You're the only kind of service guy that I would allow to work on my equipment. Most service people get in and barely do the job and get out. They don't care about going the extra mile like you did with cleaning out the dirt in the battery area and other things that you did. I commend people like you for doing what you do....
You should lean about the batts the positive cable was not all the way down and you didnt out it down its a taper fit has to go down all the way to make correct contact
Sir, I’d like to thank you for generously posting your knowledge for all to see. I really do think it’s great that you are willing to share what you know with the rest of us. I never have a problem hiring competent service people to take care of things I see as important, especially things like generator service. But when getting that service starts to become more troublesome, and I get what I feel is double talk, I sometimes feel I need to do things myself, or get raked over the coals, if you know what I mean. That’s where people like you step up and save the day. Thanks so much. And I’m grateful there is a medium out there where you can do that. Keep up the great work!
Thanks so much for this video. I've been servicing my 20 kW generator for over 10 years now and never knew about the bolts, set screws and brushes. I serviced mine yesterday and found all were fine. My battery needed water after replacing it after only a year. So, I agree that it gets overcharged. My last one had a hole in the side! The biggest challenge is the rear spark plug. I accidently dropped the new one behind the heat shield and it was quite a long ordeal to get it out. I had to remove all panels (top, back, front, sides) to gain access. Then, I had to partially remove the heat shield to get it out. Note that if I had the socket on it, it probably wouldn't been able to get dropped in there. I usually only replace the oil and filter every year and the air filter and plugs every 3 years or so depending on the number hours on the generator. Thanks again!
Also, thanks for the advice to check the tightness of the bolts under the air filter housing and the set screw on the control rod. Mine were all tight but that helps those of us who do our own basic maintenance.
Just replaced the slip ring and brushes today. It was a hell of a job and I am shocked I got it to work. Fired right up. They melted and I don’t know why. I was quoted on a whole new rotor assembly or a whole new generator, even though it only had 162 hours…..my local dealer had never seen the issue nor do I think it was ever inspected. The guys on the smokstak forum helped me tremendously! This is a great video as I’ll prob take on my own maintenance now.
My generator stopped working and said engine high speed. I was about to call a tech to come look but watched your video. The little set screw had come loose and the linkage was apart. Took me 10 minutes to fix it and it's running great now. You saved me a service call brother. All RUclips videos should be this good. Thank you.
The problem is many employers try to always rush their techs. I treat everything I work on as if it’s mine. I carry a lot of pride in my work. I would hope many others would also
Thank you. Today, of your big three, I found 2 on my unit. The 4 bolts (10mm) were all a little loose, the battery was a little low on water, but the tiny set screw was tight. 2 1/4 quarts oil did the trick. Wiped down, cleaned everything. AC PF53 oil filter, same as my riding mower uses. Blew out air cleaner, it was very clean. Reset system, back to auto, really enjoyed it. Thanks!
My stepper motor fasteners got loose and one of the control conductors became abraded. I had to pay through the nose to have it replaced, all because of a loose bolt. Thanks to you I know to regularly check for loose fasteners. Thank you.
With my Champion standby gas generator I don’t need to check the batterys (mine use two) because they are sealed and don’t need any kind of maintenance aside for changing the oil every 100 hours, because they don’t have any overcharging issues neither, but for the people who has a Kohler generator this tips are very helpful 👍
Your video helped me figure out an issue I was having with the spring to the stepper motor. Everything is fixed thanks to the few shots of the spring in this video! Thanks!
That was good on the battery maintenance; it's just like maintaining a non-sealed auto battery. Refill the cells with clean distilled water, and yes to the bottom of the plastic flanges. The metal cores must be kept covered by water (strong acid solution). I check battery water level every 90 days on my Kohler 20RESC. The recharge overvoltage can be corrected by a software upgrade or a resistor kit from Kohler.
I have a 17RES and recently found a nut on the floor of the generator housing and no idea where it came from until I watched your video. 1 nut off, two loose, only 1 tight. Yet it has been running fine, until now. Great piece of maintenance advice. Nuts replaced and tightened, it still doesn't really want to run. With a little help on the throttle, it will start, but soon the auto-throttle takes over and opens wide and the unit shuts down. Any suggestions?
My main 150amp panel is in my basement. What is the best place to install the automatic transfer switch? I'm debating on getting a Kohler 20k RCA and not sure where to place ATS inside or outside the home.. Also is OnCue worth it and don't they make a wireless kit so one doesn't need to use a cat 5 ethernet cable? Thanks😊 My gas meter is on opposite side of my house to where the electric meter is.
Thanks, you R incredibly helpful. Very thorough with a lot of integrity for what you do. Solved my issue with no start by cleaning the holes where there should have been tubes according to sb722 in 2011.
If things are vibrating loose over time, it's worth using some Loc-tite or similar on it. Batteries are also a consumable and should (rule-of-thumb) for lead-acid be swapped out after 4 - 4.5 years or so, and at the latest 5-6 years. I once dropped a large wrench on a car lead-acid battery's terminals and got one of the nice weld marks you speak of, quite exciting when it happens!
What size Allen wrench do you use on that set screw? Also, do you have a source for two replacement parts: GM100831-S (hinge assembly for cover) and GM84044 (engine cover assembly). I'm located in Marco Island, FL and do my own maintenance thanks to this video and these two parts need to be replaced. Looked online and there are a couple of sources but not very responsive, specifically Brags & Hayes and ATAN-demo store.
My Kohler 20kw is 3 years old now. I just did my own service for the first time this year and your video was a big help. The manual mentions cleaning the oil cooler with a brush or compressed air. I gather this cooler lies beneath some shroud on the machine. Maybe you could cover that in a future video???
