Kohler GM62345 User manual

INSTALLATION INSTRUCTIONS
TT-1445 7/16i
Original Issue Date: 3/08
Model: 6--60 kW Residential and Light Commercial Generator Sets
Market: Residential/Commercial
Subject: Maintenance Service Kits GM62345, GM62346, GM62347, GM62348,
GM83718, GM86771, GM89979, GM90365, GM90366, GM93396, and
GM100209
Introduction
This kit provides items necessary for general engine
maintenance and service on 6--60 kW residential and
light commercial generator sets listed in Figure 1.
Read the entire installation procedure before beginning
installation. Perform the steps in the order shown.
Generator Set Service Kit Number Sales Kit Number
8RESV(L) GM90365 GM90365-SKP1-QS
8.5RES GM62345 GM62345-SKP1-QS
10/12RESV(L) GM90366 GM90366-SKP1-QS
6VSG, 12RES(L), 14RES(A)(AL)(L) GM62346 GM62346-SKP1-QS
15RES(A)/R(E)YG,
30RES(A)/R(E)YG GM62348 GM62348-SKP1-QS
17/18RES(L),
20RES(A)(AL)(B)(C)(CL)(D)(L) GM62347 GM62347-SKP1-QS
24RCL GM93396 GM93396-SKP1-QS
30RCL, 38RCLB GM100209 GM100209-SKP1-QS
38RCL GM86771 GM86771-SKP1-QS
48RCL GM83718 GM83718-SKP1-QS
48RCLA and 60RCL GM89979 GM89979-SKP1-QS
Figure 1 Kits

2TT-1445 7/16
Safety Precautions
Observe the following safety precautions while installing
the kit.
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.
Risk of fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the air cleaner. A sudden backfire can cause
severe injury or death. Do not operate the generator set with
the air cleaner removed.
Hot engine oil.
Can cause severe injury or death.
Avoid skin contact with hot oil. Do not
start or operate the generator set with
the engine oil filler cap removed, as
hot oil can spray out. Ensure that the
lubrication system is not under
pressure when servicing. Do not
work on the generator set until it
cools.
WARNING
Used engine oil. Contact with used engine oil may cause
severe skin irritation. Repeated and prolonged skin
exposure may have other health risks. Used engine oil is a
suspected carcinogen. Avoid contact with skin. Thoroughly
wash your hands and nails with soap and water shortly after
handling used engine oil. Wash or dispose of clothing or rags
containing used engine oil. Dispose of used engine oil in a
responsible manner. Contact your local recycling center for
disposal information and locations.
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Servicing the exhaust system. Hot parts can cause
severe injury or death. Do not touch hot engine parts. The
engine and exhaust system components become extremely
hot during operation.

TT-1445 7/16 3
Maintenance Procedures
Oil and Oil Filter
When possible, drain the oil while it is warm.
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. For most models [except 8/10/12RESV(L)], a
drain plug is located on the service side of the
generator set, opposite the starter. If you have
difficulty locating the drain plug, see the service
view in your generator set operation manual. For
8/10/12RESV(L), proceed to step 3.
a. Remove one oil drain plug and the oil fill cap/
dipstick. Aim the drain tube into catch basin
and open the valve near the oil sump. Allow
ample time for complete drainage.
b. Close the valve and place the tube back in the
clip on the bulkhead wall.
c. Remove the old filter and wipe off the
adapter/base on the engine.
d. Proceed to step 4.
3. For 8/10/12RESV(L) models, use the following
procedure to avoid spilling oil into the alternator.
a. To prevent oil from spilling into the alternator,
cover the alternator with rags around the areas
near the oil drain valve and oil filter.
b. Place a drain tube (3/8 in. inside diameter) onto
the oil drain valve and place the end of the tube
into a drain pan. The tube will reduce the
potential for spilled oil.
c. Open the oil drain valve on the engine.
d. Remove the dipstick and oil fill cap. Allow time
for the engine oil to drain completely.
e. Close the oil drain valve and remove the oil
drain tube.
f. Tilt the filter upward to prevent spilling as you
remove the oil filter. Remove the old filter and
wipe off the adapter/base on the engine.
4. Place a new replacement filter in a shallow pan with
the open end up. Pour new oil (provided) through
the threaded center hole. Stop pouring when the oil
reaches the bottom of threads. Allow a minute or
two for the oil to be absorbed by the filter material.
5. Apply a thin film of clean oil to the rubber gasket on
the new oil filter.
6. Install new oil filter. Hand tighten filter clockwise
until the rubber gasket contacts the adapter, then
tighten the filter an additional 3/4--1 turn.
7. Fill the crankcase with the new oil to the For FULL
mark on the dipstick. Use a funnel to prevent
spilling. Always check the level with the dipstick
before adding more oil. Never operate the engine
with the oil level below the Lor ADD mark, or above
the For FULL mark. See Figure 2.
8. For 8/10/12RESV(L) models, remove the rags
that were used to cover the alternator.
F
TT-1484
Full Mark
Operating
Range
L
FULL
ADD
Figure 2 Oil Level/Dipstick Detail
9. Reinstall the oil fill cap/dipstick and tighten
securely.
10. Reconnect the battery cable, negative (--) lead last.
11. Test run the engine, check for leaks, and recheck
the oil level.

