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1. Figure 2 2 Programmable Interface Module PIM covered removed for illustration 36 Section 2 Accessories 2 3 2 PIM Inputs and Outputs Connect customer supplied equipment to the PIM as instructed in TT 1584 Factory default settings for the outputs are shown in Figure 2 3 The outputs are controlled by the RDC2 controller The run output is activated when the generator set is running The common fault output is activated on a fault Use a personal computer running Kohler OnCue or SiteTech software to assign functions to the other inputs and outputs and or change the settings for factory set inputs and outputs Verify that the input and output assignments match the connections to the PIM terminal strip Outputs 3 through 6 can also be controlled remotely using the OnCue program If an output is activated or deactivated through OnCue it is no longer controlled by the RDC2 controller See the OnCue Software Operation Manual for instructions PIM Connection Factory Default Setting Input 1 None Input 2 None Output 1 Relay 1 Output 2 Relay 2 Output 3 Relay 3 Output 4 Relay 4 Output 5 Relay 5 Output 6 Relay 6 Run Common Fault Low Battery Voltage programmable Not in Auto programmable Cooldown programmable Normal Source Failure programmable
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3. 8 EM 50 HZ 220 380V 50 HZ 230 400V 50 HZ 240 416V Note The current transformers CTs shown above are not used on Model 48RCL or 60RCL generator sets equipped with the RDC2 controller Figure 3 3 42 Section 3 Generator Reconnection E ROTATION B C L2 LS 12 Lead Generator Reconnection 48RCL and 60RCL ADV 5875B J TP 6809 11 13 3 4 Changing System Settings The RDC2 controllers keypad and display allow the installer to check and change the generator system settings if necessary The system settings for each generator model are set at the factory and should not normally require changes Check the genset system settings and change them ifnecessary after generator reconnection or controller replacement The following procedure explains how to change the system settings The procedure is also illustrated in Figure 3 6 Procedure to Change System Settings 1 Press the Select button to enter the main menu See Figure 3 4 and Figure 3 5 The Overview screen will be displayed 2 Press the down arrow button to navigate to the Genset System menu See Figure 3 5 3 Pressthe Select buttonto enter the Genset System menu See Figure 3 6 4 Press the down arrow button to step through the generator set system settings to the setting that you wish to change 5 When the setting is displayed for example System Voltage press the select button The value will flash
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5. Figure 1 22 Coolant Capacity 1 Engine coolant fill pressure cap not shown 2 Overflow tube 3 Coolant overflow bottle Figure 1 23 Coolant Fill TP 6809 11 13 1 8 Prestart Installation Check Review the entire installation section Inspect all wiring and connections to verify that the generator set is ready for operation Check all items in the following Prestart Checklist Prestart Checklist Air Cleaner Check that a clean air cleaner element is installed to prevent unfiltered air from entering the engine See the generator set operation manual for instructions 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 Coolant Level Check the coolant level as described in Section 1 7 Note Block Heater Damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater Enclosure Check that all enclosure panels and internal baffling are in place Exhaust System Check for exhaust leaks and blockages Check the muffler condition e Inspect the exhaust system components for cracks leaks and corrosion Check for tight exhaust system connections e
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7. Figure 2 3 PIM Factory Settings TP 6809 11 13 2 4 Load Control Module LCM The optional Load Control Module LCM provides an automatic load management system to comply with Section 702 5 of NEC 2008 Theinstaller is responsible for ensuring that the power system installation complies with all applicable state and local codes The LCM automatically manages up to six residential loads Four power relays are provided for management of non essential secondary loads and two relays are available to control two independent air conditioner loads Note Connect only non essential loads to the load control module The load on the generator set is monitored and loads are added or shed in the order of their priority The LCM is available with or without a pre wired harness for load relay connection The prewire harness requires installation of the LCM within 2 feet of the distribution panel The load control module with the optional wire harness is shown in Figure 2 4 If the harness is not used connect to the terminal blocks inside the LCM enclosure Figure 2 5 shows the load control module without the optional harness Current transformers CTs on the emergency source lines are required for LCM operation The CTs are included with the LCM kits Installation ofthe CTs inside the transfer switch enclosure is recommended See TT 1574 for detailed installation and connection instructions TP 6809 11 13 KOHLER POWER SYSTEMS
8. Figure 2 4 Load Control Module shown with optional wire harness Figure 2 5 Load Control Module cover removed to show field connection terminal blocks Section 2 Accessories 37 2 5 OnCue Generator Management System The OnCue Generator Management System allows monitoring and control of your generator set from a personal computer located in your home or at other remote locations OnCue can also be configured to send email ortext message notifications inthe eventofa generator set fault See TP 6796 OnCue Software Operation Manual for software instructions The OnCue system is available separately as a loose kit Use category 5E network cable to connect the RDC2 controller to the customer supplied Ethernet router and cable or DSL modem Route the cable with other low voltage signal wiring for example the RBUS communication leads or engine start leads to the transfer switch in separate conduit from the AC load leads If the network cable is longer than 100 meters 328 ft use a repeater or switch Recommended Use a laptop computer to verify the network connection before connecting to the generator set Checking the network connection 1 Check for and turn OFF any wireless connections to the laptop 2 Connect the network cable to the laptop Connect the other end of the network cable to the customer s router or modem 3 Verify the Internet connection by opening your web browser and going to www kohlerpowe
