Kohler 6VSG Generator Set

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

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 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

⚠ 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.

⚠ 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.

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