Kohler KG200 Generator Set

Tools: Battery hydrometer

1. Use a battery hydrometer to check specific gravity of electrolyte in each cell (filler-cap batteries only).
2. Hold the hydrometer vertically and read the value.
3. Correct the reading using the temperature correction table if the hydrometer lacks one.
4. Battery is fully charged if corrected specific gravity is 1.260 at 26.7°C (80°F).
5. Charge the battery if specific gravity is below 1.215 at 26.7°C (80°F).
6. Maintain specific gravity within ±0.01 between cells.

⚠ Do not operate the generator set with the air cleaner removed.

1. Remove the generator set from service (remove load, shut down, controller Out-of-Service mode, press emergency stop).
2. Disconnect power to battery charger.
3. Remove battery cables, negative lead first.
4. Loosen the filter clamp and remove the filter element from the air intake elbow.
5. Install new/cleaned filter element and tighten the filter clamp.

⚠ Battery acid can cause blindness and burn skin; wear splashproof goggles, rubber gloves, boots.

1. Check the electrolyte level at the specified interval on batteries with filler caps.
2. Remove the filler caps and verify electrolyte reaches the bottom of each filler hole.
3. Refill as necessary with distilled water only (do not add fresh electrolyte).
4. Tighten the filler caps.
5. If water was added during freezing temperatures, run the generator set 20-30 minutes to mix electrolyte and water.

⚠ Hot coolant and steam can cause severe injury or death.

1. Stop the generator set and allow it to cool.
2. Deenergize the block heater, if equipped.
3. Cover the pressure cap with a rag and remove it to prevent air pockets.
4. Open the radiator and/or engine block coolant drain valve(s) and allow the system to drain.
5. If mineral deposits or dirt/grease are present, proceed to flush and clean; otherwise proceed to refill.

⚠ Do not add coolant to a hot engine; wait until the engine has cooled.

1. Cover the pressure cap with a rag and remove it.
2. Close drain valve(s) and tighten hose clamps.
3. Fill the cooling system with the recommended Kohler coolant mixture, from the bottom if possible.
4. Replace the pressure cap.
5. Operate the generator set until the thermostat opens (upper hose warms).
6. Stop the engine, allow it to cool, check and repair any leaks.
7. Remove pressure cap and add coolant to just below the overflow tube opening.
8. Replace the pressure cap.
9. Check coolant level in the sight glass; maintain between high and low marks.
10. Reenergize the block heater, if equipped.

⚠ Avoid damaging fins with rough brushing or excessive jet pressure.

1. Periodically check for leakage from core or tank connections.
2. Inspect liquid level via the top tank sight glass at regular intervals.
3. Test antifreeze before cold weather periods.
4. For long standby periods, check top tank interior for scale/rust every 1-3 months.
5. Remove dirt/debris from core face with compressed air, steam, or water (stand back at least 0.9 m/3 ft if using water, keep stream parallel to fins).
6. Clean fan blades once per year using a stiff brush or air nozzle, or nonflammable solvent with brush for solid deposits.