9. Generator Set one programmable interface module PIM and or one load control module LCM See Section 1 4 8 for cable size and length specifications 8 WOO Md WOO HMd 8 8 8 WOO Md WOO HMd BE L Nid snay oL WOO MMd 8 Customer connection terminal block See Figure 1 10 for location Check the decal on the generator set for terminal block connections Connect one end of each cable shield to GROUND at the generator set See Figure 1 13 for cable specifications including maximum total cable length per run 1 run shown Connect shields together as shown Leave the end of each cable shield disconnected at the last device If accessory modules PIM or LCM are connected see Section 1 4 9 Figure 1 14 Accessory Module Communication Connection Details 24 Section 1 Installation Instructions TP 6809 11 13 Generator Set V V WOO uMd 8 WOO uMd 8 RBUS V WOO dMd 8 WOO Md 8 RBUS 7 5 8 OL 8 Note See Section 1 4 8 Cable
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13. Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Welding on the generator set Can 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 battery charging alternator connections 5 Attach the weld ground connection close to the weld location Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the
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15. 2012 2013 by Kohler Co All rights reserved KOHLER Power Systems KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 For the nearest KOHLER authorized installation service and sales dealer in the US and Canada Call 1 800 544 2444 or visit KOHLERPower com
16. 44444 444444 44444444 39 3 1 Voltage wama se gd BiG I Awa 39 3 2 Four Lead Single Phase Generator Sets 40 3 3 12 Lead Three Phase Generator Sets 40 3 4 Changing System Settings 43 3 5 Voltage Calibration 2 zera v idee IR ERE RS 46 3 5 1 Calibration using the RDC2 Controller Keypad and Menus 46 3 5 2 Calibration Using SiteTech 48 TP 6809 11 13 Table of Contents 3 Table of Contents continued Section 4 Diagrams and Drawings nna nnn nnn 51 Appendix A Abbreviations aaaaaaanan anna eee eee nana hh 67 4 Table of Contents TP 6809 11 13 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical 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 A DANGER Danger indicates the presence of a hazard that will cause
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20. 998 2200 Figure 1 1 Approximate Weights Insert lifting bars through the four holes in the mounting skid The placement of the holes maintains balance during lifting Follow these general precautions when lifting all generator sets and related equipment e Install proper size rigging at the skid lifting eyes providing a direct pull on the skid lifting eye Make sure the rigging does not work as a pry bar lever against the lifting eye e DO NOT lift the generator set using the lifting eyes attached to the engine and or alternator as these lifting eyes can not support the total weight of the generator set e DO NOT attach hoisting equipment to the enclosure Insert lifting bars through the four holes in the mounting skid e Always protect cables chains and straps from sharp edges e Use a spreader bar to prevent lifting cables from contacting the enclosure TP 6809 11 13 e Lifting should only be conducted by those trained and experienced in lifting and rigging to achieve a safe and effective lift Consideration needs to be given to but not necessarily limited to the following items o Weight and center of gravity of the equipment being lifted O Weight and center of gravity of the lifting device O Boom angles O Selection of rated rigging O Stability of lifting foundation Wind and weather conditions O O Local or regional codes that may require or restrict types of rigging T
21. installation Residential Light Commercial Generator Sets m Lini ON LI Models 38RCL 48RCL 60RCL Controller RDC2 9001 Un KOHLER mum POVVER SYSTEMS NATIONALLY REGISTERED KOHLER Power Systems California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 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 TP 6809 11 13 Table of Contents Product Identification Information 4 4 4 4 8 8
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23. 32 F The generator set engine is equipped with valves that eliminate the need to drain the cooling system before installing the block heater Refer to the installation instructions provided with the block heater kit Connect the block heater to a power source that is energized when the generator set is not running Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater 1 Block heater GM78529 C Figure 2 1 Block Heater Section 2 Accessories 35 2 3 Programmable Interface Module PIM The optional Programmable Interface Module PIM provides two programmable inputs and six dry contact outputsfour of which are programmable The PIM with enclosure is shown in Figure 2 2 See TT 1584 for PIM installation and connection instructions The PIM is mounted a NEMA 3R aluminum enclosure which can be mounted indoors or outdoors See Section 1 4 9 and the installation instructions provided with the PIM for the maximum recommended cable lengths and detailed installation instructions 2 3 1 PIM to Generator Set Connections The PIM communicates with the RDC2 generator set controller Connectthe PIM module to the generator set as shown in Section 1 4 9
