Kohler 48VDC, 36VDC, 24VDC, 6VSG User Manual

Operation

DC Generator Sets

Models:

6VSG

24VDC
36VDC
48VDC

Controller:

VSC

TP-6843 1/13a

Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

California Proposition 65

WARNING

!

Product Identification Information

Product identification numbers determine service
parts. Record the product identification numbers in
the spaces below immediately after unpacking the
products so that the numbers are readily available for
future reference. Record field-installed kit numbers
after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the
generator set nameplate(s).

Model Designation ___________________________

Specification Number _________________________

Serial Number ______________________________

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator
set operation manual, spec sheet, or sales invoice.

Controller Description _________________________

Engine Identification

Record the product identification information from the
engine nameplate.

Manufacturer ________________________________

Model Designation ___________________________

Serial Number _______________________________

Figure 1-1

Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Section 1 Descriptions and Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.3 Generator Set Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.4 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.5 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.5.1 VSC Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.6.1 Carburetor Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.6.2 OnCue® Generator Management System . . . . . . . . . . . . . . . . . 14

1.6.3 Programmable Interface Module (PIM) . . . . . . . . . . . . . . . . . . . 14

1.6.4 Communications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.7 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Section 2 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.1 Local Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.2 Remote Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.3 Engine Start Crank Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.4 Engine Cooldown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4.5 Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5 Exercise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.6 Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.6.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.6.2 Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.6.3 Resetting the Controller After a Fault Shutdown . . . . . . . . . . . . 20

Section 3 VSC Controller Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.1 VSC Generator Set Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2 Control and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.2.1 Controller Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.2.2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.2.3 LCD Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3 Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.4 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.5 Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.5.1 Procedure to Change Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.6 Setting the Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.6.1 Setting the Exerciser at Controller Power-up . . . . . . . . . . . . . . . 28

3.6.2 Changing the Exercise Settings . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.7 VSC Controller Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.8 Main Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.9 Overview Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.10 Engine Metering Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.11 Generator Metering Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.11.1 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.12 Generator Set Information Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.13 Genset Run Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.14 Genset System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

TP-6843 1/13 Table of Contents 3

Table of Contents

Section 4 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.14.1 System Parameters for Battery Bank Charging . . . . . . . . . . . . . 34

3.14.2 Setting the Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.14.3 Adjusting the Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.15 Date and Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.16 Networking Information Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.16.1 Networking Status Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.16.2 Networking Configuration Submenu (OnCue® Password) . . . . 39

3.16.3 RBUS Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.16.4 Remote Devices Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.17 Programmable Interface Module (PIM) Status Menu . . . . . . . . . . . . . . . 42

3.18 Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.18.1 Procedure to View Event History . . . . . . . . . . . . . . . . . . . . . . . . 43

4.1 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.1.1 Service Schedule, 6VSG Models . . . . . . . . . . . . . . . . . . . . . . . 46

4.2 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.1 Low Oil Pressure Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.2 Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.3 Engine Oil Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.4 Oil Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2.5 Resetting the Maintenance Timer. . . . . . . . . . . . . . . . . . . . . . . . 48

4.3 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4.4 Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.6 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.7 Engine Starting Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

4.8 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.8.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.8.2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.8.3 Cylinder Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.8.4 Exterior Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.8.5 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Section 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.2 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.3 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.3.1 Controller Internal Circuit Protection. . . . . . . . . . . . . . . . . . . . . . 53

5.3.2 Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.4 Controller Service Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4 Table of Contents TP-6843 1/13

Safety Precautions and Instructions

DANGER

!

WARNING

!

CAUTION

!

NOTICE

WARNING

!

WARNING

!

IMPORTANT SAFETY INSTRUCTIONS
Electro-mechanical equipment, including
generator sets, transfer switches,
switchgear, and accessories, can cause
bodily harm and pose life-threatening
danger when improperly installed,
operated, or maintained. To prevent
accidents be aware of potential dangers
and act safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.

This manual has several types of
safety precautions and instructions:
Danger, Warning, Caution, and Notice.

Danger indicates the presence of a
hazard that will cause severe

personal injury, death, or
substantial property damage.

Warning indicates the presence of a
hazard that can cause severe personal

injury, death, or substantial property
damage.

Caution indicates the presence of a
hazard that will or can cause minor
personaI injury or property damage.

Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.

Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.

Accidental Starting

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.

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.