4TT-1445 7/16
Spark Plugs
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Before removing the spark plug(s), clean or blow
out the area around the base of the plug(s) to keep
dirt and debris out of the engine. Wear suitable eye
protection, as required.
3. Using a spark plug socket, remove and discard the
old spark plug(s).
D24RCL, 30RCL, and 38RCLB: 13/16 in. socket
DOther models: 5/8 in. spark plug socket
4. Check and set the gap of the new spark plug(s)
using a wire feeler gauge. See Figure 4. Adjust the
gap by carefully bending the ground electrode.
SeeFigure3.
5. For easy removal, apply a light coating of
anti--seize lubricant to the spark plug threads. Wipe
away any excess compound.
6. Install the new spark plug(s) and torque as shown
in Figure 4.
7. Reconnect the spark plug lead(s).
8. Reconnect the battery cable, negative (--) lead last.
TT-1484
1. Spark plug
2. Wire gauge
3. Gap
4. Ground electrode
2
1
43
Figure 3 Servicing Spark Plug
Model 8.5RES
6VSG,
8/10/12RESV(L),
12RES(L), 14RES(L),
14RESA(L)
17/18RES(L),
20RES(L),
20RESA(L), 20RESB,
20RESC(L), 20RESD
15RES(A),
15R(E)YG,
30RES(A),
30R(E)YG 24RCL
30RCL,
38RCLB
38RCL,
48RCL,
48RCLA,
60RCL
Spark plug gap,
mm (in.) 0.51 (0.02) 0.76 (0.03) 0.8--0.9
(0.03--0.04)
0.9--1.0
(0.036--0.04)
0.7--0.8
(0.028--0.030) 0.89 (0.035)
Torque,
Nm (ft. lb.)
24.4--29.8
(18--22)
24.4--29.8
(18--22) 25 (18) 18 (13.3) 25 (18.4) 15 (11)
Figure 4 Spark Plug Gap and Torque

TT-1445 7/16 5
Air Cleaner Element and Precleaner
6VSG, 8.5RES, 12RES(L), 14RES(A)(AL)(L)
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Loosen the cover retaining knob 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, precleaner, element
cover, element cover nut, and the air cleaner cover.
6. Secure the cover with the cover retaining knob.
7. Reconnect the battery cable, negative (--) lead last.
1
2
3
4
5
6
7
586536
1. Cover knob
2. Air cleaner cover
3. Element cover nut
4. Element cover
5. Foam precleaner
6. Air cleaner element
7. Air cleaner base
Figure 5 Air Cleaner; 6VSG, 8.5RES, 12RES(L),
14RES(A)(AL)(L)
8RESV(L)
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Loosen the cover retaining knobs and remove the
cover.
3. Remove and discard the old air cleaner element.
4. Install the paper element and the air cleaner cover.
Secure the cover with the cover retaining knobs.
5. Reconnect the battery cable, negative (--) lead last.
1. Air cleaner base
2. Air cleaner element
3. Element cover
4. Air cleaner knob
1
2
4586536
3
Figure 6 Air Cleaner; 8RESV(L)