24. Genset Calibration Factor Voltage L2 L3 0 z 3 Genset Calibration Factor Voltage L3 L1 ATENY EA Engine Timing Event History 1 Device 1 Connected 1002 Events 2 Active Alerts 1 Voltage calibration factor Figure 3 9 Voltage Calibration Factor in SiteTech TP 6809 11 13 Section 3 Generator Reconnection 49 Notes 50 Section 3 Generator Reconnection TP 6809 11 13 Section 4 Diagrams and Drawings See the generator set Operation Manual for service views if necessary This section contains dimension drawings wiring diagrams and schematics for the enclosed generator set Figure 4 1 lists the drawing numbers and page numbers Drawings are arranged in numerical order on the following pages Drawing Description Dimension Drawing Dimensions Installation clearances 38RCL 48RCL 60RCL Drawing Number ADV 8494 1 of 2 ADV 8494 2 of 2 Drawing Number ADV 8494 1 of 2 ADV 8494 2 of 2 Drawing Number ADV 8545 1 of 2 ADV 8545 2 of 2 Wiring Diagrams Schematic Generator Set Sheet 1 Generator Set Sheet 2 Generator Set Sheet 3 Alternator Wiring Diagram Generator Set Sheet 1 Generator Set Sheet 2 Alternator ADV 8484 1 of 3 ADV 8484 2 of 3 ADV 8484 3 of 3 GM85226 1 of 2 GM85226 2 of 2 Figure 4 1 Drawing Numbers and Locations TP 6809 11 13 ADV 8061 1 of 2 ADV 8061 2 of 2 ADV 6957 GM79871 1 of 2 GM79871 2 of 2 GM35943 ADV 80
25. gt TP 6809 11 13 Changing System Settings on the RDC2 Controller 1 Press the Select button to enter the main menu Overview gt 7 When the desired setting is shown press Select The value stops flashing Press Display 1 2h Press Display System Voltage 220 V 2 Press the down arrow button to navigate to the Genset System menu See Figure 3 5 Press 3 Press the Select button to enter the genset system menu Genset Display System System Voltage Display 240 V Press 4 Pressthe down arrow button if necessary to step to the setting that you want to change 5 When the setting is displayed for example System Voltage press the select button The value will flash Press 6 Press the up or down arrow buttons to increase or decrease the setting Press System Voltage Display 240 V System Voltage Display 220 V Figure 3 6 Changing Genset System Settings TP 6809 11 13 8 Press the down arrow to step to the next setting Press Display 9 To exit press the down arrow button until Return is displayed Press Display 10 Press the Select button to exit the menu Press System Freq 60 Hz Overview 1 2h gt gt Display 11 Press Auto to signal the controller to exit the menus and return to the
26. 3 Setthe time and date and then setthe exerciser to run the generator set once a week or every other 34 Section 1 Installation Instructions TP 6809 11 13 2 1 Introduction Accessories are available factory installed and or shipped loose Obtain the most current list of accessories from the generator set specification sheet or by contacting an authorized Kohler distributor dealer Have accessories installed by your local authorized Kohler distributor dealer or authorized representative Follow the installation instructions provided with each kit Use separate conduitfor AC and DC leadsto reduce the possibility of electrical interference Use shielded cable for all analog inputs Verify that the leads and conduit do not interfere with the operation of the generator set or obstruct the service areas Refer to the wiring diagrams in Section 4 for more information regarding generator set electrical connections Verify that the accessory installation complies with the National Electrical Code NEC and all applicable local and state codes The following sections detail a few common accessories and their functions The instructions provided with the accessory kit supersede these instructions if different TP 6809 11 13 Section 2 Accessories 2 2 Block Heaters Block heaters are available as loose accessories Use block heaters on standby applications where the generator set is frequently subjected to temperatures below 0 C
27. 3016 9 100 mao D 0 4 LHM 099 pO ao 86 0 4 ma z d zi red uzi 3SVHd 319NIS HJTIOHINOO 5308 Test 1219 vdan 5 38 348 10 8 00 5 8 585043 SNINYHA MaN z1 82 2 Noise awa XOB 65 Section 4 Diagrams and Drawings Figure 4 15 Wiring Diagram 38RCL Generator Set GM85226 Sheet 1 of 2 TP 6809 11 13 4 a 92268W9 H3TIOBINOO 2208 TZ wal nos MM 82 SNINIM AYNOVIGO CERES BN NOVEL 3O 35 0 65 5088 TY 133 Msi TH C3 E 8M 5 84 55 i S go zid 143 S LM HN N Nid OLM 6N N Nid 6M 9N Nf Nid SNOLO3NNOO tld SNOIIO3NNOO Std SNOILOJNNOO iid 2 Ne L 3 ba oh 0 0 8 NOLYIGYU 3NISN3 qv 55 8 BL NUES Eld 12 8015153 15 8 S3M N 1d 6N N Eu O 40 2ld 8N OLM AHdLIva s LM CHN Gee T 98 80 8238 Caen S tld Z44 SNSSNK m A tiM SEN 8M 7 W Zld VZ4H gt 1 2 09 36969 963 PE 1101210151010000 a 5 Zaca G9 6369 sam r vold Hsu Na 3
28. 31 168 331630 Fax 31 168 331631 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 66 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 663 701 7131 TP 6809 11 13 1 1 Introduction Review this entire section and the Safety Precautions before starting the installation procedure The generator set specification sheet also contains data that may be required during the installation process The generator set and accessories must be installed by an authorized Kohler distributor dealer or authorized representative The installation must comply with the National Electrical Code NEC and local codes For Canadian installations refer to the Canadian Electrical Code CEC Note These instructions outline one procedure for installing the generator set Local codes may require different procedures The generator set must be installed ou
29. 32 17 0 wiring system 64 1 4 226 Note If a connector has a clamp screw such as a 79 5 16 31 1 slotted hexagonal head screw with more than 9 5 3 8 42 4 one means oftightening test the connector using 12 7 1 2 56 5 both applicable torque values provided in 14 3 9 16 67 8 Figure 1 8 For values of slot width or length not corresponding to those specified select the largest torque value associated with the conductor size Slot width is the nominal design value Slot length is to be measured at the bottom of the slot Figure 1 7 Tightening Torque for Pressure Wire Connectors with Internal Drive Socket Head Screws Tightening Torque Nm in Ib Wire Size for Unit Hexagonal Head External Connection Slot Head 4 7 mm No 10 or Larger Drive Socket Wrench Slot Width 1 2 mm 0 047 in Slot Width gt 1 2 mm 0 047 in Split Bolt Other AWG kcmil mm Slot Length 6 4 mm 0 25 in Slot Length gt 6 4 mm 0 25 in Connectors Connections 0 82 5 3 4 0 9 0 0 85 75 8 4 4 5 9 0 80 85 75 13 3 21 2 5 1 18 6 68 124 10 26 7 5 6 31 1 275 169 150 33 6 5 6 31 1 275 169 150 42 4 5 6 31 1 275 169 50 1 0 2 0 53 5 67 4 5 6 43 5 385 20 3 180 3 0 4 0 85 0 107 2 5 6 56 5 500 28 2 250 250 350 127 177 5 6 73 4 650 367 325 400 203 5 6 93 2 825 36 7 325 500 253 5 6 93 2 825 42 4 375 600 750 304 380 5 6 113 0 1000 4