Battery

!

WARNING

Sulfuric acid in batteries.
Can cause severe injury or death.

Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.

Explosion.
Can cause severe injury or death.

Relays in the battery charger
cause arcs or sparks.

Locate the battery in a
well-ventilated area. Isolate the
battery charger from explosive
fumes.

Battery electrolyte is a diluted
sulfuric acid. Battery acid can
cause severe injury or death.

Battery acid can cause blindness and
burn skin. Always wear splashproof
safety goggles, rubber gloves, and
boots when servicing the battery. Do
not open a sealed battery or mutilate
the battery case. If battery acid
splashes in the eyes or on the skin,
immediately flush the affected area for
15 minutes with large quantities of
clean water. Seek immediate medical
aid in the case of eye contact. Never
add acid to a battery after placing the
battery in service, as this may result in
hazardous spattering of battery acid.

Battery acid cleanup. Battery acid
can cause severe injury or death.

Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

TP-6843 1/13 Safety Precautions and Instructions 5

Battery gases. Explosion can

WARNING

!

WARNING

!

cause severe injury or death.

Battery gases can cause an explosion.
Do not smoke or permit flames or
sparks to occur near a battery at any
time, particularly when it is charging.
Do not dispose of a battery in a fire.
To prevent burns and sparks that
could cause an explosion, avoid
touching the battery terminals with
tools or other metal objects. Remove
all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery.
To avoid sparks, do not disturb the
battery charger connections while the
battery is charging. Always turn the
battery charger off before
disconnecting the battery connections.
Ventilate the compartments containing
batteries to prevent accumulation of
explosive gases.

Battery short circuits. Explosion
can cause severe injury or death.

Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (–) lead first when
disconnecting the battery. Reconnect
the negative (–) lead last when
reconnecting the battery. Never
connect the negative (–) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.

Engine Backfire/Flash Fire

Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator

set with the air cleaner removed.

Servicing the fuel system. A flash
fire can cause severe injury or
death. Do not smoke or permit flames

or sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.

Combustible materials. A fire can
cause severe injury or death.

Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.

Exhaust System

Carbon monoxide.
Can cause severe nausea,

fainting, or death.

The exhaust system must be
leakproof and routinely inspected.

Carbon monoxide detectors.
Carbon monoxide can cause severe
nausea, fainting, or death. Install

carbon monoxide detectors on each
level of any building adjacent to the
generator set. Locate the detectors to
adequately warn the building’s
occupants of the presence of carbon
monoxide. Keep the detectors
operational at all times. Periodically
test and replace the carbon monoxide
detectors according to the
manufacturer’s instructions.

Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon

monoxide is a poisonous gas present
in exhaust gases. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death
if inhaled for even a short time.
Carbon monoxide poisoning
symptoms include but are not limited
to the following:

• Light-headedness, dizziness

• Physical fatigue, weakness in
joints and muscles

• Sleepiness, mental fatigue,
inability to concentrate or speak
clearly, blurred vision

• Stomachache, vomiting, nausea

If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie
down, or fall asleep. Alert others to
the possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of
breathing fresh air.

Generator set operation. Carbon
monoxide can cause severe
nausea, fainting, or death. Carbon

monoxide is an odorless, colorless,
tasteless, nonirritating gas that can
cause death if inhaled for even a short
time. Avoid breathing exhaust fumes

Fire.
Can cause severe injury or death.

Do not smoke or permit flames or
sparks near fuels or the fuel system.

6 Safety Precautions and Instructions TP-6843 1/13

when working on or near the generator
set. Never operate the generator set
inside a building. Never operate the
generator set where exhaust gas
could seep inside or be drawn into a
potentially occupied building through
windows, air intake vents, or other
openings.

Fuel System

WARNING

!

CAUTION

!

DANGER

!

WARNING

!

CAUTION

!

Explosive fuel vapors.
Can cause severe injury or death.

Use extreme care when handling,
storing, and using fuels.

The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly

explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel
to the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate
the generator set in the presence of
fuel leaks, fuel accumulation, or
sparks. Repair fuel systems before
resuming generator set operation.

Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an

explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to 6-8
ounces per square inch (10-14 inches
water column). Do not use a soap
solution containing either ammonia or
chlorine because both prevent bubble
formation. A successful test depends
on the ability of the solution to bubble.

