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Kohler KG80

Kohler KG80
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Models:
KG80, KG80R, KG100, KG125, KG125R,
KG150, KG150R, KG180, KG200
Industrial Generator Set
TP-7173 10/20a
Maintenance
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Kohler KG80 Specifications

General IconGeneral
Fuel TypeGasoline
AC Output120/240V
Displacement420cc
Run Time at 50% Load14 hrs
Starting SystemElectric
DC Output12V
Weight204 lbs

Summary

Product Identification

Generator Set Identification

Record of model, specification, and serial numbers for service.

Controller Identification

Record of controller description for service.

Engine Identification

Record of engine model, specification, and serial numbers.

Safety Precautions

Accidental Starting

Precautions to prevent accidental generator set startup during maintenance.

Battery Safety

Engine Backfire and Flash Fire Hazards

Flash Fire and Backfire Risks

Warnings related to fire hazards from engine backfire and fuel systems.

Exhaust System Hazards

Carbon Monoxide Safety

Warnings regarding carbon monoxide poisoning from exhaust fumes.

Fuel System Hazards

Explosive Fuel Vapor Safety

Warnings about the dangers of explosive fuel vapors.

Hazardous Noise Information

Hearing Protection

Information on noise levels and hearing protection requirements.

Electrical and Moving Parts Hazards

Electrical Hazard Warnings

Warnings about electrical hazards and risks from moving components.

Grounding and Short Circuit Safety

Procedures for safe electrical grounding and avoiding short circuits.

Heavy Equipment Handling

Safe Lifting Procedures

Guidelines for safely lifting generator sets using proper equipment.

Hot Parts Safety Precautions

Hot Engine and Exhaust System Safety

Precautions for handling hot engine and exhaust system components.

Introduction and Related Literature

Related Literature

List of recommended manuals and documentation for generator sets.

Service Assistance and Support

Service Schedule

Service Safety Precautions

Critical safety warnings before performing maintenance tasks.

Generator Set Maintenance Overview

Overview of routine maintenance for the generator set.

Controller Maintenance

ECU Diagnostic Port

Alternator Maintenance

Check Alternator Operation

Procedures for inspecting alternator function and connections.

Check Alternator Ventilation

Ensuring proper airflow through the alternator.

Check Alternator Windings

Guidance on inspecting alternator windings for service.

Check Alternator Bearings

Procedures for inspecting and servicing alternator bearings.

Gaseous Fuel Systems

Gaseous Fuel System Concept

Explanation of how single-fuel gaseous systems operate.

Natural Gas and LPG Conversion

Information on converting generator sets between fuel types.

Dual Fuel System Changeover Kits

How dual fuel systems automatically switch between natural gas and LPG.

Dual Fuel Reset Box Operation

Functionality of the reset box for dual fuel systems.

Fuel System Maintenance

Routine maintenance for fuel systems, including filter cleaning.

Lubrication System

Oil Change Procedure

Procedure for changing engine oil and filters.

Air Cleaner System

Air Filter Element Replacement

Steps for replacing the air filter element.

Air Cleaner Restrictor Indicator

How to use the indicator to determine air filter replacement needs.

Cooling System

Coolant Level Check

Procedure for checking and maintaining coolant levels.

Drain Cooling System Procedure

Steps for safely draining the engine's cooling system.

Refill Cooling System Procedure

Steps for refilling the cooling system with coolant.

Radiator Maintenance

Guidelines for cleaning and maintaining the radiator.

Battery System Maintenance

Electrolyte Level Inspection

Checking battery electrolyte levels and adding distilled water.

Specific Gravity Check

Measuring battery electrolyte specific gravity for charge status.

Battery Charging

Maintaining battery charge using a charger or alternator.

Storage Procedure

Lubrication System Storage

Preparing the engine's oil system for long-term storage.

Cooling System Storage

Preparing the cooling system for storage.

Battery Storage

Procedures for storing the battery correctly.

Appendix A: Abbreviations

Appendix B: Hardware Guidelines

Appendix C: Torque Specifications

Appendix D: Service Log

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