Mine hunts a lot, first was natural gas meter was too small, had uograded by certified plumber, still hunting, rep suggested diaphram carb/fuel/air might have bugs that crawled up tubes and messed up fuel/air mixture causing engine to run funny. Checked governor ohms, they were good. Great advise on tightening bolts under air filter. Trying this tomorrow with service & fuel diaphram insoection.
Hi great video! My question is how do I fix a “locked Rotor” I’ve done my oil change and a tech has also updated the computer on my Koehler generator…I think the “rotor locked” because I did not flip the power switch back on before I pressed the “run” button . I have also reset the the maintenance message. Any advice to fix the “rotor lock” is appreciated…Thank You
On my 14 RESA the battery was charged so heavily that I had to fill the battery with water monthly. After replacing the battery twice in 2 years due to over charging I removed the charge lead coming from the controller going to the starter solenoid and placed 2 layers of heat shrink tubing over it to insulate it. I then went out and bought and installed a 6 Amp. Battery Tender sealed charger in the enclosure and attached it to the solenoid. I now never have to fill the battery and it is always at full charge plus it is 5 years old and still tests good with a refractometer.
Ever thought about using low strength loctite on that stepper set screw and use a torque screw driver to test tightness on every maintenance nut and bolt? Just curious 🤔, I believe it would make maintenance more simple and less guessing if all is in spec., I would like to hear your thoughts on this. Thanks for sharing this video.
About to perform my spring maintenance on my Kohler 20K. This was very informative and I made notes to check mentioned bolts and battery maint. I just wondering if I have to pump out the oil or will gravity be enough to drain out the old oil? Is it ok to just air compressor the air filter instead of replacing every year? Are you replacing the spark plugs every season as well? Thank you for a great video. Pete in Canada.
I ran my generator in manual 5 minutes, let cool for 5 minutes, oil drained well. Gravity does well, oil cap removed helps. After 5 minute drain, remove oil filter, more oil then drains out. I clean my plugs, swap them around, replace at 2 years.
Checked my kohler engine oil today. Oil on dip stick looked clean. When I plulled the oil filler cap off. There was some milky moisture on the inside of the filler cover. The kohler generator was installed Sept.2022..
what difference is there in model years since this is 2021 and this is from 2018 and which in your opinion is the better cabinet composite or metal and what is better higher off the ground and how close should it be to electrical panel and how far away from windows or doors
There are two Phillips head screws at the top of the side cover - visible when the top is lifted up. Take these out and the end cover lifts out. This lets you access the battery and oil drain hose. I have never had to take the side cover off to do oil, battery, spark plug, or air filter maintenance. You can just reach in and turn the valve to drain the oil. It drains slow so start it draining and go do something else for an hour.
I started using blue locative on the carb bolts. Haven’t been applying long enough yet I’m sure it will help. It helped on my Milwaukee impact driver belts clip. It would never stay tight until I applied blue locative about 8 months ago. Haven’t worked with the purple yet will have to look into it
I just replaced the stepper motor coupler and related parts (including the screw-down you showed to tighten) - can't find anything that shows whether there is a correct location when installing the new part, i.e. set the throttle to closed and/or the motor shaft should be at a certain location. Anything on that would be helpful. Thank you.
Another good video. I just seen that fan in your video. I was not aware milwaukee makes a battery power fan. What's your take on the fan? Just curious.
I used it all summer and just took it out of my truck a week ago. It is awesome. about 3-1/2 hours using hi-setting with the 4amp 18V batteries. The 2 amp battery only made it an hour. This video I made when I first got it and I test the 2 and 4 amp batteries. ruclips.net/video/lOv5PVVntoE/видео.html This also has a power adapter if needed yet that doesn't charge the batteries. I thought I would be using it on hi setting instead I used the mid or low often and the fan lasted all day.
For a kohler 20kw resa, is it possible for a home owner to install a programmable interface module (pim) for it, then use the OnClue program for monitoring? How complicated it the job?
My Koehler generator is running a little rough (surging) a little. But then after about 30-40 minutes it quits producing electricity, although engine keeps running. I have the Kohler model no. KOH20RESC-SELS Size 20kw Engine: CH1000 4-Cycle
Proper way to fill the battery is to add distilled water to just below the level gauge. If filled to or above these, the electrolyte can wick out and cause a conductive moisture on top of the battery. Then corrosion begins to build up. Pro Tip: A clean and moisture free battery top will never corrode.
what's your thoughts regarding the base. Should I install a concrete base and maybe so isolators to stop vibration or is the standard base on crushed stone okay? Thanks Chocobill
I would go with the concrete base which is what I thought was the standard base. You want the generator lifted up off the ground a few inches. Makes draining oil easier. Also helps with water drainage. Crushed stone bases always seem to sink. As for vibration dampening that’s not easy. Usually you will want to anchor to the cement to prevent the generator from shifting from vibration
Recommend a Kohler dealer in San Antonio, Tx? Last months' local freeze rung a bell and got me interested in a gen. No fun sitting in a dark, unheated home. Was thinking of a Generac, but there are some unfavorable reviews out there. Thanks.
How do we keep mice out of the enclosure? We got our 20 KW Kohler installed a year ago. I'm a contractor and had my electrician do the work. I got alerts that it's due for the first service but other than bi weekly run schedules it doesn't run that often. Should I change the spark plugs and air filter this soon? I would think just the oil would need to be done at this stage.
Third shouldn’t be any openings mice could get into the generator. If they can seals are missing or installed wrong. I only seen insects mostly ants get in.
Checking resistance on the coil of the stepper motor. It should be around 33 ohms or close each coil. Since resistance changes with temperatures. As long as both coils (black &yellow) (red &white) have the same resistance the stepper motor is good. Make sure the red Molex plug is together strapped onto the dipstick. Also that the plug is properly seated onto the bottom of the controller. Can you manually move the stepper motor with little resistance or is it really tight?