Hazardous Noise

Hazardous noise.
Can cause hearing loss.

Never operate the generator set
without a muffler or with a faulty
exhaust system.

Engine noise. Hazardous noise can
cause hearing loss. Generator sets

not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to
noise levels greater than 85 dBA can
cause permanent hearing loss. Wear
hearing protection when near an
operating generator set.

Hazardous Voltage/Moving Parts

Hazardous voltage.
Will cause severe injury or death.

This equipment must be installed
and serviced by qualified electrical
personnel.

!

WARNING

Hazardous voltage. Moving parts.
Can cause severe injury or death.

Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.

If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.

Welding the generator set.
Can cause severe electrical
equipment damage.

Never weld components of the
generator set without first
disconnecting the battery,
controller wiring harness, and
engine electronic control module
(ECM).

Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution

is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the
main circuit breakers of all power
sources before servicing the
equipment. Never contact electrical
leads or appliances when standing in
water or on wet ground because these
conditions increase the risk of
electrocution.

Operate the generator set only when
all guards and electrical enclosures
are in place.

TP-6843 1/13 Safety Precautions and Instructions 7

Welding on the generator set. Can

WARNING

!

WARNING

!

cause severe electrical equipment
damage. Before welding on the

generator set perform the following
steps: (1) Remove the battery cables,
negative (–) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors. (4)
Disconnect the engine battery­charging alternator connections. (5)
Attach the weld ground connection
close to the weld location.

Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.

Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).

Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can

cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing
the equipment.

Hot Parts

Hot engine and exhaust system.
Can cause severe injury or death.

Do not work on the generator set
until it cools.

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.

Servicing the engine heater. Hot
parts can cause minor personal
injury or property damage. Install

the heater before connecting it to
power. Operating the heater before
installation can cause burns and
component damage. Disconnect
power to the heater and allow it to cool
before servicing the heater or nearby
parts.

Heavy Equipment

Unbalanced weight.
Improper lifting can cause severe

injury or death and equipment
damage.

Do not use lifting eyes.
Lift the generator set using lifting
bars inserted through the lifting holes
on the skid.

8 Safety Precautions and Instructions TP-6843 1/13

Introduction

This manual provides operation and maintenance
instructions for the DC (direct current) variable speed
model 6VSG generator sets equipped with Kohler VSC
generator set controllers.

This generator set is approved for use in stationary
applications in locations served by a public utility,
photovoltaic cells, wind turbines or any combination of
power sources tied to a battery bank. Have the
generator set installed by an authorized
distributor/dealer or service technician. Refer to
Installation Manual, for installation instructions.

Information in this publication represents data
available at the time of print. Kohler Co. reserves the
right to change this publication and the products
represented without notice and without any obligation
or liability whatsoever.

Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow
the Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

List of Related Literature

Figure 2 identifies related literature available for the
generator sets covered in this manual. Only trained
and qualified personnel should install or service the
generator set.

Figure 2

Literature Type Part Number

Installation Manual, Model 6VSG
Generator Set TP-6842

Service Manual, 6VSG Generator Set TP-6844

®

Operation Manual, OnCue

Operation Manual, SiteTech

Installation Instructions, Programmable
Interface Module (PIM) TT-1584

Parts Catalog, Model 6VSG TP-6845

Software

™

Software

Figure 2 Related Literature

TP-6796

TP-6701

The equipment service requirements are very
important to safe and efficient operation. Inspect the
parts often and perform required service at the
prescribed intervals. Obtain service from an
authorized service distributor/dealer to keep
equipment in top condition.

Figure 1

Figure 1 6VSG Generator Set

TP-6843 1/13 Introduction 9

Nameplate

GM12070

Emission Information

The following illustration shows a typical generator set
nameplate. Copy the model, serial, and specification
numbers from the nameplate into the spaces provided
in the product information section on the inside front
cover of this manual. See the service views in Section

1.7 for the nameplate location.

Figure 3

Figure 3 Typical Nameplate

The Kohler Model CH740 engine used on the 6VSG
generator set is certified to operate using natural gas
or LPG fuel.

The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the
number of operating hours for which the engine has
been shown to meet CARB or EPA emission
requirements. Figure 4 provides the engine
compliance period (in hours) associated with the
category descriptor, which may be found on the
certification label.

