Kohler 30REZGT Generator Set

⚠ Never use compressed air to clean brake components; some components may contain asbestos.

Tools: Adjustment tool or large slotted screwdriver, Jack stands

1. Raise the trailer with wheels off the ground and block safely with jack stands; remove the wheel.
2. Remove the rubber plug from the backing plate slot.
3. Insert an adjustment tool or large slotted screwdriver in the slot and rotate the star wheel to expand the shoe against the drum.
4. Expand the shoe until the drum can't be turned by hand to center each shoe.
5. Back off the adjustment in the other direction until the drum turns freely with slight resistance.
6. Replace the rubber plug in the backing plate slot.
7. Repeat procedure for remaining wheels.

⚠ Do not move the voltage selector switch while the generator set is running.

⚠ Affix voltage reconnection decal 246242 after reconnecting to a different voltage.

Tools: User-supplied load lug wrench

1. Press the generator set master control OFF/RESET button.
2. Open the main line circuit breaker.
3. Navigate to Generator Info then Voltage Selector Switch menu; press the selector dial.
4. Select Present Position and change to the desired selection (Three Phase Wye 480 V, Three Phase Wye 208 V, or Single Phase Dogleg).
5. Rotate the voltage selector switch on the junction box to match the desired voltage shown on the controller.
6. Disconnect the engine starting battery, negative lead first; disconnect battery charger power.
7. Make lead connections between load devices and the load lugs or camlocks.
8. Make a ground connection to earth ground per NEC guidelines.
9. Replace all electrical guards, barriers, and covers.
10. Reconnect the battery, negative lead last; reconnect battery charger power.
11. Press RUN to start and check voltages on the display.
12. Press OFF/RESET to stop.
13. Close the main line circuit breaker and any downstream circuit breakers.

⚠ Hazardous voltage. Disconnect all power sources before opening the enclosure.

Tools: User-supplied load lug wrench

1. Press the generator set master control OFF/RESET button.
2. Open the main line circuit breaker.
3. Navigate to Generator Info, then Configuration, then Generator Config menu.
4. Set System Voltage L--L to the desired voltage (208 V, 240 V, or 480 V).
5. Set System Phase to Three Phase or Single Phase.
6. Verify settings match the desired voltage/frequency/phase.
7. Disconnect the engine starting battery, negative lead first; disconnect battery charger power.
8. Use the reconnection diagram to route leads through current transformers and reconnect.
9. Make load connections and a ground connection per NEC guidelines.
10. Replace all electrical guards, barriers, and covers.
11. Reconnect the battery, negative lead last; reconnect battery charger power.
12. Press RUN to start and check voltages.
13. Press OFF/RESET to stop.
14. Close the main line circuit breaker and any downstream circuit breakers.

⚠ Correct wheel torque prevents loose wheels, broken studs, and wheel/axle separation.

Tools: Torque wrench

1. Start all wheel lug nuts by hand to prevent cross threading.
2. Tighten the nuts in the sequence shown.
3. Perform the wheel lug nut tightening sequence in stages using the torque value recommendations.
4. Torque wheel lug nuts before the first road use and after each wheel removal.
5. Check and retorque after the first 40 km (25 miles) and again at 120 km (75 miles), and at the specified service interval.

⚠ Wear protective goggles and clothing; battery acid may cause blindness and burn skin.

Tools: Wire brush

1. Clean the battery by wiping it with a damp cloth; keep connections dry and tight.
2. If corrosion exists, disconnect the cables and remove corrosion with a wire brush.
3. Clean the battery and cables with a solution of baking soda and water; do not allow the solution to enter battery cells.
4. Flush with clean water and wipe with a dry cloth.
5. After reconnecting the cables, coat the terminals with petroleum jelly, silicon grease, or other nonconductive grease.

⚠ There may still be liquid or gas propane in the supply line; use opening care.

Tools: User-supplied vacuum pump with manual shutoff valve and 0--15 psi vacuum gauge, Exhaust venting system, Approved leak detector solution

1. Source a fitting connecting the main fuel supply line to the manual shutoff valve/vacuum pump assembly.
2. Connect the vacuum pump outlet to the exhaust venting system.
3. Open the exhaust venting system manual shutoff valve (A).
4. Remove the main fuel supply line at the vaporizer.
5. Attach the gaseous fuel tank line to the manual shutoff valve (B)/vacuum pump assembly with the vacuum gauge between (B) and the tanks.
6. With manual shutoff valves (C) and (D) closed, connect the gaseous fuel tank to the LPG supply tank at the 1 3/4 ACME fitting.
7. Open the manual override shutdown valve (E) for tanks to be purged; close all others.
8. Switch the controller to ECM ON mode.
9. Activate the vacuum pump until the vacuum gauge indicates 0--2 psia.
10. Close the manual shutoff valve (B) at the vacuum pump inlet.
11. Place the controller back to ECM OFF mode and turn off the vacuum pump.
12. Open the LPG supply tank valve, fill the gaseous fuel tank to 5%, and close the valve.
13. Disconnect the gaseous fuel tank from the LPG supply tank at the ACME fitting.
14. Close the manual override shutdown valve (E) of the tank just filled; repeat for remaining tanks.
15. Check all fittings and connections for leaks using an approved leak detector solution.