30. 338 8 1 908 anita NEN NOW N Eld 20 21d 8N Li gt La 8544 5 61 Zi 8 56 vz4u 7 S3H HN 083 93N 010 559 ZHN L LM 94 21d IHN H01SIS3H LSvTIVa 538 O O LM SHN EE 68 53 COGOR GOOGXOOOOOQQ QQQDADOBGO gv zid Z 0 Zld 904 Wf Nid SNOILO3NNOO VOLd na i BG S 133HS Old GV Z1d ZHI r vold Hii 80 21d iid v id 4 7 1va sod 64 239 LN 8 49 9N s38 838 011 21d SN 983 82 N Lld KN IN QOBBOBAOBE 100096600860 xo83snd Zla LIM 23 8 OLO 6 LIM 63 s iid 1 3 83 LIM 9 N 49 um LIM ZN 93 4 59 Ziad 93 11M O N 3 S Eld 9 N 9 2 N zo 83 59 2 19 li o N 058 2 N 68 88 9 N za 9 N 98 o N Sa ya ev zid ca za 98 25 i8 Gn ol VOLd 8 Z ld 8v z void 8 0 8 SM 8M 9v SM ev 8 59 W t vold am 98 Wit Nid SNOIIO3NNOO Zld SX AVES AVI 58 48 Di VOR d N k
31. 8 Communication Cable Specifications 23 1 4 9 System Connections with Accessory Modules 24 1 4 10 Other Accessories 4 4 4 8 8488894944 27 1 5 Engine Starting Battery 28 1 6 EUelSVSIOITI 2 00 0 ARE d dated MAE at ide 29 1 6 1 XI HN Pru 29 1 6 2 Gas Regulators Les Rede dee Ee e ALARA 30 1 6 8 Install and Connect Fuel Supply 30 1 6 4 Fuel Conversion Procedures 31 41 2 GOOlING SyStem ed a to ode t Ca bed tle e bob t s 32 1 8 Prestart Installation Check 33 T9 Set EXerciser i oes fot uode bv ue PIS Re 33 1 10 Operation Tests rci oe db dy ae fads aorta aan lw PIT 34 Sectiori2 Accessories o e see Re DERI E EE RU EG E REDE REN FREE RR 35 2 1 Introductionm sc eoe ei dyr Bes ittis da xo Jade dtes tals cedet 35 22 Block Heaters AA ise spese e 3 PEU RR XE dT pL 35 2 3 Programmable Interface Module PIM 36 2 3 1 PIM to Generator Set Connections 36 2 3 2 PIM Inputs and Outputs 36 2 4 Load Control Module LCM mamnannnn 37 2 5 OnCue Generator Management System 38 Section 3 Generator Reconnection
32. 938 14 2 Sd IW gt id GANA Wid 9 54 e a voc arse 1NO2D E 3OVJH3INI W93 m ea zid gt vi Zld xog AvI34 3snJ 1 Zld P 448 8687119 034813 XOA 3503 NI SKA 4058 5 12906 SNWY O NAN NOSIE 53 Section 4 Diagrams and Drawings Figure 4 3 Schematic Diagram 48RCL 60RCL Generator Set ADV 8061 Sheet 1 of 2 TP 6809 11 13 a 1908 AQV of 1 Lm 6981 2 0 ANIONS WO M M 8 STWAONadY OLLYWJHOS WYHOVIO 036652 BY NOUN 82 Nsa 30 5088 T won 2 140 HIA NOLOZNYKO MI LEE 0 28 LON ISAN Aut 09 SI IMLA ONY MIS WI NAWO 580 ST POSS UM YHON SNIISIS 5804 05 dA 10122 F moon on 5 xnv CL rN 9 Md xnv 296233 xnv 1 AS How IHW NHO I1 ma xa ax Naa 940 NHA SG S12 INI 9S S11 103 97 mad 6 Z Sdl 17 Mad 0L L Sdl 02 L Qnd vNY xnv E 38nss3Hd T10 SZ 1 WWO NINTAG ES OHIOJH Wid Xnv vS TJ 38 85 id 55 H07HNd 88 MATE 188 78 596 58 3d 55 0 85 17 8 38 8 85 DE
33. 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 Ib 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 Use a BCI group 24 size 12 volt battery with a minimum rating of 630 cold cranking amps CCA at 0 F 1 Ensure that the starting battery is fully charged before placing the battery in service 2 Clean the battery posts and or adapters if necessary 3 Install battery post adapters if needed 4 See the dimension drawing in Section 4 for the battery rack location Place the
34. C wire No AWG Use 60 C wire No AWG EZ 75 C 167 F Use No AWG 75 C wire Use 75 C wire either No t AWG Cu or No Use 75 C wire No AWG AWG Al Ed 90 C 194 F Use No AWG 90 C wire Use 90 C wire either No t AWG Cu or No Use 90 C wire No f AWG AWG AI The wire size for 60 C 140 F wire is not required to be included in the marking If included the wire size is based on ampacities for the wire given in Table 310 A of the National Electrical Code in ANSI NFPA 70 and on 115 of the maximum current that the circuit carries under rated conditions The National Electrical Code is a registered trademark of the National Fire Protection Association Inc Use the larger of the following conductors the same size conductor as that used for the temperature test or one selected using the guidelines in the preceding footnote Figure 1 6 Terminal Markings for Various Temperature Ratings and Conductors 16 Section 1 Installation Instructions TP 6809 11 13 1 4 2 Terminal Connector Torque Socket Size Across Tightening Torque Use the torque values shown in Figure 1 7 or Figure 1 8 Flats mm un Nm in Ib for terminal connectors Refer to UL 486A UL 486B 3 2 1 8 5 1 and UL 486E for information on terminal connectors for 4 0 5 32 11 4 aluminum and or copper conductors Comply with 4 8 3 16 13 8 applicable national and local codes when installing a 5 6 7
35. Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed Oil Level 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 notleave rags tools or debris on or near the generator set TP 6809 11 13 1 9 Set Exerciser When power is applied to the RDC2 controller that is when the battery is connected you will be prompted to setthe date and time and then to setthe exerciser Set the exerciser to automatically run the generator set on the desired day and time every week or every two weeks Figure 1 24 shows the controller screens The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move onto the next Repeat until the date time and exercise are set and the controller display shows the main menu See TP 6810 Generator Set Operation Manual for more detailed instructions to set the date and time and set the exerciser Date Setting will flash 05Dec2011 Press the up and down arrow buttons to change the setting Press Select to save the setting Next Exercise 08 31a 12Dec2011 Figure 1 24 Set Date Time and Exercise RDC2 Controller In order to set a loaded exercise using the RDC2 controller a Kohler Model RXT transfe