Hello, our new Kholer 20kw generator’s battery can’t last for a week to start next exercise, should it comes with a battery charger to keep enough power to start the every other week’s exercising? Thanks 🙏
Yes depending on model of generator. RES models had an external battery charger. Any generator with the RDC controls external. They had red display. The rdc2 controller grey display the battery charger was built in. Also many generators were installed with gfci breakers. If that is tripped then the battery charger has no power.
First time viewer of your videos, very helpful thank you for making these. I have a Kohler 20RESB Natural gas just like this one. Since last year it will crank but not start and ends up in overcrank error. I have changed oil, spark plugs, air filter, the 15A 250V fuse thats connected to the fuel shutoff valve/solenoid. I am also going to try to see if its the thermostat -- looking at the diagram I cant figure out where this is actually located in the genset. Any thoughts? I dont think its fuel pressure (but I could be wrong) since there is nothing to indicate that the fuel pressure was bad (this ran from 2016-2021 without a problem. Total of only 96 hours on the genset actual runtime.
@@ericdvorak7030 I did get it resolved actually but it was such a "dumb solution". The fuel solenoid was stuck and wouldn't open. I had to pay a service company $300 to come and just whack it with a mallet and it has fires right up since. Sometimes these components are just temperamental.
My battery got low. I replaced it but lost the original programing. I had it connected to Wi-Fi but after the new battery was installed i could no longer use my kohler app on my android . Mainly I could not set the generator to run every other week . Plus I have to manually reset the run time if I want to change the time of exercising. How do I reset the program ?
There is a 'Maintenance Required' message displaying on the control board. Will the generator still run if this message is displayed? Thanks in advance.
Yes, it will still run normally. Once you do your maintenance, hold down the off and auto button at the same time until the maintenance timer resets to 150 hours / 12 months.
I wear a GoPro wearing a chest mount. When I use a tripod the audio is off in my videos. Downfall to the chestmount is at times I am filming my legs instead of what I am working on
3:02 Yup, batteries seem to not last too long in these. Also, our 20 KW uses oil! Ran for over 2 days and it was nearly a quart low... Half it's capacity.
At 1:52 you show the hinged inner cover, could you tell me what it does and the part number to replace it ? Mine has shredded and duct tape does not work. Thank you
if you're having problems disconnect the battery charger and install a Schemacher maintainer. I think i have around five of them at this point and not one has failed or overcharged in over ten years.
So what kind of running hours do these air cooled generators get before the engine begins to show signs of distress or needing to replaced? I know water cooled engines like the diesel generators are easily expected to get 10,000 hours or more before they begin to think about rebuilding them.
To generate clean power at 60 cycle a generator that has one field must turn at 3600 RPM, now if you use a generator that has three fields the engine can turn at 1200 RPM. If it turns slower it will run longer but this kind of generator needs a more powerful engine and is three times more expensive. The small engine in the home series is air cooled and gas fueled. No radiator/coolant maintenance, no fuel aging problems and less maintenance needed. If it's for occasional power shortages that kind of unit, well maintened, can last certainly 25 years. If it's used every week for many hours then it could last only five years before needing a rebuilt engine. (I might not have used the right terms speaking of fields and cycles, please correct me, it gives an idea of the reason behind the durability question.))
With the newer fiberglass bodies they should last longer than the older style generacs with the metal casings. The older generacs remind me of the Toyota pick up trucks driving around in the 80’s with the rusted out bodies. The engines are strong and do run at 3600rpms. As long as oil level is maintained they should last around 5-10k hours of operation.
Why not get a Lithium Ion battery and eliminate the lead acid battery issues? My Kohler 14 kW generator gets delivered in 2 weeks and that battery swap is at the top of my list. I have an outlet right next to the generators spot. Why not run a battery tender to the Litium Ion Battery once a month?
Lithium batteries very expensive. Customers don’t want to spend a fortune on a battery that might not start during a power failure, in extremely cold weather. A lead acid battery will provide 3-4 years of power for a generator starter. They need around 500 CCA / cold cranking amps to turn over starter. Let me know how it works out. I’m not against this if it can work. The generator has a built in trickle charger for the battery
Our company always checks the line voltage at the p5 connector on the back of the controler for the charger. We also have seen the white wire for the stepper motor connector back out enough to not make contact like some of the old ford connectors
I have had popped fuses. Kohler years ago wanted gfci and they were tripping all the time. They stopped requiring the gfci after receiving many rdc2's back under warranty. Look for loose steppers the 10 mm always seem to loosen up that fasten them down.
I know this is an old thread you may not even see it I've got a Kohler 20 kW just had it installed about 4 months ago it's been exercising just fine every week around 1pm. this morning power goes off at 5am generator doesn't come on. I go outside after it's daylight lift up the hood red lights flashing fault code speedfall I believe what it said engine felt warm even though I don't even think it had run maybe it had this power went off intermittently several times during the night. this is a brand new generator I cannot believe I've got an issue with it.
The one nagging problem I have is the back spark plug; it is very difficult to get to. I have seen people online suggest taking the back panel off during regular maintenance, which I guess I could do. What if I cut a small hinged trap door in the back panel? There's nothing back there except the plastic shell and the insulation. What do you think?
I just use a swivel head ratchet a short socket extension and 5/8 spark plug socket. It comes right out. In this video, I pull the plugs out. ruclips.net/video/eEE_YUlCMDc/видео.html I only take the back plate off if I am testing the starter or the older style Kohlers RES models that need the mag-pick up adjusted or replaced from LRA lockouts. Is this your generator or you work as a Tech. The rear plug gets easier. The hinged trap door would be more time consuming than just removing the plug.
@@thehvachacker It's my generator so I do this every year. The other video is helpful, especially the extension trick. Right now I have a different kind of problem. For the first time, I can't get the spark plug wire off (that back plug). I have rocked it, twisted it till I'm blue in the face and it just won't come off. Be cause of the tight space, it's hard to apply upward force on it, and I don't want to damage the wire. Any tips?