⚠ Hot engine and exhaust system. Do not work on the generator set until it cools.

1. Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature.
2. Stop the generator set.
3. With the engine still warm, drain the oil from the crankcase.
4. Remove and replace the oil filter.
5. Refill the crankcase with oil suited to the climate.
6. Run the generator set for two minutes to distribute the clean oil.
7. Stop the generator set.
8. Check the oil level and adjust, if needed.

⚠ Filling and maintenance should only be done by a trained and certified gaseous fuel service technician.

⚠ Never fill above the maximum safe fill level of 80%.

Tools: LP fuel supply line, Approved leak detector solution, Clean rag

1. Press the generator set master control OFF/RESET button.
2. Disconnect the engine starting battery, negative lead first; disconnect battery charger power.
3. Remove the yellow seal cap and connect the LP fuel supply line to the fuel tank ACME connector.
4. Loosen (but do not remove) the fuel fill bleed valve.
5. Dispense gaseous fuel and fill to 80% full; when fuel flows from the bleed valve, stop supply flow and close the valve.
6. Disconnect the fuel supply line from the ACME connector and reinstall the yellow seal cap.
7. Repeat steps for each remaining fuel tank.
8. Check all fittings and connections for leaks using an approved leak detector solution.
9. Wipe the fuel fill and bleed off valve areas; close the fuel tank access doors.
10. Reconnect the engine starting battery, negative lead last; reconnect battery charger power.

⚠ Hot coolant and steam. Allow the generator set to cool before removing the pressure cap.

⚠ Dispose of all waste materials in an environmentally safe manner.

1. Deenergize the block heater, if equipped.
2. Remove the pressure cap to allow the entire system to drain and prevent air pockets.
3. Open the radiator and/or engine block coolant drain valve(s) and allow the system to drain.
4. If the inside of the radiator has mineral deposits, flush and clean the cooling system; otherwise refill.

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

1. Remove the pressure cap.
2. Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose clamps.
3. Open the air-bleed petcocks, if equipped; close when coolant begins to flow from them.
4. Add coolant additives or water pump lubricants according to engine manufacturer recommendations.
5. Fill the cooling system with the recommended coolant/antifreeze mixture.
6. Replace the pressure cap.
7. Fill the coolant recovery tank (if equipped) to the low mark.
8. Operate generator set until the thermostat opens.
9. Stop the engine and allow it to cool; check and repair any coolant leaks.
10. Remove the pressure cap and add coolant to just below the overflow tube opening of the filler neck.
11. Replace the pressure cap.
12. Maintain the coolant level in the coolant recovery tank between the high and low marks.

⚠ Use care when removing the main fuel supply line at the vaporizer as this will bleed off any remaining fuel.

1. Turn the manual override shutoff valve clockwise to close the valve at each gaseous fuel tank.
2. Press the generator set master switch RUN button to start and run the generator set.
3. The generator set will briefly run and then stop due to lack of fuel.
4. After the generator set stops, press the OFF/RESET button.
5. Allow the generator set to rest for approx. 10 minutes.
6. Press the RUN button; the generator set attempts to start and run. After three failed cycles it stops and an overcrank fault appears.
7. Reset the controller by pressing the OFF/RESET button.
8. Let the generator set rest for approx. 10 minutes to ensure all liquid propane is purged before maintenance.

⚠ Do not purge with liquid propane.

⚠ There may still be liquid or gas propane in the supply line; use care when opening fittings.

⚠ Wear personal protective equipment; liquid propane can cause frostbite on contact.

Tools: User-supplied fitting, Exhaust venting system, Approved leak detector solution

1. Source a fitting connecting the main fuel supply line to the exhaust venting system.
2. Open the exhaust venting system manual shutoff valve.
3. Remove the main fuel supply line at the vaporizer.
4. Attach the gaseous fuel tank line to the exhaust vent piping.
5. Open the manual override shutoff valve at each gaseous fuel tank.
6. Purge excess pressure by switching the controller to ECM ON mode for at least 10 seconds, then back to ECM OFF.
7. Connect the generator set gaseous fuel tanks to the LPG supply tank at the 1 3/4 in. ACME fitting(s).
8. Open the manual supply valve until 15 psi tank pressure is indicated; then close it.
9. Purge the gaseous fuel tanks by switching to ECM ON mode for at least 10 seconds, then back to ECM OFF.
10. Repeat steps for a minimum of four cycles to sufficiently purge all air and/or contaminants.
11. Close the exhaust venting system manual shutoff valve.
12. Disconnect the main fuel supply line from the venting system and reattach to the vaporizer.
13. Open the manual supply valve until the gas fuel tank contains 5% of capacity; close the valve.
14. Activate ECM ON mode for at least 10 seconds; return to ECM OFF.
15. Check all fittings and connections for leaks using an approved leak detector solution.