36. Specifications Customer connection terminal block See Figure 1 10 for location Check the decal on the generator set for terminal block connections Connect one end of each cable shield to GROUND at the generator set Communication cable Belden 9402 or equivalent 20 AWG shielded twisted pair cable one pair Connect shields together as shown 12 AWG or 14 AWG leads for PWR and COM Figure 1 15 Accessory Module Connections with 12 14 AWG Power Leads one cable run with three modules shown TP 6809 11 13 Section 1 Installation Instructions 25 Generator Set Customer Connection Terminal Block Notes e See Figure 1 10 for terminal block location on generator set Check the decal on the generator set for terminal block connections e See Figure 1 13 for maximum total cable length per run 3 runs with 1 module each shown e See Figure 1 14 for communication connection detail e Use splices or wire nuts to collect multiple leads for connection to the generator set terminal block See Figure 1 17 1p6809 Figure 1 16 Accessory Module Connections three cable runs with one module each Generator Set 9402 CABLE 9402 CABLE Note See Figure 1 13 for cable specifications 1 Customer connection terminal block See Figure 1 10 for location Check the decal on the generator set for terminal block connecti
37. Zld xog AvI34 ISNA 448 Figure 4 5 Schematic Diagram 38RCL Generator Set ADV 8484 Sheet 1 of 3 55 Section 4 Diagrams and Drawings TP 6809 11 13 z a F8v8 AQV wa E 6981 2 0 MM 8 68 6 gl 3 8 3 WO M 104 89 OLLYWJHOS Wvuovia WA YHON SNIISIS 5804 05 dA WEZ Testizio nwa ONMM HOIWN OL 3 04 scan 42 55 98 6662019 5 80 MAN ad noszy 2 9 ex iX 3 388 OL 3 z1 4 15 3SVHd 33MHl SZ8S ACV 335 335 SNOIIO3NNOO HOLYH1N39 804 310N 9 lt 53 gt 2 ayog 313 HdILIOXI OLOHd 9Nd ASVHd ov 9 4 ja 2 08 ald 83113 3 04086 96 yaiva OL ASVHd SIONIS y 7 133HS OL 1 133HS OL Figure 4 6 Schematic Diagram 38RCL Generator Set ADV 8484 Sheet 2 of 3 TP 6809 11 13 56 Section 4 Diagrams and Drawings a 8 8
38. an illustration of the 48RCL generator set 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 followthe Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference Model 48RCL Generator Set Figure 1 TP 6809 11 13 Introduction List of Related Materials 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 Literature Type Part Number Specification Sheet 38RCL G4 214 Specification Sheet 48RCL G4 211 Specification Sheet GORCL G4 233 Operation Manual Generator Set TP 6810 TP 6101 TP 6811 Operation Manual Engine Service Manual Generator Set Service Manual 38RCL Engine Mechanical Service Manual 48 60RCL Engine Mechanical TP 6103 TP 6104 Service Manual Engine ECM Diagnostics Service Manual 38RCL Alternator Service Manual 48 60RCL Alternator Parts Catalog 38RCL Engine Parts Catalog 48 60RCL Engine Parts Catalog Generator Set TP 6724 TP 635
39. battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Safety Precautions and Instructions 7 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 Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines Heavy Equipment A WARNING Unbalanced weight Improper lifting can cause
40. calibration procedure for voltage across L2 L3 and L3 L1 7 Use the arrow buttons to step down to the Return Screen Press Select to exit the Generator Metering menu 8 Press OFF to stop the generator set Reset Calibration Pressing the select button when Reset Calibration Yes is displayed will discard the changes and reset the calibration to the original settings See Figure 3 7 TP 6809 11 13 Generator gt Metering A Three phase y Volts L1 L2 e gt gt Calibrate 240 V M Volts L2 L3 m gt Calibrate 240 V f Volts L3 L1 I Calibrate 240 V t Frequency 60 0 Hz Single phase Volts Frequency 60 0 Hz A gt 2 Calibrate To Calibrate Voltage 1 Press Select when the voltage is displayed The voltage flashes Press the Up or Down arrow but ton to change the setting Pressthe Select button to save the setting Press the down arrow button to move to the next menu Y Reset Calibration Return Note Pressing select when Reset Calibration Yes is displayed will discard the changes and reset the calibration to the original settings Fig
41. generator set status display Press IQ AUTO Genset State pisplay Standby Note If no buttons are pushed the controller returns to the status display after 5 minutes Section 3 Generator Reconnection 45 3 5 Voltage Calibration A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under 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 Correct voltage calibration is necessary for proper generator set operation Check the voltage ca
42. last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING 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 gases Explosion can 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 electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or d
43. 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 Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools A WARNING 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 pres sure when servicing 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 Notice NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6809 11 13 This manual provides installation instructions for the Model 38RCL 48RCL and 60RCL generator sets Operation manuals are available separately See Figure 1 for
44. severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause Severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE 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 TP 6809 11 13 Accidental Starting A 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
45. 076 Q3A0W3H 3LON OSS H3XVN NOISIOJQ 184 1178 8 86998 30 1ivi30 80115 A009 Qv31 9 80 65 1 2 8 SNI IMVYG M N 0 6 1 NOISIA2H ava SOIVH3N39 Figure 4 2 Schematic 48 60RCL Alternator ADV 6957 TP 6809 11 13 52 Section 4 Diagrams and Drawings 1908 AOV mom ge R 1 2 1 ma 59 NON gue 155 5 3NION3 WO M 104 8 65 06 6 M gv 1 366 SWAOdady OIVN3HOS WVYOVIC mem GARE RN NOUN 00 1527 08 sem L oo z x 2 HO HM mumeo 44 7 GISA e ION sm savane 00 2 Y kok 00 IAD Si ibn KOSZA M YES SIRI YS 89095 WA 98 SNAISAS 5809 do pex 63 S THO put ANNOYS o018 ANIONS F QNO 0078 TWNINYSL 3Ov4H3INI HIHOISNO 1AL ano NiOMvHO 48 78 Z Sd ke nio QION310S Nilvls SS HOLL HALHVIS WS i SU OMI E AS 1NdNI M3ONVHO AM3LIVH Sd t 1HM d3ndans w3Wolsno WNINH3L I93NNOO XIND Mr INANI M3ONVHO AWALLYB L Gd yna ANANI ALNILA OVAOZ L oma Pd 3 6 3801834769 Nyodo MOT 151 NAA dOlS IUVIS ALOWIH Zl Ld e MOSN3S 38 1 83 9 HIV IN3WIMVdOO 3NION3 S193 S10M1NO9 3 FINGOW TOWINOO OiNOMID313 NOI ss SG NO YNOLLdO HOLMS dOIS AON3OW3H3 ZI Ld EEEE 68287 HOLIMS 8048 3 3883 3 803 69
