Kohler 15ERG Generator Set

⚠ Also check the fan belt for cracks or tears and replace the belt if necessary.

1. Disconnect the battery, negative lead first.
2. Loosen the pivot and adjusting screws.
3. While prying the battery charging alternator outward, tighten the adjusting screw.
4. Tighten the pivot screw.
5. Recheck and adjust as necessary.
6. Reconnect the battery, negative lead last.

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

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

⚠ 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

1. Move the master switch to RUN; the engine starts and runtime hours display.
2. Hold the Select button about 5 seconds until the program version number displays.
3. Press the down arrow key then the up arrow key 3 times to enter adjustment mode.
4. 1P: adjust voltage coarse in large increments (approximately 5-7 volts per step).
5. 2P: adjust voltage fine in smaller increments (approximately 0.5-0.7 volts per step).
6. Adjust voltage stability (gain) coarse and fine.
7. 3P: set volts/Hz (00=low, 09=high).
8. 4P: adjust engine governor speed coarse and fine.
9. 5P: adjust engine governor stability (gain) coarse and fine.
10. Enter SAVE mode and save settings before exiting the adjustment mode.

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

1. Move the generator set master switch to the OFF/RESET position.
2. Disconnect the generator set from the load using the line circuit breaker or ATS.
3. Identify and correct the cause of the fault shutdown. Refer to Troubleshooting.
4. Start the generator set by moving the master switch to RUN. Test operate to verify the cause is corrected.
5. Shut the generator off by moving the master switch to the OFF/RESET position.
6. Reconnect the generator set to the load using the line circuit breaker or ATS.
7. Move the master switch to the AUTO position for startup by remote transfer switch, remote start/stop switch, or remote digital gauge.

⚠ 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

1. Record generator set information required for configuration: model, market, voltage, frequency, phases, battery voltage.
2. Place the generator set master switch in the OFF position.
3. Disconnect power to the battery charger, if equipped.
4. Disconnect the engine starting battery(ies), negative lead first.
5. Open the junction box; disconnect the controller at P1, J15, and J16.
6. Models ECD/EFCD, EGD/EFGD, EGZD only: disconnect the CO sensor harness at the 4-pin connector.
7. Remove four controller mounting screws and remove the old controller.
8. ECD/EFCD, EGD/EFGD, EGZD only: install CO sensor module assembly GM46362 on the back of the new controller GM47982.
9. Install the new controller and secure with the mounting screws.
10. Reconnect the P1, J15, and J16 connectors; connect the CO sensor harness on applicable models.
11. 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.
12. Check that the generator set master switch is in the OFF position.
13. Reconnect the engine starting battery, negative lead last.
14. Reconnect power to the battery charger, if equipped.
15. Check the controller application software version and load the latest application code if necessary.

⚠ Do not clean the element in any liquid or use compressed air as these will damage the filter element.

⚠ Do not operate the generator set with the air cleaner removed; a sudden backfire can cause severe injury or death.

1. Release the spring clips to open the housing and remove the air silencer element.
2. Tap the element lightly against a flat surface to dislodge loose surface dirt.
3. Examine the element and housing for damage. Replace the element or housing if necessary.
4. Wipe the cover and base with a clean rag. Make sure sealing surfaces fit correctly and reattach the spring clips.

⚠ Pay special attention to the coolant level.

1. Remove the radiator's pressure cap to allow the entire system to drain and prevent air pockets.
2. Open the radiator's coolant drain valve to drain the cooling system.
3. After the coolant drains, allow time for complete refill of the engine water jacket and check the coolant level.

⚠ Do not add coolant to a hot engine; it can crack the cylinder block or cylinder head.

⚠ A coolant solution of 50% ethylene glycol provides freezing protection to -37 C (-34 F) and overheating protection to 129 C (265 F). Do not use alcohol or methanol antifreeze.

1. Close the radiator's coolant drain valve and tighten the hose clamps.
2. Fill the radiator with the recommended coolant mixture of 50% ethylene glycol and 50% clean, softened water.
3. Replace the radiator's pressure cap.
4. Operate the engine until the thermostat opens and the radiator upper hose becomes hot.
5. Stop the engine and allow it to cool.
6. Remove the radiator's pressure cap.
7. Add coolant to the radiator to just below the overflow tube on the filler neck.
8. Replace the radiator's pressure cap.
9. Maintain the coolant level in the coolant overflow bottle between the High and Low markings.

⚠ Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

1. Remove the pressure cap, open the radiator's coolant drain valve and let the system drain completely.
2. Drain, clean, and flush the coolant overflow bottle.
3. Flush the system with clean water.
4. Close the radiator's coolant drain valve.
5. Fill the system with the recommended coolant.
6. Replace the pressure cap.

⚠ Run the generator set once a month whenever possible.

1. Start and run the generator set until it reaches operating temperature or about 15 minutes.
2. Stop the generator set.
3. Change the oil and oil filter.
4. Drain the fuel completely from the fuel tank.
5. Check the engine coolant protection; use antifreeze capable of withstanding the lowest possible temperatures.
6. Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs.
7. Clean the exterior and spread a light film of oil or silicon spray over exposed surfaces.
8. Seal the air inlet, exhaust pipe, and fuel tank cap with tape.
9. Disconnect and remove the battery; store in a warm, dry location. Recharge the battery once a month.
10. Select a well-ventilated (not humid or dusty) location to store the generator.
11. Cover the entire unit with a dust cover.

⚠ Too high an oil level causes high oil consumption and engine carbonizing. Too low a level damages the engine.

⚠ Do not pollute the environment. Dispose of used engine oil in a safe, approved manner.

1. Stop the generator set.
2. To drain the oil, open the oil-drain valve.
3. Drain the oil into a suitable container.
4. Allow ample time for all oil to drain.
5. Close the oil-drain valve.
6. Remove the oil-fill cap.
7. Replace the engine oil filter per the service schedule and Section 3.3.5.
8. Fill crankcase with oil; replace the oil-fill cap.
9. Start the generator set and check for oil leaks.
10. Stop the generator set. Check the oil level. Add oil to bring the level to the Full mark.

⚠ Wash hands after any contact with engine oil.

⚠ If also performing an oil change, skip steps 4 and 5 and go back to the oil change procedure.

1. Loosen the oil filter by turning it counterclockwise. Remove the oil filter and clean up spilled oil.
2. Clean the contact surface of the oil filter adapter.
3. Lightly lubricate the gasket surface of the new filter with fresh engine oil. Thread on until the gasket contacts, then hand-tighten an additional one-half turn.
4. Start the generator set and check for oil leaks.
5. Stop the generator set. Check oil level. Add oil as necessary to bring level to the Full mark.