12RESV(L), place a drain tube (3/8 in. inside diameter) onto the oil drain valve into a drain pan.
8. For 8/10/12RESV(L), open the oil drain valve, remove the dipstick and oil fill cap, and drain completely.
9. For 8/10/12RESV(L), close the oil drain valve and remove the oil drain tube.
10. Remove the old filter, tilting it upward to prevent spilling, and wipe off the adapter/base on the engine.
11. Place a new replacement filter open end up in a shallow pan; pour new oil (provided) through the threaded center hole to the bottom of threads.
12. Allow a minute or two for the oil to be absorbed by the filter material.
13. Apply a thin film of clean oil to the rubber gasket on the new oil filter.
14. Install the new oil filter; hand tighten clockwise until the gasket contacts the adapter, then tighten an additional 3/4--1 turn.
15. Fill the crankcase with new oil to the F/FULL mark on the dipstick; reinstall cap/dipstick, reconnect battery cable negative (--) lead last, test run, check for leaks, and recheck oil level.

⚠ Clean area around spark plug to prevent unfiltered air entry

Tools: Wire feeler gauge, Spark plug socket

1. Clean area around base of spark plug to keep dirt and debris out.
2. Remove spark plug and check condition.
3. Replace spark plug if worn or reuse is questionable.
4. Check spark plug gap using wire feeler gauge.
5. Adjust gap if needed by carefully bending ground electrode.
6. Reinstall spark plug into cylinder head.
7. Torque spark plug to 24.4-29.8 Nm (18-22 ft. lb.)

⚠ Servicing the air cleaner: a sudden backfire can cause severe injury. Do not operate with the air cleaner removed.

Tools: 13/16 in. socket, 5/8 in. spark plug socket, Wire feeler gauge, Torque wrench

1. Disable set: press OFF button, disconnect battery charger power, remove battery cables, negative (--) lead first.
2. Clean or blow out the area around the base of the plug(s) before removal to keep dirt out of the engine; wear eye protection.
3. Using a spark plug socket, remove and discard the old spark plug(s).
4. 24RCL, 30RCL, and 38RCLB: use a 13/16 in. socket. Other models: use a 5/8 in. spark plug socket.
5. Check and set the gap of the new spark plug(s) using a wire feeler gauge.
6. Adjust the gap by carefully bending the ground electrode.
7. Apply a light coating of anti-seize lubricant to the spark plug threads and wipe away any excess compound.
8. Install the new spark plug(s) and torque as shown in Figure 4.
9. Reconnect the spark plug lead(s).
10. Reconnect the battery cable, negative (--) lead last.