Kohler 8RESV 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

⚠ Accidental starting can cause severe injury or death; disconnect battery cables before working on the generator set, negative lead first.

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

⚠ Hot surfaces: disconnect power to the heater and allow it to cool before servicing.

1. Open enclosure roof; locate controller and air cleaner.
2. Turn off the generator set (master switch or controller OFF button, per model).
3. Disconnect AC power to the generator set at the distribution panel breaker.
4. Disconnect the starting battery, negative lead first.
5. Check nameplate model/spec number and locate heater position per Figure 4.
6. Remove the air cleaner cover if needed for access.
7. Disconnect the heating element from the power cord at the plug connector.
8. Insert the heating element into the threaded opening on the engine and tighten.
9. Reconnect the power cord to the heater.
10. Route and connect the power cord per the applicable model wiring option (steps 10-12).
11. Replace the air cleaner cover if it was removed.
12. Affix decal GM22387 onto the air cleaner cover.
13. Reconnect the starting battery, negative lead last.
14. Reconnect AC power by closing the distribution panel breaker.
15. For standby operation, move switch to AUTO and reinstall enclosure panels.

⚠ Accidental starting can cause severe injury or death; disconnect battery cables before working on the generator set, negative lead first.

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

⚠ Hot surfaces: install the heater before connecting it to power; disconnect power and allow it to cool before servicing.

1. Open the enclosure roof.
2. Press the OFF button on the generator set controller.
3. Disconnect AC power to the generator set at the distribution panel breaker.
4. Disconnect the starting battery, negative lead first.
5. Locate the carburetor heater per Figure 14; remove side panel or air cleaner cover if needed.
6. Remove and discard the M8 bolt from the carburetor at the heater location.
7. Thread adapter GM91361 into the M8 hole.
8. Insert carburetor heater GM57968 into the adapter and tighten.
9. Connect the extension cord (GM91360 or 3-way GM95628) to the heater cord.
10. Route the cord to the AC receptacle, securing away from throttle linkage and exhaust.
11. Plug the cord into the AC receptacle on the generator bulkhead.
12. Affix decal GM22387 onto the air cleaner cover.
13. Reconnect the starting battery, negative lead last.
14. Reconnect AC power by closing the distribution panel breaker.
15. Press AUTO for standby operation and reinstall enclosure panels.

⚠ Disconnect battery cables before working on generator set; remove negative lead first.

⚠ Disconnect all power sources before opening enclosure.

⚠ Install heater before connecting power; allow to cool before servicing.

1. Open enclosure roof; locate controller and engine air cleaner.
2. Turn off generator set: 17/18RES/RESL move master switch OFF; 20RES/RESL press OFF and remove fuse F3; 20RESA/AL/B/C/CL/D press OFF.
3. Disconnect AC power by opening circuit breaker in distribution panel.
4. Disconnect engine starting battery, negative lead first.
5. Check nameplate model/spec; see Figure 4 for heater location. Heater fits threaded opening on carburetor below air cleaner.
6. Remove air cleaner cover if easier access needed.
7. Disconnect heater element from power cord at plug connector (GM57968 or GM88228).
8. Insert heating element into threaded opening on engine and tighten.
9. Reconnect power cord to heater.
10. For 17/18RES/RESL and 20RES/RESL: remove air intake panel; install bushing X-634-15 or X-634-16; route cord through bulkhead; plug into 120 VAC receptacle under controller.
11. For 120 V 20RESA/AL/B/C/CL/D: route cord away from hot parts; plug into receptacle in engine compartment; use 3-way cord GM95628 if multiple accessories; secure excess cable.
12. For 240 V 14/20RESA and 20RESC: remove controller screws, remove bulkhead knockout, route cord and insert plug; disconnect 120 VAC harness at 3-pin; connect 3-pin to new 240 VAC connector.
13. Replace air cleaner cover if removed; affix decal GM22387 as shown.
14. Check master switch OFF (17/18); reconnect battery, negative last; close distribution breaker. 20RES/RESL: reinstall fuse F3.
15. For standby, move master switch to AUTO or press AUTO. Reinstall enclosure panels; close and lock roof.

⚠ Disconnect battery cables before working on generator set; remove negative lead first.

⚠ Disconnect all power sources before opening enclosure.

⚠ Install heater before connecting power; allow to cool before servicing.

1. Open enclosure roof.
2. Press OFF button on generator set controller.
3. Disconnect AC power by opening circuit breaker in distribution panel.
4. Disconnect engine starting battery, negative lead first.
5. See Figure 13 for heater location. Remove louvered side panel and/or air cleaner cover for access if necessary.
6. Remove and discard M8 bolt from carburetor at heater location.
7. Thread adapter GM91361 into M8 hole.
8. Insert carburetor heater GM57968 into adapter and tighten.
9. Connect extension cord GM91360 or 3-way extension cord GM95628 to heater cord.
10. Route cord to AC receptacle as shown; secure with cable ties away from throttle linkage and exhaust.
11. Plug cord into AC receptacle on generator bulkhead.
12. Affix decal GM22387 onto air cleaner cover.
13. Reconnect battery, negative lead last.
14. Reconnect AC power by closing circuit breaker.
15. For standby, press AUTO. Reinstall enclosure panels; close and lock roof.

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 and disconnect utility power and battery
2. Loosen cover retaining knobs and remove cover
3. Remove paper element
4. Replace element if dirty, bent, or damaged
5. Check air cleaner base for condition
6. Check element cover for damage
7. Reinstall paper element and air cleaner cover
8. Secure cover with retaining knobs
9. Reconnect battery and utility power

⚠ 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

⚠ Accidental starting can cause severe injury or death.

⚠ Risk of fire from fuel system.

⚠ Do not smoke near carburetor or fuel system.

Tools: oil filter wrench, funnel, rags, drain pan

1. Press OFF button to shutdown generator set.
2. Disconnect utility power to generator set.
3. Disconnect engine starting battery (negative lead first).
4. Remove side panel on exhaust side of enclosure.
5. Clean area around dipstick and oil fill cap.
6. Cover alternator with rags to prevent oil spillage.
7. Insert drain tube onto oil drain valve.
8. Open oil drain valve and allow oil to drain completely.
9. Close oil drain valve and remove drain tube.
10. Clean area around oil filter.
11. Loosen oil filter with wrench and remove carefully.
12. Clean gasket sealing surface.
13. Apply light coat of clean oil to new filter seal.
14. Thread new oil filter by hand until resistance, then 3/4 turn more.
15. Fill engine with recommended oil to Full mark on dipstick.

⚠ 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.