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....

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 KZfaq videos should be this good. Thank you.

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!

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!

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.

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!

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.

Man I wish all service techs I had to deal with were as thorough and considerate as you.

Nice to see a professional who is knowledgeable and cares. Seems to be getting harder to find these days! Great job!!

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!

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.

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.

very thorough video. you seem like a great technician. And that place looks like a beautiful property.

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.

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 👍

Lots of great maintenance tips- thanks !

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?

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!

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.

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

What a really great video! Thank you!

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?

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.

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.

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

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???

do you have a schematic for the components on a 6vsg control board?

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

Do you have a video on how to install a carburator heater on a 20RESAL?? Thanks

Thanks. Getting a Kohler 14kw installed in the next few weeks. Think these issues have been resolved in newer models?

Do you ever have to adjust the valves on the engine or do Kohler engines have hydraulic valves ?

Hello. Have you got video how to do valve clearance adjustment on this generator?

wondering if I should swap mine out for an agm battery now

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.

Great tips. Thank you

Great Video, Thank you!!

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.

Looking at purchasing a Kohler or a Generac.Whats your opinion?What would you get?why?Thank you

Glad to see someone doing things right.😁

which standby would you buy nd why?

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 ?

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.

Great video 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!

other than oil and filters what spare parts would you recommend i keep on hand for a 14RCAL ?

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.

Great stuff. When filling is it necessary to remove terminals?

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.

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..

how often you need to service the generator?

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.

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.

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???

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

Great vid

What upgrade are you referring to to prevent battery overcharging? Thanks.

How to access rear sparkplug?

Please use Locktite it may save you or a customer during an emergency. Imagine losing the set screw!

Nice video.

How do you get front/side covers off 20RESD to access 1) battery; 2) oil drain plug/hose and 3) other areas?

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.

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

Do you lose the programming when you disconnect the battery?

Can you tell me how how he subassembly and rotor can melt when I have always had it servic d twice a year

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.

Sir may i got Service maual of kohiler 5.6kva petrol generator.

Where are you located? I want to hire you to go over my generator. I am in Northern NJ.

There is a 'Maintenance Required' message displaying on the control board. Will the generator still run if this message is displayed? Thanks in advance.

Glad I just bought an AGM battery for my Kohler.

How do you reset maintenance notice after service?

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.

! like your camera work. What do you use and where is it mounted?

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 🙏

Hacker that was a good service call. Peace brother

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.

👍

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.

did not see you disconnect the battery charger before removing battery

How to repair Kohler winding 15 kW

I changed the battery and now I can’t set date and time and exercise time. Can’t get into system. Thanks

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.

do you use 5w 50 in the battery?

thanks man

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

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?

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?

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?

Why don’t they put lock tight on the darn bolts? And why not use a sealed battery duh?

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.

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.

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.

Loctite?

Lock tight

Any idea what causes the battery acid level to drop? Is it a condition unique to Kohler ?

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

I didn't know they still made batteries that needed water!

You can keep the battery inside the house and run wires into it, safe from nature elements .

My engine needs oil, the electric charge doesn’t work (idk what that means) and the rotor isn’t working.

Starting an engine and just shutting it down without letting it warm up causes condensation inside the engine.