Have you tried hose pliers or any pliers to grab the boot and pull. Should come off. If your having problems with it put some non dielectric grease on the new spark plug before putting boot bacj on. The back should come off with removing all the other panels. Worst case senerio
@@thehvachacker Well, I went ahead and took the back panel off. Once I was able to pull the spark plug wire straight up, it came off OK. I did put some dielectric grease on the tip of the new spark plug. taking the back panel off is a bit of a pain in the butt! Still thinking about that trap door - flip it down, do your thing, and flip it back up! Thanks for all of your help!
Happy to hear you were able to remove it. I find it’s easier to remove that rear spark plug with the air filter cover off. Never hurts to try and create a way into the generator if it’s yours. The grease should help you get it off next time.
That battery being what looks like 2 years old already, and being run dry, I would have changed it out. I have the same unit, and get about 2-3 years from my batteries. I do have the upgrade board to solve the overcharging problem, but have been too lazy to change it for the time being.
Check the heat shield on the wiring harness to the control panel to make sure it is protecting the wiring harness. Due to a manufacturing defect, the heat shield was not properly connected on mine and the wiring harness shorted out against the muffler, taking out the control panel. This happened over a month ago on my year old generator (that I have a 10 year warranty on) and I am still waiting for my $2600 refund from the Kohler Warranty department for the repair.
Hello sir! sir i need plc of this generator i am from pakistan please guide me my generator of 18 KVA And it's of no use without a card please help me tell me from where i can purchase this card and how much will it cost i will wait for your reply
@Sam Max I like your idea of keeping the battery indoors. Depending on the location of the generator, this might mean a long run of two large conductors. I mentioned this idea to my guy when he installed the unit. He was not impressed with my suggestion.
Also, my 20RESC (installed Sept 2016), gets new oil, plugs, air filter yearly. My oil level stays steady, oil is always super-clear on the dipstick, but I get a milky oil residue on the inside of the rubber oil plug caps. Test cycle 20min runs weekly, and I have had only short power outages (few minutes to an hour or two) since install.
Milky white on the rubber cap is cavitation. You need to let the generator run under a load for 30 minutes to build up heat in the cylinders. The weekly exercise will not do this. This why at maintenance visits we run the generator with the house load for 30 mins or so. Hope this helps
Russel are u running a full load exercise if not your machine is just building up condensation. I also recommend the advice Tom gave you at least once a month shut power off to your house and let it power your house for an hour. That will burn the moisture out of the engine.
No replacing the main control board does help. The control boards with green bottoms were overcharging. Kohler had a diode kit they include with all the newer boards to help remedy this
@@thehvachacker I have a green board and no diode kit. My recent battery lasted exactly 37 months. The previous battery lasted five years. The green controller is terrible and my guy never told me it was a bad design, nor did he offer to install the diode kit.
You're the only kind of service guy that I would allow to work on my equipment. Most service people get in and barely do the job and get out. They don't care about going the extra mile like you did with cleaning out the dirt in the battery area and other things that you did. I commend people like you for doing what you do....
You should lean about the batts the positive cable was not all the way down and you didnt out it down its a taper fit has to go down all the way to make correct contact
@@davidcolasurdo2282 Could we get that in English?
Sir, I’d like to thank you for generously posting your knowledge for all to see. I really do think it’s great that you are willing to share what you know with the rest of us. I never have a problem hiring competent service people to take care of things I see as important, especially things like generator service. But when getting that service starts to become more troublesome, and I get what I feel is double talk, I sometimes feel I need to do things myself, or get raked over the coals, if you know what I mean. That’s where people like you step up and save the day. Thanks so much. And I’m grateful there is a medium out there where you can do that. Keep up the great work!
Thanks so much for this video. I've been servicing my 20 kW generator for over 10 years now and never knew about the bolts, set screws and brushes. I serviced mine yesterday and found all were fine. My battery needed water after replacing it after only a year. So, I agree that it gets overcharged. My last one had a hole in the side!
The biggest challenge is the rear spark plug. I accidently dropped the new one behind the heat shield and it was quite a long ordeal to get it out. I had to remove all panels (top, back, front, sides) to gain access. Then, I had to partially remove the heat shield to get it out. Note that if I had the socket on it, it probably wouldn't been able to get dropped in there.
I usually only replace the oil and filter every year and the air filter and plugs every 3 years or so depending on the number hours on the generator. Thanks again!
Also, thanks for the advice to check the tightness of the bolts under the air filter housing and the set screw on the control rod. Mine were all tight but that helps those of us who do our own basic maintenance.
The stepper motor 10mm fasteners loosen up from engine vibrations. I find them loose on many maintenances.
Just replaced the slip ring and brushes today. It was a hell of a job and I am shocked I got it to work. Fired right up. They melted and I don’t know why. I was quoted on a whole new rotor assembly or a whole new generator, even though it only had 162 hours…..my local dealer had never seen the issue nor do I think it was ever inspected.
The guys on the smokstak forum helped me tremendously! This is a great video as I’ll prob take on my own maintenance now.
My generator stopped working and said engine high speed. I was about to call a tech to come look but watched your video. The little set screw had come loose and the linkage was apart. Took me 10 minutes to fix it and it's running great now. You saved me a service call brother. All RUclips videos should be this good. Thank you.
Nice to see a professional who is knowledgeable and cares. Seems to be getting harder to find these days! Great job!!
The problem is many employers try to always rush their techs. I treat everything I work on as if it’s mine. I carry a lot of pride in my work. I would hope many others would also
Thank you. Today, of your big three, I found 2 on my unit. The 4 bolts (10mm) were all a little loose, the battery was a little low on water, but the tiny set screw was tight. 2 1/4 quarts oil did the trick. Wiped down, cleaned everything. AC PF53 oil filter, same as my riding mower uses. Blew out air cleaner, it was very clean. Reset system, back to auto, really enjoyed it. Thanks!