Figure 4

Emission Compliance Period

EPA Category C

250 hours

CARB Moderate 125

hours

Category B

500 hours

Intermediate

250 hours

Category A
1000 hours

Extended 500

hours

Figure 4 Emission Compliance Period

Refer to the certification label for engine displacement.
The exhaust emission control system for the CH740
engines (6VSG) is EM for U.S. EPA, California, and
Europe. See Figure 1-2 for engine certification label
location.

10 Introduction TP-6843 1/13

Service Assistance

For professional advice on generator set power
requirements and conscientious service, please
contact your nearest Kohler distributor or dealer.

• Consult the Yellow Pages under the heading
Generators—Electric.

• Visit the Kohler Power Systems website at
KOHLERPower.com.

• Look at the labels and stickers on your Kohler
product or review the appropriate literature or
documents included with the product.

• Call toll free in the US and Canada 1-800-544-2444.

• Outside the US and Canada, call the nearest
regional office.

Headquarters Europe, Middle East, Africa
(EMEA)

Kohler Power Systems
3 rue de Brennus
93200 Saint Denis
France

Phone: [phone]

Fax: [phone]

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore

Phone: [phone]

Fax: [phone]

China

North China Regional Office, Beijing

Phone: [phone]

(86) 10 6518 7951
(86) 10 6518 7952

Fax: [phone]

East China Regional Office, Shanghai

Phone: [phone]

Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India

Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan

Phone: [phone]

Fax: [phone]

Latin America

Latin America Regional Office
Lakeland, Florida, USA

Phone: [phone]

Fax: [phone]

TP-6843 1/13 Service Assistance 11

Notes

12 Service Assistance TP-6843 1/13

Section 1 Descriptions and Service Views

KPS_048
GM77569

1.1 Introduction

The generator set specification sheets provide specific
generator and engine information. Refer to the spec
sheet for data not supplied in this manual. Consult the
generator set service manual, engine operation
manual, and engine service manual for additional
specifications. Obtain copies of the latest spec sheets,
manuals, diagrams, and drawings from your local
distributor/dealer.

1.2 Engine

The generator set has a four-cycle, twin cylinder,
air-cooled Kohler engine. The engine operates on
cleanburning natural gas or LPG fuel. Engine
features include:

• Efficient overhead valve design and full pressure
lubrication for maximum power, torque, and
reliability under all operating conditions.

• Dependable, maintenance-free electronic ignition.

• Precision-formulated cast iron construction of parts
subjected to the most wear and tear.

1.4 Alternator

The 6VSG is a direct current (DC) output machine. It
utilizes a 24-pole permanent magnet construction to
create high frequency three-phase alternating current
which is rectified to produce low-ripple DC output.

1.5 Controller

The Model 6VSG generator set comes equipped with
the VSC controller. See Figure 1-1. The controller
provides integrated control for the generator set and
the optional programmable interface module (PIM) or
optional communications kit interface board.

The controller’s two-line LCD screen displays status
messages and system settings that are clear and easy
to read in all lighting conditions, including direct
sunlight and low light.

Figure 1-1

• Field-convertible multi-fuel systems that allow fuel
changeover from natural gas to LPG (and vice
versa) while maintaining CARB emission
certification.

• The variable-speed engine runs at 2300 rpm at no
load and 2900 rpm when supplying full load.

1.3 Generator Set Enclosure

The generator set is housed in a steel enclosure with
Power Armor powder coat paint. The enclosure has a
hinged, locking door that allows easy access to the
generator set controller when required, but locks
securely to prevent unauthorized access.

To open the door, insert the tool provided with the
enclosure and turn counterclockwise 1/2 turn.

Be sure to close and lock the enclosure, and keep the
tool in a secure location.