6TT-1445 7/16
10/12RESV(L)
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Rotate the air cleaner cover levers outward to
unlock cover; remove the air cleaner cover.
3. Remove and discard the old air cleaner element.
4. Install the paper element onto the air cleaner base.
Make sure the element is flat and properly seated.
5. Position the air cleaner cover with levers outward
over air cleaner; turn levers inward to lock.
6. Reconnect the battery cable, negative (--) lead last.
tp6515
1. Air cleaner cover lever
2. Air cleaner element
3. Base
4. Blower housing
5. Air cleaner cover
2
3
1
4
5
Figure 7 Air Cleaner; 10/12RESV(L)
17/18RES(L), 20RES(A)(AL)(B)(C)(CL)(D)(L)
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Loosen the two cover retaining knobs and remove
the cover.
3. Rotate the air filter latch counterclockwise to
unlock, then remove the paper element.
4. Install the paper element onto the air cleaner base.
Make sure the element is flat and properly seated.
Rotate the latch clockwise, over the molded lip on
the element.
5. Install the air cleaner cover and secure with the two
retaining knobs.
6. Reconnect the battery cable, negative (--) lead last.
1
tp6515
1. Knobs (qty.2)
2. Cover
3. Paper element
4. Base
3
2
4
Figure 8 Air Cleaner; 17/18RES(L),
20RES(A)(AL)(B)(C)(CL)(D)(L)

TT-1445 7/16 7
15RES(A)/R(E)YG and 30RES(A)/R(E)YG
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Release the retaining clips to open the housing and
then remove the air cleaner element.
3. Remove and discard the old air cleaner element.
4. Install the new element.
5. Wipe the cover and housing with a clean rag. Make
sure the sealing surfaces fit correctly and reattach
the retaining clips.
6. Reconnect the battery cable, negative (--) lead last.
GM21379
1. Cover
2. retaining clip(s)
3. Housing
4. Pressure tap (1/8--27 NPT)
5. Primary element
6. Dust ejector
1
23
5
6
4
Figure 9 Air Cleaner; 15RES(A)/R(E)YG, and
30RES(A)/R(E)YG
24RCL, 30RCL, 38RCLB, 48RCLA, and 60RCL
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Release the retaining clips to open the housing and
then remove the air cleaner element.
3. Remove and discard the old air cleaner element.
4. Install the new element.
5. Wipe the cover and housing with a clean rag. Make
sure the sealing surfaces fit correctly and reattach
the retaining clips.
6. Reconnect the negative battery cable and spark
plug lead(s).
GM90280
1. Cover
2. retaining clip(s)
3. Housing
4. Primary element
5. Dust ejector
1
23
4
5
Figure 10 Air Cleaner; 24/30/60RCL, 48RCLA, and
38RCLB

8TT-1445 7/16
KOHLER CO., Kohler, Wisconsin 53044 USA
Phone [phone], Fax [phone]
For the nearest sales and service outlet in the
US and Canada, phone [phone]
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]
38/48RCL
1. Before working on the generator set or connected
equipment, disable the generator set as follows:
a. Press the OFF button on the generator set controller.
b. Disconnect the power to the battery charger.
c. Remove the battery cables, negative (--) lead first.
2. Remove the wing nut and remove the air cleaner
retaining plate.
3. Remove and discard the old air cleaner element.
4. Install the new element.
5. Wipe the cover and housing with a clean rag.
Reinstall the retaining plate and secure with the
wing nut.
6. Reconnect the battery cable, negative (--) lead last.
A--273699
1. Cover
2. Housing
3. Pressure tap (1/8 in. NPT)
4. Wing nut
12
3
4
Figure 11 Air Cleaner; 38/48RCL
A
vailability is subject to change without notice. Kohler Co. reserves the
right to change the design or specifications without notice and without any
obligation or liability whatsoever. Contact your local Kohlerrgenerator
set distributor for availability.
2008, 2009, 2011, 2012, 2014, 2015, 2016 by Kohler Co. All rights reserved.