46. 2 4 375 800 1000 406 508 5 6 124 3 1100 56 5 500 1250 2000 635 1016 124 3 1100 67 8 600 For values of slot width or length not corresponding to those specified select the largest torque value associated with the conductor size Slot width is the nominal design value Slot length is to be measured at the bottom of the slot Note If a connector has a clamp screw such as a slotted hexagonal head screw with more than one means of tightening test the connector using both applicable torque values Figure 1 8 Tightening Torque for Screw Type Pressure Wire Connectors TP 6809 11 13 Section 1 Installation Instructions 17 1 4 3 Ground and Neutral Connections Ground the generator set The grounding method must comply with NEC and local codes Connect the grounding strap to the generator set ground lug terminal GRD inside the junction box or on TB2 See Figure 1 10 Connect the ground to the GND terminals on terminal block TB2 Various regulations and site configurations including the National Electrical Code NEC local codes and the type of transfer switch used in the application determine the grounding ofthe neutral atthe alternator NEC 2002 Section 250 20 is one example that has a very good explanation of the neutral grounding requirements for generator sets Generator sets are shipped with the generator set neutral attached to the alternator in the jun
47. 3 TP 6783 TP 6730 TP 6731 TP 6812 Installation Instructions Load Control Module LCM Installation Instructions Programmable Interface Module PIM Operation Manual OnCue Software Operation Installation Manual RXT ATS Operation Installation Manual RDT ATS Installation Manual RSB Transfer Switch TT 1574 TT 1584 TP 6796 TP 6807 TP 6345 TP 6486 TP 6487 Operation Manual RSB Transfer Switch Figure 2 Related Literature Warranty Registration Complete the startup and installation checklists supplied with the startup notification form Complete and sign the startup notification form and register the unit using the Kohler online Warranty processing System Introduction 9 Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest authorized Kohler distributor dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KOHLERPower com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone
48. 6 SNOIISSNNOO Zd 5882388585 id 6 29 8 9 24 ZA 65 9 OMG 335 3 ia 115 TaM OINOS M OL 0018 TYNINHAL 84 6 1 aka 325 193NNOO HOIND 8 2 94 wis ae Z YOLOSNNOD 5 84 VIS 85 if Na JAWA Tans Ad SNOIS3NNOO vd QNRnOM9 52018 3NION3 982 QN3931 386893 85 488 58 o v 3 IHM 21 0 1 65 2308 QNO 3585 NYO Z Tzzoso12 aaivaan MIA a TIOUINOO 0 4 yore 8 i Nd 6 12808 oN Manj 08 NGLSNNE SNOIIO3NNOO Gd 7 Nisaa Section 4 Diagrams and Drawings 63 Figure 4 13 Wiring Diagram 48RCL 60RCL Generator Set GM79871 Sheet 1 of 2 TP 6809 11 13 LZ86ZN9 ee czw d 77 t MA 87 ONIMIM WYY YIA 99598 BW 6590908189 655 8 20 5968 om Z zA aene Op eS IH CN SNL 8M Z44 5 HN N Nid SNOILOJNNOO vid 2 NYJ indi Ed NOLYIGVH a me Eig Pld W3TIOMINOO 308 MA 87 29 idu 5 OLM 6N Nf Nd SNOILO3NNOO ld Nv Nyd IN3IISYdINOO MOLVIOVH 3NION3 go zid 143 S 6M 9N Nf Nid SNOLOJNNOJS Lid AM3LIV8 p om UM SOd 93N LIM SaN 220901 1 I33Hs
49. 6 Press the up or down arrow buttons to increase or decrease the setting 7 When the desired setting is shown press Select The value stops flashing and the new setting is saved TP 6809 11 13 8 Press the down arrow to step to the next setting 9 To exit press the down arrow button until Return is displayed Press the Select button to exit the menu 10 Press the AUTO or OFF button to exit the main menu Note If no buttons are pushed the controller exits the menus and returns to the generator set status display after 5 minutes 1 Display 2 Select button 3 AUTO button Figure 3 4 RDC2 Controller User Interface Section 3 Generator Reconnection 43 Status Displays Overview gt gt 12h System voltage frequency and phase adjustments are in the Genset System menu ATS configuration appears only if a Model RXT transfer switch is connected Figure 3 5 RDC2 Main Menu 44 Section 3 Generator Reconnection Ol M Engine Metering Y ATS gt Configuration Generator gt Metering Y Date and Time Genset gt Information Y I Network gt Information Y Genset gt Run Time PIM gt Status Load Control Event Log
50. 6 2 Gas Regulators Gas regulators reduce high incoming fuel pressures to lower levels acceptable for engines See the generator set specification sheet for fuel supply pressure requirements Primary gas regulator The primary regulator reduces the high pressure from a tank or transmission line to the lower pressure required by the secondary regulator on the engine The fuel supplier provides the primary regulator The fuel supplier is also responsible for providing sufficient gas pressure to operate the primary regulator Secondary gas regulator The secondary regulator is factory installed on the generator set engine and controls the inlet pressure to the engine The models covered by this manual use an electronic pressure regulator See Section 1 6 4 Note The Integrated Electronic Pressure Regulator IEPR and air fuel mixer are specially calibrated emission control devices Do notadjustthe IEPR or the air fuel mixer 1 6 3 Install and Connect Fuel Supply Note Have the fuel piping and regulator installed by the fuel supplier The fuel supply installation must comply with NEC and local codes 1 Seethe generator set spec sheet for the fuel supply requirements Add up the fuel requirements for the generator set plus all other gas fired equipment fueled by the same supply 2 Check that the primary regulator and gas meter have sufficient capacity for the fuel requirements for the generator set plus all other gas fired equipmen
