Kohler CH740/CH1000 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

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

⚠ 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

1. Press Select then down arrow to Networking Information menu
2. Press Select for Networking Status
3. Press Down arrow for Networking Configuration
4. Press Select for Reset OnCue Password
5. Press and hold Select until 'Reset OnCue Password? No' appears
6. Press Up arrow to change No to Yes
7. Press Select to reset; serial number and new password display for 10 seconds

⚠ Do not load settings from a green-board controller onto a red/blue-board controller or vice versa

Tools: voltmeter

1. Review service kit information and confirm correct kits
2. Open enclosure roof
3. Press OFF button, disconnect utility power, verify with voltmeter
4. Disconnect starting battery, negative lead first
5. Remove two mounting screws, lift controller, disconnect harnesses
6. Remove old controller
7. If replacing original green-board controller with revised controller, install relay/breaker kit GM95104
8. Reconnect harnesses, install new controller, reconnect battery negative last
9. Reconnect utility power
10. Set date/time/exerciser, update firmware, run Controller Setup and Voltage Calibration
11. Replace covers/panels; reset OnCue password if used

⚠ Hazardous voltage can cause severe injury or death; disconnect all power sources before opening enclosure

⚠ Accidental starting can cause severe injury or death; disconnect battery cables, negative first

Tools: voltmeter, enclosure locking tool, screwdriver

1. Open enclosure roof using locking tool
2. Press OFF button on controller
3. Disconnect utility power at building distribution panel; verify off with voltmeter
4. Disconnect engine starting battery, negative lead first
5. Remove two controller mounting screws and lift bottom edge of controller
6. Note connections on back of controller, then disconnect all harnesses and leads
7. Remove old controller
8. Reconnect all harnesses to new controller assembly
9. Install controller onto junction box with the two screws
10. Reconnect battery, negative lead last
11. Reconnect utility power by closing distribution panel breaker
12. Set date/time and exerciser when prompted
13. Check and update firmware to latest version via SiteTech or USB utility
14. Perform Controller Setup (Section 5)
15. Perform Voltage Calibration (Section 6)

Tools: voltmeter

1. Open/remove enclosure service door
2. Press OFF, disconnect utility power
3. Disconnect starting battery negative lead first
4. Remove customer connection access panel, verify power off with voltmeter
5. Remove two mounting screws, lift controller, disconnect P1/P2/P4/P5/P6
6. Remove old controller, reconnect harnesses to new controller
7. Install controller, replace access panel
8. Reconnect battery and utility power
9. Update firmware, set date/time/exerciser, run Controller Setup and Voltage Calibration

Tools: voltmeter

1. Open enclosure roof, press OFF, disconnect utility power
2. Disconnect starting battery negative lead first
3. Remove two mounting screws, lift controller
4. Verify utility power off at AC connections with voltmeter
5. Disconnect harnesses, remove old controller
6. Reconnect harnesses to new controller, install with screws
7. Reconnect battery, reconnect utility power
8. Set date/time/exerciser, update firmware, run Controller Setup and Voltage Calibration

Tools: voltmeter

1. Review service kit info, open enclosure roof
2. Press OFF, disconnect utility power, verify with voltmeter
3. Disconnect starting battery negative lead first
4. Remove two mounting screws, lift controller, disconnect harnesses
5. Remove old controller; if upgrading from green to revised board install relay kit GM92804
6. Reconnect harnesses, install controller, reconnect battery negative last
7. Reconnect utility power, update firmware
8. Run Controller Setup and Voltage/Current Calibration
9. Reset OnCue password if used