Figure 1-1 VSC Controller

1.5.1 VSC Controller Features

• Six-button keypad

◦ OFF, AUTO, and RUN pushbuttons

◦ Select and arrow buttons for access to system

configuration and adjustment menus

• LED indicators for OFF, AUTO, and RUN modes

• LED indicators for percentage of load being output

•LCD display

◦ Two lines x 16 characters per line

TP-6843 1/13 Section 1 Descriptions and Service Views 13

◦ Backlit display with adjustable contrast for

excellent visibility in all lighting conditions

• Scrolling system status display

◦ Generator set status

◦ Voltage and percent load

◦ Engine temperature

◦ Oil pressure

◦ Battery voltage

◦ Engine runtime hours

• Date and time displays

• Smart engine cooldown senses engine temperature

• Digital voltage regulation: ±1.0% RMS no-load to
full-load

• Automatic start with programmed cranking cycle

• Programmable exerciser can be set to start
automatically on any future day and time, and run
every week or every two weeks

• Three exercise modes

• Front-access mini USB connector for SiteTech
connection

• Integral Ethernet connector for Kohler

• Built-in 2.5 amp battery charger

• Remote two-wire start/stop capability

• Diagnostic messages

®

OnCue

™

®

◦ Displays diagnostic messages for the engine,

generator, and programmable interface
module (PIM)

◦ Over 70 diagnostic messages can be displayed

• Maintenance reminders

• System settings

◦ System voltage and percent load

◦ Voltage adjustment

1.6 Accessories

The following optional accessories are offered for the
6VSG generator sets.

1.6.1 Carburetor Heater

An optional carburetor heater is recommended for
improved cold starting in locations where the ambient
temperature drops below 0°C (32°F). The carburetor
heater prevents condensation and carburetor icing.
The heater requires a continuous source of AC power.

See the generator set Installation manual for more
information.

1.6.2 OnCue® Generator Management System

The Kohler® OnCue® Generator Management System
allows monitoring and control of your 6VSG generator
set from a personal computer located in your home or
at other remote locations. OnCue
configured to send email or text message notifications
in the event of a generator set fault.

Note: Be sure to obtain the correct version of the

OnCue

OnCue
generator sets.

®

kit for the VSC controller.

®

version 3.1 or higher is required for 6VSG

1.6.3 Programmable Interface Module (PIM)

The optional Programmable Interface Module (PIM)
provides two programmable inputs and six
programmable dry contact outputs for connection to
customer-supplied equipment. The outputs are
controlled by the VSC controller, and can also be
controlled remotely using the OnCue

The PIM is mounted in a NEMA 3R aluminum
enclosure, which can be mounted indoors or outdoors.
See the installation instructions provided with the PIM.

1.6.4 Communications Kit

®

can also be

®

program.

◦ Measurement system, English or metric

• Programmable Interface Module (PIM) status
displays

◦ Input status (active/inactive)

◦ Output status (active/inactive)

14 Section 1 Descriptions and Service Views TP-6843 1/13

The optional communications kit includes the following
factory-installed items:

• Interface board with factory-set inputs and outputs
and customer connection terminal blocks

• Fuel pressure switch

• Enclosure intrusion alarm switch

1.7 Service Views

kps_002.eps
ADV-8060

1. Exhaust air outlet

2. Air cleaner

3. Oil fill

4. Oil drain

5. Oil drain valve

6. Oil filter

7. Muffler

8. Alternator air inlet

9. Customer connection blocks (located behind panel)

10. Electrical inlet access panel

11. Engine starting battery location (battery not included)

12. Lifting hole

13. Controller

14. Engine certification label

15. Load circuit breaker

16. Oil dipstick

17. Exhaust outlet

18. Fuel inlet

19. Electrical inlet

20. Battery cables (included)

21. Nameplate

1

2

3

4

5

6

7

8

9

10

11

12

16

13

14

15

17

18

19

20

21

Figure 1-2

Figure 1-2 Service View (see Figure 1-3 for optional communications kit components)

TP-6843 1/13 Section 1 Descriptions and Service Views 15

Figure 1-3

ComKitB
GM85956C

1. Interface board (factory-wired to terminal blocks)

2. Intrusion alarm switch

3. Interface board input and output connection terminal blocks

4. Fuel pressure switch

1

2

3

4

Figure 1-3 Optional Communications Kit Components

16 Section 1 Descriptions and Service Views TP-6843 1/13

Section 2 Generator Set Operation

KPS_105

KPS_106

2.1 Theory of Operation

The generator set utilizes a permanent-magnet
alternator to produce 3-phase AC voltage. This
voltage is rectified using a full-wave 3-phase rectifier
(single block rectifier for 36V and 48V, three individual
rectifier blocks for 24V) to produce low-ripple DC
output. See Figure 2-1 and Figure 2-2.