My stepper motor fasteners got loose and one of the control conductors became abraded. I had to pay through the nose to have it replaced, all because of a loose bolt. Thanks to you I know to regularly check for loose fasteners. Thank you.
With my Champion standby gas generator I don’t need to check the batterys (mine use two) because they are sealed and don’t need any kind of maintenance aside for changing the oil every 100 hours, because they don’t have any overcharging issues neither, but for the people who has a Kohler generator this tips are very helpful 👍
Your video helped me figure out an issue I was having with the spring to the stepper motor. Everything is fixed thanks to the few shots of the spring in this video! Thanks!
That was good on the battery maintenance; it's just like maintaining a non-sealed auto battery. Refill the cells with clean distilled water, and yes to the bottom of the plastic flanges. The metal cores must be kept covered by water (strong acid solution). I check battery water level every 90 days on my Kohler 20RESC. The recharge overvoltage can be corrected by a software upgrade or a resistor kit from Kohler.
Yes it can be corrected with a diod Kit. That forwhatever reason our Koehler distributor doesn’t want t give to us
Surprised maintenance free batteries are not being used here
I have a 17RES and recently found a nut on the floor of the generator housing and no idea where it came from until I watched your video. 1 nut off, two loose, only 1 tight. Yet it has been running fine, until now. Great piece of maintenance advice. Nuts replaced and tightened, it still doesn't really want to run. With a little help on the throttle, it will start, but soon the auto-throttle takes over and opens wide and the unit shuts down. Any suggestions?
My main 150amp panel is in my basement. What is the best place to install the automatic transfer switch? I'm debating on getting a Kohler 20k RCA and not sure where to place ATS inside or outside the home.. Also is OnCue worth it and don't they make a wireless kit so one doesn't need to use a cat 5 ethernet cable? Thanks😊 My gas meter is on opposite side of my house to where the electric meter is.
Great video, thanks for sharing, love getting insight from the guys that actually do the work!
Great job young man. You are a true professional.
Thanks, you R incredibly helpful. Very thorough with a lot of integrity for what you do. Solved my issue with no start by cleaning the holes where there should have been tubes according to sb722 in 2011.
If things are vibrating loose over time, it's worth using some Loc-tite or similar on it. Batteries are also a consumable and should (rule-of-thumb) for lead-acid be swapped out after 4 - 4.5 years or so, and at the latest 5-6 years. I once dropped a large wrench on a car lead-acid battery's terminals and got one of the nice weld marks you speak of, quite exciting when it happens!
What size Allen wrench do you use on that set screw? Also, do you have a source for two replacement parts: GM100831-S (hinge assembly for cover) and GM84044 (engine cover assembly). I'm located in Marco Island, FL and do my own maintenance thanks to this video and these two parts need to be replaced. Looked online and there are a couple of sources but not very responsive, specifically Brags & Hayes and ATAN-demo store.
My Kohler 20kw is 3 years old now. I just did my own service for the first time this year and your video was a big help. The manual mentions cleaning the oil cooler with a brush or compressed air. I gather this cooler lies beneath some shroud on the machine. Maybe you could cover that in a future video???
It’s on engine tiny black radiator looking thing with 2 black hoses. It’s rare those ever get dirty.
very thorough video. you seem like a great technician. And that place looks like a beautiful property.
What size Allen wrench do you use on that set screw? Is it metric? Thank You!
Mine hunts a lot, first was natural gas meter was too small, had uograded by certified plumber, still hunting, rep suggested diaphram carb/fuel/air might have bugs that crawled up tubes and messed up fuel/air mixture causing engine to run funny. Checked governor ohms, they were good. Great advise on tightening bolts under air filter. Trying this tomorrow with service & fuel diaphram insoection.
Great stuff. When filling is it necessary to remove terminals?
Hi great video! My question is how do I fix a “locked Rotor” I’ve done my oil change and a tech has also updated the computer on my Koehler generator…I think the “rotor locked” because I did not flip the power switch back on before I pressed the “run” button . I have also reset the the maintenance message. Any advice to fix the “rotor lock” is appreciated…Thank You
On my 14 RESA the battery was charged so heavily that I had to fill the battery with water monthly. After replacing the battery twice in 2 years due to over charging I removed the charge lead coming from the controller going to the starter solenoid and placed 2 layers of heat shrink tubing over it to insulate it. I then went out and bought and installed a 6 Amp. Battery Tender sealed charger in the enclosure and attached it to the solenoid. I now never have to fill the battery and it is always at full charge plus it is 5 years old and still tests good with a refractometer.
Ever thought about using low strength loctite on that stepper set screw and use a torque screw driver to test tightness on every maintenance nut and bolt? Just curious 🤔, I believe it would make maintenance more simple and less guessing if all is in spec., I would like to hear your thoughts on this. Thanks for sharing this video.
Thanks. Getting a Kohler 14kw installed in the next few weeks. Think these issues have been resolved in newer models?
other than oil and filters what spare parts would you recommend i keep on hand for a 14RCAL ?
Man I wish all service techs I had to deal with were as thorough and considerate as you.
About to perform my spring maintenance on my Kohler 20K. This was very informative and I made notes to check mentioned bolts and battery maint. I just wondering if I have to pump out the oil or will gravity be enough to drain out the old oil? Is it ok to just air compressor the air filter instead of replacing every year? Are you replacing the spark plugs every season as well? Thank you for a great video. Pete in Canada.
I ran my generator in manual 5 minutes, let cool for 5 minutes, oil drained well. Gravity does well, oil cap removed helps. After 5 minute drain, remove oil filter, more oil then drains out. I clean my plugs, swap them around, replace at 2 years.