51. 61 1 of 2 ADV 8061 2 of 2 ADV 6957 GM79871 1 of 2 GM79871 2 of 2 GM35943 Section 4 Diagrams and Drawings 51 00 52785 L869 AQ0Y 5 soy oo sr 0 95 9 goa Sh 0 61 S8 wwa OLLYWJHOS AVMOVIO mu 31 0 STYMOWddY 02 83538 28 NOLINZANI WO NOIS3Q JO SLHORI TV MOM 02 331HOX HLM NOLOGNNOO NI Id3OX3 035 38 ION ISNN GNY 1858089 03 M3IHON 130 ANY NOIS3Q NI NIAYMO SIKI WSM 9 IM N31HON SN3ISAS u3MOd 03 831868 539 F SNOLOVUA xm _ ow rox HSINI4 30V4uns o XK 2 59 FOO i38V SJONVHJIOL e SIHONI Ni duy SNOISNANIG i dabtosas JSWSZNIO SS3INN YOLVLS 1VIS Q4vOH G31 AYVNOLLWLS HIS AI8W3SSV 334933 SNIIVIOJ Ved YOLVYSNAD 13 IN3NVW3H3d OWd EDENI ava zl LVLS aval 9 4515 jsvHd 3381 GZ8S AQV 335 335 SNOLLOJNNOO MNOIVH3N39 804 ALON SNOILOSNNOO 8OIVIS LIOA 009 9 335 SNOIIO3 ASVHd ddHHl GZBG AOV 335 NNOO SOIVH3N39 804 310N ov 9 3 14 HAL 9d 13 3 ov GHv0d OLOHd 86
52. All AC circuits must include circuit breaker or fuse protection The circuit breaker must be rated for a maximum of 12596 of the rated generator set output current The circuit breaker must open all ungrounded connectors The generator set is equipped with a factory installed circuit breaker 1 4 1 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation Most field installed accessory kits include installation instructions Comply with applicable national and local codes when installing a wiring system For Canadian installations refer to the Canadian Electrical Code CEC For customer supplied wiring select the wire temperature rating in Figure 1 6 based upon the following criteria e Select row 1 2 3 or 4 if the circuit rating is 110 amperes or less or requires 1 AWG 42 4 mm or smaller conductors e Select row 3 or 4 if the circuit rating is greater than 110 amperes or requires 41 AWG 42 4 mm or larger conductors Row Temp Rating Copper Cu Only Cu Aluminum Al Combinations AI Only Use No AWG 60 C wire or use No AWG 75 C wire 60 C 140 F or 75 C 167 F Use 60 C wire either No AWG Cu or No AWG Al or use 75 C wire either No AWG Cu or No AWG Al E 60 C 140 F Use No AWG 60 C wire Use 60 C wire either No AWG Cu or No AWG AI Use 60 C wire No AWG or use 75
53. D 888 I8 GSH NSD I 02 85 I 1 DG 9 HOLOJNNOO ONILWN ON 5 NOIO3NNOO cenizio z SEBHS 335 6662015 5 80 Mani NOISIAGR 038 88 11 82 085 Zy QNnouo L 4404001 ZL Z 4404001 LL 25 5 2 olg xnv 8 5 GNd vNV 9 and ww SE L 9 6 GNd vNV te HOLIMSA 6 HALWYIS EL L NVO 8h L NO S WMd XnW IS IYBA AH 9 WL 11027 avs ZE 8 8 818 98 18 188 THAT IT IAWNTB n 85 0 789 8 8 83 5 5 85 TVN NSB NVI NSB NVI 629 88 HG mameya 5W0 NT8 HQ 940 018 HQ 88 yazaa ma 38 2665 TATUS d TIME ya NYI ANd NIZINA gy 5 MSA 14 NYL ANd NVI JNd 18 789 Maini Na 3mg8 ri NATE XNd mH NATE IHW mE IHME IAWNIA THAN NV1 O38 NvL O38 IHW NHG aNnoxs 5 1404001 AHYWId 4104901 0235 3 04 AVY xnv 133135 Tans Zand yny cand YNY xnv 1 09 rand YNY MSA ONvWWOO 4315 Nvo wo 5 Wid xnv 32 4 34 WO3 ma IVIHM 88 15 NAD 0 38 NK DK_GRN ma 7 88 NL dy 0 Gy W93 Z4 188 8 1
54. Electronic Pressure Regulator IEPR and air fuel mixer are specially calibrated emission control devices Do notadjustthe IEPR or the air fuel mixer Check the connections to the fuel solenoid valve to verify that the fuel system is set up for the type of fuel that will be used See Figure 1 20 for the location of the fuel solenoid valve To change the fuel type change the connection to the fuel solenoid valve as described below and shown in Figure 1 21 LP Connections e Disconnect lead 73A from the fuel valve e Connect lead 73B to the fuel valve e Connect lead 65 to lead N3 ground Natural Gas Connections e Disconnect lead 65 from N3 e Disconnect lead 73B from the fuel valve e Connect lead 73A to the fuel valve TP 6809 11 13 FOR LP REMOVE 73A LEAD FROM FV1 AND PLUG IN 73B LEAD QCON1 gt 738 P8 C JOM 73A P8 B QCON2 5 3 65 P8 H Eu 3 M QCONS FOR LP FUEL CONNECT 65 AND N3 70A W2 N2 W1 BU TO ECM FV2 NATURAL GAS CONFIGURATION SHOWN ss Figure 1 21 Fuel Type Connections Converting the fuel will change the generator set rating See the generator set specification sheet for ratings with natural gas and LP Order a new nameplate with the updated rating and fuel information from an authorized distributor dealer if necessary Prov
55. HM SVJHV u3HlO YO 9011 4 Sv3uv AVld LV Q3LOJHIQ LON SI LSNVHX3 2 3W8NLONHLS FHL OL HO WOH4 AVMY Q3WIV SI LSNVHX3 I S3NI 130109 1 19 6 jlON 335 8 JION 335 3JION 335 000 ais 32 835 6 JION 335 8 JlON 335 ALON 335 8 JION 335 3unionuls Q3ldn5350 3HNLONHLS Q3ldf220 310N 335 N 2000 3015 331 835 RZ 41ON 335 34NLONHLS 31 220 48NLONHLS 03 2330 Drawing 38 48RCL ADV 8494 Sheet 2 of 2 imension Figure 4 9 D Section 4 Diagrams and Drawings TP 6809 11 13 2 5 8 amm mm 398 umo LNIHd NOISN3WIQ STWKOWddY 03 83538 357 NOILNIANI 80 891530 40 SLHOIY 3 08 OD 83 0 HLIM 8011338803 NI 1433 3 0350 38 108 19 ONY 4 934084 09 83103 51 118130 ANV 851530 NI SNIAVKG SIHL Y S D ROES IM U31HOM SN3LSAS 83 0 19150910 9 0 M3N EI 01 0l 2583 125026 O9 831 2331 801816 6 OW 1988 335 rao 2115000910 3196 SIN31VAInO3 QHVONYLS HSI19N3 34V NI SNOISN3NIQ 310N 868 0822 7051 0821 j i 1304 EA TE 761 086 III 0 S310H 9NI LNNOW F 16 TET 608 T ty OT 1 1871 2 1 J3NYd 55333 IE e 8S
56. HW OD 831 oe A 08 2 5315 awans iz EN 0 x 30v 6328861104 9160912 9814 89 M3N E 01 0 41 SIOISINTG 3368 75 189806 971 13 31 NOISIAGN 804 ON LUYA 335 SOMO 3 1504803 NO 31 0 6 jlON 335 000 3015 33 359 L 340 335 9N11002 HOLVH3N39 3408 4 38 5 3 OL 1334 40 3ONVISIQ WAWINIW Y 3 3 OL 34N 38 IWIYJLYW 8 19 YVAN SNOILYTIVLSNI YO4 Iviu3lvW J31I8ILSNAWOO V 1333 15 3 lv 18 QINOHS JONVISIG SIHL 831 15 S3NIGUNI SVO ANY S3NION3 NOI LSNAWOJ AUVNOIIVIS 40 35 ANY NOIIVTTIVISNI JHL 803 SQUVONVIS LE VddN S3009 1v201 GNV 31VIS NO 1N30N3d3Q SI 38 123 815 V WOY 3ONVISIQ Q3QN3NWOO3H FHL ALON 8000 3015 331 835 6 JION 335 N Pam 310N 33S 8 JION 335 310N 335 SINIVHLSNOO NOIIVTIVISNI H3HlO 804 IYNNYW SU3NMO OL 33339 01 13S 40 QN3 LSNVHX3 WOHd4 1334 9 ISV3 LV 3uv 2313 3unliNund Ollvd 91 3JAILISN3S 6 v3uv 13Avu9 NI SATGILSNGWOD HJHLO HO SGNYHS SINV Td ON 131100 LSNYHX3 WOHJ 14 v QN3LX3 OL 038 T3AVH9 8 Q33M 53015 NO 13SN39 QNOA38 9 9NIQN31X3 AYd 313HONOO YDIHL v 13S 40 QN3 LSNVHX3 Wodi 1334 01 1SY31 LV 38V S3MVINI HVTIWIS H3HLO QNV 33 8 3 Q3s010 34V STIVM IN3OVfOV NO SHOOQ SMOQONIM 3unionsul
