Kohler GM62345, GM62346, GM62347, GM62348, GM83718 Installation Instructions Manual

INSTALLATION INSTRUCTIONS

Original Issue Date: 3/08

Model: 6--60 kW Residential and Light Commercial Generator Sets

Market: Residential/Commercial

Subject: Maintenance Service Kits GM62345, GM62346, GM62347, GM62348,

GM83718, GM86771, GM89979, GM90365, GM90366, GM93396, and
GM100209

Introduction

This kit provides items necessary for general engine
maintenance and service on 6--60 kW residential and
light commercial generator sets listed in Figure 1.

Read the entire installation procedure before beginning
installation. Perform the steps in the order shown.

Generator Set Service Kit Number Sales Kit Number

8RESV(L) GM90365 GM90365-SKP1-QS

8.5RES GM62345 GM62345-SKP1-QS

10/12RESV(L) GM90366 GM90366-SKP1-QS

6VSG, 12RES(L), 14RES(A)(AL)(L) GM62346 GM62346-SKP1-QS

15RES(A)/R(E)YG,

30RES(A)/R(E)YG

17/18RES(L),

20RES(A)(AL)(B)(C)(CL)(D)(L)

24RCL GM93396 GM93396-SKP1-QS

30RCL, 38RCLB GM100209 GM100209-SKP1-QS

38RCL GM86771 GM86771-SKP1-QS

48RCL GM83718 GM83718-SKP1-QS

48RCLA and 60RCL GM89979 GM89979-SKP1-QS

Figure 1 Kits

GM62348 GM62348-SKP1-QS

GM62347 GM62347-SKP1-QS

TT-1445 7/16i

Safety Precautions

Observe the following safety precautionswhile installing
the kit.

WARNING

WARNING

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.

Hot engine oil.
Can cause severe injury or death.

Avoid skin contact with hot oil. Do not
start or operate the generator set with
the engine oil filler cap removed, as
hot oil can spray out. Ensure that the
lubrication system is not under
pressure when servicing. Do not
work on the generator set until it
cools.

Used engine oil. Contact with used engine oil may cause
severe skin irritation. Repeated and prolonged skin
exposure may have other health risks. Used engine oil is a

suspected carcinogen. Avoid contact with skin. Thoroughly
wash your hands and nails with soap and water shortly after
handling used engine oil. Wash or dispose of clothing or rags
containing used engine oil. Dispose of used engine oil in a
responsible manner. Contact your local recycling center for
disposal information and locations.

WARNING

WARNING

Risk of fire.
Can cause severe injury or death.

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

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

the air cleaner removed.

Hot engine 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.

2 TT-1445 7/16

Maintenance Procedures

e. Close the oil drain valve and remove the oil

drain tube.

Oil and Oil Filter

When possible, drain the oil while it is warm.

1.

Before working on the generator set or connected
equipment, disable the generator set as follows:

a. Press the OFF button on the generator set controller.

b. Disconnect the power to the battery charger.

c. Remove the battery cables, negative (--) lead first.

2. For most models [except 8/10/12RESV(L)], a

drain plug is located on the service side of the
generator set, opposite the starter. If you have
difficulty locating the drain plug, see the service
view in your generator set operation manual. For
8/10/12RESV(L), proceed to step 3.

a. Remove one oil drain plug and the oil fill cap/

dipstick. Aim the drain tube into catch basin
and open the valve near the oil sump. Allow
ample time for complete drainage.

b. Close the valve and place the tube back in the

clip on the bulkhead wall.

f. Tilt the filter upward to prevent spilling a s you

remove the oil filter. Remove the old filter and
wipe off the adapter/base on the engine.

4. Place a new replacement filter in ashallow panwith
the open end up. Pour new oil (provided) through
the threaded center hole. Stop pouring when the oil
reaches the bottom of threads. Allow a minute or
two for the oil to be absorbed by the filter material.

5. Apply a thin film of clean oil to the rubber gasket on
the new oil filter.

6. Install new oil filter. Hand tighten filter clockwise
until the rubber gasket contacts the adapter, then
tighten the filter an additional 3/4--1 turn.

7. Fill the crankcase with the new oil to the F or FULL
mark on the dipstick. Use a funnel to prevent
spilling. Always check the level with the dipstick
before adding more oil. Never operate the engine
with the oil level below the L or ADD mark, or above
the F or FULL mark. See Figure 2.

8. For 8/10/12RESV(L) models, remove the rags
that were used to cover the alternator.

c. Remove the old filter and wipe off the

adapter/base on the engine.

d. Proceed to step 4.

3. For 8/10/12RESV(L) models, use the following

procedure to avoid spilling oil into the alternator.

a. To prevent oil from spilling into the alternator,

cover the alternator with rags around the areas
near the oil drain valve and oil filter.

b. Place a drain tube (3/8 in. inside diameter) onto

the oil drain valve and place the end of the tube
into a drain pan. The tube will reduce the
potential for spilled oil.

c. Open the oil drain valve on the engine.

d. Remove the dipstick and oil fill cap. Allow time

for the engine oil to drain completely.

Full Mark

F

Operating

Range

FULL

L

ADD

Figure 2 Oil Level/Dipstick Detail

9. Reinstall the oil fill cap/dipstick and tighten
securely.

10. Reconnect the battery cable, negative (-- ) lead last.

11. Test run the engine, check for leaks, and recheck
the oil level.

TT-1484

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