Checked my kohler engine oil today. Oil on dip stick looked clean.
When I plulled the oil filler cap off. There was some milky moisture on the inside of the filler cover.
The kohler generator was installed Sept.2022..
what difference is there in model years since this is 2021 and this is from 2018 and which in your opinion is the better cabinet composite or metal and what is better higher off the ground and how close should it be to electrical panel and how far away from windows or doors
How do you get front/side covers off 20RESD to access 1) battery; 2) oil drain plug/hose and 3) other areas?
There are two Phillips head screws at the top of the side cover - visible when the top is lifted up. Take these out and the end cover lifts out. This lets you access the battery and oil drain hose. I have never had to take the side cover off to do oil, battery, spark plug, or air filter maintenance. You can just reach in and turn the valve to drain the oil. It drains slow so start it draining and go do something else for an hour.
What about using blue loctite (242) or purple loctite (222) on the carb bolts to keep them from vibrating loose. 222 is for small bolts.
I started using blue locative on the carb bolts. Haven’t been applying long enough yet I’m sure it will help. It helped on my Milwaukee impact driver belts clip. It would never stay tight until I applied blue locative about 8 months ago. Haven’t worked with the purple yet will have to look into it
I just replaced the stepper motor coupler and related parts (including the screw-down you showed to tighten) - can't find anything that shows whether there is a correct location when installing the new part, i.e. set the throttle to closed and/or the motor shaft should be at a certain location. Anything on that would be helpful. Thank you.
Hello. Have you got video how to do valve clearance adjustment on this generator?
Please use Locktite it may save you or a customer during an emergency. Imagine losing the set screw!
I second the use of loctite...med (Blue) Saves a lot of issues.
Looking at purchasing a Kohler or a Generac.Whats your opinion?What would you get?why?Thank you
I have a 20K generator and just received a Low Generator Frequency Shutdown Fault. What causes this and what do I do to fix it? Thanks!
Another good video. I just seen that fan in your video. I was not aware milwaukee makes a battery power fan. What's your take on the fan? Just curious.
I used it all summer and just took it out of my truck a week ago. It is awesome. about 3-1/2 hours using hi-setting with the 4amp 18V batteries. The 2 amp battery only made it an hour. This video I made when I first got it and I test the 2 and 4 amp batteries. ruclips.net/video/lOv5PVVntoE/видео.html This also has a power adapter if needed yet that doesn't charge the batteries. I thought I would be using it on hi setting instead I used the mid or low often and the fan lasted all day.
For a kohler 20kw resa, is it possible for a home owner to install a programmable interface module (pim) for it, then use the OnClue program for monitoring? How complicated it the job?
My Koehler generator is running a little rough (surging) a little. But then after about 30-40 minutes it quits producing electricity, although engine keeps running. I have the Kohler
model no. KOH20RESC-SELS
Size 20kw
Engine: CH1000 4-Cycle
Proper way to fill the battery is to add distilled water to just below the level gauge. If filled to or above these, the electrolyte can wick out and cause a conductive moisture on top of the battery. Then corrosion begins to build up. Pro Tip: A clean and moisture free battery top will never corrode.
Do you ever have to adjust the valves on the engine or do Kohler engines have hydraulic valves ?
what's your thoughts regarding the base. Should I install a concrete base and maybe so isolators to stop vibration or is the standard base on crushed stone okay? Thanks Chocobill
Definetley better with a concrete pad and anchor the generator to it.
I would go with the concrete base which is what I thought was the standard base. You want the generator lifted up off the ground a few inches. Makes draining oil easier. Also helps with water drainage. Crushed stone bases always seem to sink. As for vibration dampening that’s not easy. Usually you will want to anchor to the cement to prevent the generator from shifting from vibration
Recommend a Kohler dealer in San Antonio, Tx? Last months' local freeze rung a bell and got me interested in a gen. No fun sitting in a dark, unheated home. Was thinking of a Generac, but there are some unfavorable reviews out there. Thanks.
How do we keep mice out of the enclosure? We got our 20 KW Kohler installed a year ago. I'm a contractor and had my electrician do the work. I got alerts that it's due for the first service but other than bi weekly run schedules it doesn't run that often. Should I change the spark plugs and air filter this soon? I would think just the oil would need to be done at this stage.
Third shouldn’t be any openings mice could get into the generator. If they can seals are missing or installed wrong. I only seen insects mostly ants get in.
@@thehvachacker I’ll have to look and see where. It’s brand new summer of 2020. The two end panels have that mesh screen. Seals around lid are good.
Do you lose the programming when you disconnect the battery?
You will need to reset the clock and exercise time. When battery power is lost or disconnected.
wondering if I should swap mine out for an agm battery now
Can you tell me why the coil on the linkage to the carburetor is not moving on startup? Is there a way to test the coil???
Checking resistance on the coil of the stepper motor. It should be around 33 ohms or close each coil. Since resistance changes with temperatures. As long as both coils (black &yellow) (red &white) have the same resistance the stepper motor is good. Make sure the red Molex plug is together strapped onto the dipstick. Also that the plug is properly seated onto the bottom of the controller. Can you manually move the stepper motor with little resistance or is it really tight?
Glad to see someone doing things right.😁
Hello, our new Kholer 20kw generator’s battery can’t last for a week to start next exercise, should it comes with a battery charger to keep enough power to start the every other week’s exercising? Thanks 🙏
Battery needs to be in a constant charge state. 120 v is needed at all times to the utility terminals on the generator
Yes depending on model of generator. RES models had an external battery charger. Any generator with the RDC controls external. They had red display. The rdc2 controller grey display the battery charger was built in. Also many generators were installed with gfci breakers. If that is tripped then the battery charger has no power.
Do you have a video on how to install a carburator heater on a 20RESAL?? Thanks
which standby would you buy nd why?
how often you need to service the generator?