Figure 2-1

The VSC measures the average DC voltage on the
output and lists this on the auto-scrolling display, in the
Overview menu and in the Generator metering menu.

Figure 2-1 Basic VSG Power Connections

Figure 2-2

Figure 2-2 Output Waveform, with Rectified Signal

The voltage is regulated to maintain a constant output
voltage, which is equal to the System Voltage setting.
When the load on the 6VSG generator increases, the
generator controller increases the engine speed. The
6VSG series is designed to produce rated voltage at
2300 rpm with no load and at 2900 rpm when
supplying full load. The output current and power
increase with the engine speed. The engine speed is
limited to a maximum of 2900 rpm. See
Section 3.14.1 for more information.

2.2 Prestart Checklist

To ensure continued satisfactory operation, perform
the following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks
require verification after the unit starts.

Air Cleaner. Check for a clean and installed air
cleaner element to prevent unfiltered air from entering
the engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

the battery manufacturer’s instructions regarding
battery care and maintenance.

Enclosure. Check that all enclosure panels and
internal baffling are in place.

TP-6843 1/13 Section 2 Generator Set Operation 17

Exhaust System. Check for exhaust leaks and
blockages. Check the muffler condition.

• Inspect the exhaust system components for cracks,
leaks, and corrosion. Check for tight exhaust
system connections.

• Check for corroded or broken metal parts and
replace them as needed.

• Check that the exhaust outlet is unobstructed.

Oil Level. Check the oil level before starting the
generator set and at the intervals given in Section 4,
Scheduled Maintenance. Maintain the oil level at or
near, not over, the full mark on the dipstick.

Operating Area. Check for obstructions that could
block the flow of cooling air. Keep the air intake area
clean. Do not leave rags, tools, or debris on or near
the generator set.

2.3 Exercising the Generator Set

2.4.3 Engine Start Crank Cycle

The controller attempts to start the generator set three
times (three crank cycles, 15 seconds crank and
15 seconds off). If the generator set does not start in
three attempts, the system shuts down on an
overcrank fault. See Section 2.6.

Cranking 1, 2, and 3 are displayed during the crank
cycle. Pressing the OFF button during the crank cycle
stops the cranking. No other buttons are
acknowledged during the crank cycle.

2.4.4 Engine Cooldown

The engine cooldown time delay allows the engine to
run after the loads have been removed.

The engine cooldown time delay is set to 5 minutes.
The engine stops before the cooldown time delay
expires if the temperature drops below the
cooled-down temperature level, or if the temperature
rises above the high limit during the cooldown cycle.

Operate the generator set without load once each
week or every 2 weeks for 20 minutes. See Section

2.5, Exercise. For instructions to set the exerciser, see

Section 3.6.

2.4 Generator Set Operation

2.4.1 Local Starting and Stopping

Start: Press the RUN button to immediately start the

generator set.

Stop: Press the OFF button. The engine stops.

Run the generator set with no load for at least
2 minutes to ensure adequate engine cooldown.

2.4.2 Remote Starting and Stopping

The generator set must be in automatic mode for
remote operation. Press the AUTO button on the VSC
controller.

A remote switch connected to terminals 3 and 4 can be
used to start and stop the generator set. Close the
switch to start and run the generator set. Open the
switch to stop the generator set.

2.4.5 Automatic Operation

The 6VSG monitors the voltage of a storage battery
bank connected to (+) and (–) of the output block to
determine charge condition of the storage battery (see
Figure 2-3).

• If the storage battery voltage falls below the
minimum voltage for more than 3 minutes, or if a
remote start command is received, the generator
set starts. A remote start command can be
activated by closing the remote start contacts
across 3 and 4 or by a start exercise command.

• When the generator set load falls below the
minimum % load for more than 3 minutes, or a
remote stop command is received, the generator set
stops. A remote stop command can be caused by
opening the remote start contacts across 3 and 4 or
by the exercise time ending.

The minimum voltage, minimum load, and time delays
are adjustable using a personal computer and Kohler
SiteTech™ software. Contact your Kohler distributor.

®

Run the generator set with no load for at least
2 minutes to ensure adequate engine cooldown.

18 Section 2 Generator Set Operation TP-6843 1/13