First time viewer of your videos, very helpful thank you for making these. I have a Kohler 20RESB Natural gas just like this one. Since last year it will crank but not start and ends up in overcrank error. I have changed oil, spark plugs, air filter, the 15A 250V fuse thats connected to the fuel shutoff valve/solenoid. I am also going to try to see if its the thermostat -- looking at the diagram I cant figure out where this is actually located in the genset. Any thoughts? I dont think its fuel pressure (but I could be wrong) since there is nothing to indicate that the fuel pressure was bad (this ran from 2016-2021 without a problem. Total of only 96 hours on the genset actual runtime.
Just wondering if you resolved the issue, mines doing the same thing, been fine since 2011, cranks but I’m not getting a spark from the plugs.
@@ericdvorak7030 I did get it resolved actually but it was such a "dumb solution". The fuel solenoid was stuck and wouldn't open. I had to pay a service company $300 to come and just whack it with a mallet and it has fires right up since. Sometimes these components are just temperamental.
My battery got low. I replaced it but lost the original programing.
I had it connected to Wi-Fi but after the new battery was installed i could no longer use my kohler app on my android . Mainly I could not set the generator to run every other week . Plus I have to manually reset the run time if I want to change the time of exercising. How do I reset the program ?
Great info in this video. But I'm wondering, how are the Kohler generators killing batteries? Is it because of the low water inside the battery?
Obviously overcharging that heats/evaporates the water. Add water to cover the plates, but leave room for expansion.
Kohler has a diode kit to compensate for overcharging
I put a few dozen in
There is a 'Maintenance Required' message displaying on the control board. Will the generator still run if this message is displayed?
Thanks in advance.
Yes, it will still run normally. Once you do your maintenance, hold down the off and auto button at the same time until the maintenance timer resets to 150 hours / 12 months.
! like your camera work. What do you use and where is it mounted?
I wear a GoPro wearing a chest mount. When I use a tripod the audio is off in my videos. Downfall to the chestmount is at times I am filming my legs instead of what I am working on
3:02 Yup, batteries seem to not last too long in these. Also, our 20 KW uses oil! Ran for over 2 days and it was nearly a quart low... Half it's capacity.
At 1:52 you show the hinged inner cover, could you tell me what it does and the part number to replace it ? Mine has shredded and duct tape does not work. Thank you
do you have a schematic for the components on a 6vsg control board?
What upgrade are you referring to to prevent battery overcharging? Thanks.
if you're having problems disconnect the battery charger and install a Schemacher maintainer. I think i have around five of them at this point and not one has failed or overcharged in over ten years.
Can you tell me how how he subassembly and rotor can melt when I have always had it servic d twice a year
Brush assembly
Great video thank you !
Lots of great maintenance tips- thanks !
Where are you located? I want to hire you to go over my generator. I am in Northern NJ.
So what kind of running hours do these air cooled generators get before the engine begins to show signs of distress or needing to replaced? I know water cooled engines like the diesel generators are easily expected to get 10,000 hours or more before they begin to think about rebuilding them.
To generate clean power at 60 cycle a generator that has one field must turn at 3600 RPM, now if you use a generator that has three fields the engine can turn at 1200 RPM. If it turns slower it will run longer but this kind of generator needs a more powerful engine and is three times more expensive. The small engine in the home series is air cooled and gas fueled. No radiator/coolant maintenance, no fuel aging problems and less maintenance needed. If it's for occasional power shortages that kind of unit, well maintened, can last certainly 25 years. If it's used every week for many hours then it could last only five years before needing a rebuilt engine. (I might not have used the right terms speaking of fields and cycles, please correct me, it gives an idea of the reason behind the durability question.))
With the newer fiberglass bodies they should last longer than the older style generacs with the metal casings. The older generacs remind me of the Toyota pick up trucks driving around in the 80’s with the rusted out bodies. The engines are strong and do run at 3600rpms. As long as oil level is maintained they should last around 5-10k hours of operation.
I changed the battery and now I can’t set date and time and exercise time. Can’t get into system. Thanks
Why not get a Lithium Ion battery and eliminate the lead acid battery issues? My Kohler 14 kW generator gets delivered in 2 weeks and that battery swap is at the top of my list. I have an outlet right next to the generators spot. Why not run a battery tender to the Litium Ion Battery once a month?
Lithium batteries very expensive. Customers don’t want to spend a fortune on a battery that might not start during a power failure, in extremely cold weather. A lead acid battery will provide 3-4 years of power for a generator starter. They need around 500 CCA / cold cranking amps to turn over starter. Let me know how it works out. I’m not against this if it can work. The generator has a built in trickle charger for the battery
Sir may i got Service maual of kohiler 5.6kva petrol generator.
Glad I just bought an AGM battery for my Kohler.
Great Video, Thank you!!
What a really great video! Thank you!
Our company always checks the line voltage at the p5 connector on the back of the controler for the charger. We also have seen the white wire for the stepper motor connector back out enough to not make contact like some of the old ford connectors
Found a few of the kohlers that the fuse for the p5 connector popped and had no charger
I have had popped fuses. Kohler years ago wanted gfci and they were tripping all the time. They stopped requiring the gfci after receiving many rdc2's back under warranty. Look for loose steppers the 10 mm always seem to loosen up that fasten them down.
How to access rear sparkplug?
Hacker that was a good service call. Peace brother
Thanks
I know this is an old thread you may not even see it I've got a Kohler 20 kW just had it installed about 4 months ago it's been exercising just fine every week around 1pm.
this morning power goes off at 5am generator doesn't come on.
I go outside after it's daylight lift up the hood red lights flashing fault code speedfall I believe what it said engine felt warm even though I don't even think it had run maybe it had this power went off intermittently several times during the night.
this is a brand new generator I cannot believe I've got an issue with it.
did not see you disconnect the battery charger before removing battery
Just a tip, if the negative is not on the battery, there will be no spark on your wrench if you touch the generator. Just a comment
Why don’t they put lock tight on the darn bolts? And why not use a sealed battery duh?
The one nagging problem I have is the back spark plug; it is very difficult to get to.
I have seen people online suggest taking the back panel off during regular maintenance, which I guess I could do. What if I cut a small hinged trap door in the back panel? There's nothing back there except the plastic shell and the insulation. What do you think?
I just use a swivel head ratchet a short socket extension and 5/8 spark plug socket. It comes right out. In this video, I pull the plugs out. ruclips.net/video/eEE_YUlCMDc/видео.html I only take the back plate off if I am testing the starter or the older style Kohlers RES models that need the mag-pick up adjusted or replaced from LRA lockouts. Is this your generator or you work as a Tech. The rear plug gets easier. The hinged trap door would be more time consuming than just removing the plug.
@@thehvachacker It's my generator so I do this every year. The other video is helpful, especially the extension trick. Right now I have a different kind of problem. For the first time, I can't get the spark plug wire off (that back plug). I have rocked it, twisted it till I'm blue in the face and it just won't come off. Be cause of the tight space, it's hard to apply upward force on it, and I don't want to damage the wire. Any tips?
Have you tried hose pliers or any pliers to grab the boot and pull. Should come off. If your having problems with it put some non dielectric grease on the new spark plug before putting boot bacj on. The back should come off with removing all the other panels. Worst case senerio
@@thehvachacker Well, I went ahead and took the back panel off. Once I was able to pull the spark plug wire straight up, it came off OK. I did put some dielectric grease on the tip of the new spark plug. taking the back panel off is a bit of a pain in the butt! Still thinking about that trap door - flip it down, do your thing, and flip it back up! Thanks for all of your help!
Happy to hear you were able to remove it. I find it’s easier to remove that rear spark plug with the air filter cover off. Never hurts to try and create a way into the generator if it’s yours. The grease should help you get it off next time.
That battery being what looks like 2 years old already, and being run dry, I would have changed it out. I have the same unit, and get about 2-3 years from my batteries. I do have the upgrade board to solve the overcharging problem, but have been too lazy to change it for the time being.
Kohlers kill the batteries
Check the heat shield on the wiring harness to the control panel to make sure it is protecting the wiring harness. Due to a manufacturing defect, the heat shield was not properly connected on mine and the wiring harness shorted out against the muffler, taking out the control panel. This happened over a month ago on my year old generator (that I have a 10 year warranty on) and I am still waiting for my $2600 refund from the Kohler Warranty department for the repair.
Hello sir! sir i need plc of this generator i am from pakistan please guide me my generator of 18 KVA And it's of no use without a card please help me tell me from where i can purchase this card and how much will it cost i will wait for your reply
Great tips. Thank you
do you use 5w 50 in the battery?
use distilled water
I usually go for 0w-20 fully synt5
You can keep the battery inside the house and run wires into it, safe from nature elements .
You can but the generator has a housing for the battery.
@@thehvachacker
The housing for it does not have heat and air conditioner,the weather really effect the efficiency of the battery.
Yes but not many homeowners want the battery inside there house.
You could also buy a AGM battery.
@Sam Max I like your idea of keeping the battery indoors. Depending on the location of the generator, this might mean a long run of two large conductors. I mentioned this idea to my guy when he installed the unit. He was not impressed with my suggestion.
How do you reset maintenance notice after service?
overview menu select push down till you reach maintenance it shows time left till next maintenance, click select and it will ask if you want to reset.
I didn't know they still made batteries that needed water!
Then you are stupid
@@abdulrehmanmian1476 thank you because I didnt know I was supposed to keep on things like that. It must be great knowing everything
Lead acid batteries can handle the large surge current of a big engine.
Great vid
Nice video.
Thanks
My engine needs oil, the electric charge doesn’t work (idk what that means) and the rotor isn’t working.
but I loved this video and I’m going to keep watching it.
Also, my 20RESC (installed Sept 2016), gets new oil, plugs, air filter yearly. My oil level stays steady, oil is always super-clear on the dipstick, but I get a milky oil residue on the inside of the rubber oil plug caps. Test cycle 20min runs weekly, and I have had only short power outages (few minutes to an hour or two) since install.
Can some tell me how to replace the spring on Kohler resc? Or a picture would help greatly. Much appreciated.
Milky white on the rubber cap is cavitation. You need to let the generator run under a load for 30 minutes to build up heat in the cylinders. The weekly exercise will not do this. This why at maintenance visits we run the generator with the house load for 30 mins or so. Hope this helps
Russel are u running a full load exercise if not your machine is just building up condensation. I also recommend the advice Tom gave you at least once a month shut power off to your house and let it power your house for an hour. That will burn the moisture out of the engine.
@@tommyg5565 Perhaps you meant to say "Condensation".
@@thehvachacker Is a 30-minute fully loaded exercise the same as shutting power off to the house for 30 minutes?
How to repair Kohler winding 15 kW
Loctite?
LOCTITE
Starting an engine and just shutting it down without letting it warm up causes condensation inside the engine.
Any idea what causes the battery acid level to drop?
Is it a condition unique to Kohler ?
The controller overheats the battery from the trickle charger. It’s good to check the battery once a year
@@thehvachacker Does a firmware update fix this issue?
No replacing the main control board does help. The control boards with green bottoms were overcharging. Kohler had a diode kit they include with all the newer boards to help remedy this
The water evaporates from the acid/water mix mostly due to heat of charging. That's why you only add water (distilled).
@@thehvachacker I have a green board and no diode kit. My recent battery lasted exactly 37 months. The previous battery lasted five years. The green controller is terrible and my guy never told me it was a bad design, nor did he offer to install the diode kit.