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58. Nyo TA ma 4 L NYO nama aNnouo 9 9 Given Nvl G38 Lewis 1 NVL G38 og ais 94 85 H0 HNd NOLLOJNNOJ OLISONOWIA L 1338 Sd 30V HALNI 863 OL 85 XQPXNd dy GL 89 0 NDI 4 8 3 za Hie 90 ZL v akale Figure 4 7 Schematic Diagram 38RCL Generator Set ADV 8484 Sheet 3 of 3 57 Section 4 Diagrams and Drawings TP 6809 11 13 U a 6 Hid 2 383 3 LHOM 2 laws on avo 0170 awos SUN lNiHd NOISN3WIG SUN 57 084 03 83538 357 01183 1 EO 891530 40 SLHOIY 3 08 OD 83 0 HLIM NOILO3NNOO NI 1433 3 0350 38 108 19 ONY 4 834084 02 83103 51 118130 ONV 851530 NI 9NINVEO SIHL Y S D ROES IM 31 09 SWALSAS 83 0 2593 125 58 53 831 6 ELLLSLO 857 SYM 08 01583 10 2 19111131 981489 MIN T3431 NOISIA3U 804 ON 18 335 SOMO 3 1504803 NO SINJ1VAInO3 QUVQNVIS HSI19N3 38V NI SNOISN3NWIQ Q3AON3H YOOd M_NMOHS ONIN3dO 8000 SE L68 SALON li Tv 051 82 8 51 08 1 NIVYO 868 0822 55333 NOI123NNO 91 9l X7 NIVY LNY 1000 S 322V OL TANVd SIHL JAOW3H Q3AON3H HOOJ M NMOHS
59. O3 SAHNI Ni 28 SNOISNANIG I Gaiioe 3suMWaHIO SSZINN YOLVYANSD 304 TALON av31 9 x IN090 0A 6 S81 6 8 S81 8 4 LA 881 ZA 1 AINO LTOA 009 dv37 9 SNOILO3NNOO Ld av31 ZL G 8G AQV 335 SNOILO3NNOO MOIVH3N39 304 310N LNO9D 6A G81 6A 8A GAL 8A LA S81 A vog OLOHd 0z 1d ag 91 12 ag YOLWIS LWIS 8 08 30010 9NLLLIN3 LHOIM AHVNOILVIS 815 AI8W3SSY M3lJLO3M ONILVLON vaa MOlVM3N3O LINOVN INANYWJJd OWd Dd QN3931 96056 3 0 3 ALON OSS N3xvW NOISIO3G 183 z Y LL 8 8v998 daddy 77130 10A 009 2 9 SNOILOANNOO 1d V 80 61 LL 2 6 G3AOWJUH 498S AGV 8 90 02 6 oesez 300 310N OLIYWAHOS 404 1 90 01 1 2 8 9 N3N 0 NOISIA3H 34 0 YOLVYANAD TP 6809 11 13 Figure 4 12 Wiring Diagram 48 60RCL Alternator GM35943 62 Section 4 Diagrams and Drawings a ZIE sz ic a eic SERIES ame TORT We ws aj a Sh ONIAIM_ WYHDVIQ bya eo am L oo z x WSM Tu mu MP NAK WAM a 52 e OD 85 18 Euer uM
60. T8 XNd m8 IHW mE THW ME TAN IHW NHE NV1 O3H NyL 038 IHW NHG aNnoxs 5 1404001 AHYWId 4104901 0235 3 04 AVY xnv 133135 Tans Zand yny cand YNY xnv 1 09 rand YNY MSA ONvWWOO 4315 Nvo 0 5 Wid 32 4 34 W03 ma IVIHM 88 15 NED 0 38 NK DK_GRN ma IVIHM Nv1 G3U INY OL Gai W93 24 188 8 8878 CH NO 4 L NYO aNnouo 9 N E wizaz 18 19815 1 NVL G38 og ais 94 NOUO3NNOS Io PAM OLISONOWIA L 13348 sd 3OV3H3INI 863 OL NYO H0 XNd WY GL 85 0 Nol 4 zai 028 i 50 zi v AHALIYB Figure 4 4 Schematic Diagram 48RCL 60RCL Generator Set ADV 8061 Sheet 2 of 2 TP 6809 11 13 54 Section 4 Diagrams and Drawings z Y8Y8 ACY Cana R 1 51 papa NN kaa 3 8 3 WO M 104 8 8 56 857 OLLYWAHOS WVYOVIG oo 086 0018 ANIONS F GERS BN NOVIA 50 O30 65 08 TY uon 2 NHN HIM Molino M LEO GS JA ON zane Aut 09 SI IMLA ONY 56 0 MI NAWO SHI 7 ST 97065 UM YHON SNAISJS 5804 2A Tere 05 dA VH CONI
61. Z 230 400V 50 HZ 240 416V 12 LEAD ALTERNATOR 4 WIRE DELTA 60 HZ 120 240V PHASE ROTATION NOTES A B C CURRENT TRANSFORMER DOT OR H1 TOWARD GENERATOR L1 L2 L3 ADV 5875E P Figure 3 2 12 Lead Generator Reconnection 38RCL TP 6809 11 13 Section 3 Generator Reconnection 41 12 LEAD ALTERNATOR 3 WIRE SINGLE PHASE 60 HZ 100 200 60 HZ 120 240 50 HZ 100 200V 50 HZ 110 220V SOME SETS NOT RATED FOR SINGLE PHASE SEE MANUALS CT3 NOT USED 7 UWE LO METER SCALE LAMP JUMPER vg OPTIONAL DROOP COMP CT EAD ALTERNATOR 4 WIRE DELTA 60 HZ 120 240V 50 HZ 110 220V L2 4 8 CT2 4 8 D v8 LO 11 10 4 7 5 CTI gt A A 6 wm 3 0 12 E CTS 6 L1 METER SCALE LAMP JUMPER OPTIONAL DROOP COMP CT 95 L3 ALTERNATOR 4 WIRE LOW WYE 120 208 50 127 220 50 139 240V 50 HZ OPTIONAL DROOP COMP CT 11 Pd vg Vi 2 8 dos 2 8 Wis METER SCALE LAMP JUMPER vo W 1 m Gia Y ee 1274 i 110 190V 115 200V 120 208V 8 12 LEAD ALTERNATOR 4 WIRE HI WYE 60 HZ 220 380V 60 HZ 240 416V 60 HZ 277 480V L1 ON AA 1 4 WA v7 vo 100 11 zi e v9 9 823 TIONAL 0800 5 COMP CT 7186 METER SCALE LAMP JUMPER 3
62. a noncombustible surface DO NOT allow accumulation of combustible materials under or around the generator set e Permit vibration isolation to reduce noise and prevent damage Not be subject to flooding Allow safe expulsion of exhaust e Provide clearance for cooling air flow and access for service See Figure 1 5 and the dimension drawings in Section 4for required clearances from obstructions and combustible materials e Minimize the risk of public or unauthorized access Notice DO NOT locate the generator set near patios decks play areas or animal shelters Keep items such as lawn furniture toys sports equipment and all combustible materials away from the generator set exhaust outlet Remind family members children and visitors to use caution near the generator set Generator sets connected to automatic transfer switches start automatically during exercise periods and power outages Some generator set components become hot when the generator set is running and remain hot for a time after the generator set shuts down 14 Section 1 Installation Instructions A QQ SERVICE SIDE i A dy NY 4 A Figure 1 5 Air Intake and Exhaust 1 3 2 Mounting Surface Install the generator set on a single level concrete mounting pad This method provides maximum stability and ensures correct cooling air flow through the generator set The recommended mounting pad dimensions are shown in the dimension dra
63. ank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory RS 485 proprietary communications relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay root mean square round read only read only memory rotate rotating revolutions per minute right side Resistance Temperature Detectors RTU RTV RW SAE scfm SCR S Sec SI SI EO sil SMTP SNMP SPDT SPST spec specs Sq Sq cm Sq in SMS SS std stl tach TB TCP TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo typ UF UHF UIF UL UNC UNF univ URL US VAC VAR VDC VFD VGA VHF WCR w WO w o xfmr remote terminal unit room temperature vulcanization read
64. ath Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina 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 28 Section 1 Installation Instructions Battery electrolyte is a diluted sulfuric acid
65. battery on the battery rack on the skid 5 Connect the red battery cable to the positive battery terminal 6 Connectthe black battery cable to the negative battery terminal 7 Place the boots over the battery terminals When power is applied to the RDC2 controller that is when the battery is connected you will be prompted to set the date and time and then to set the exerciser See Section 1 9 and the generator set operation manual for instructions Ifthe battery is disconnected for service or replacement the exercise settings on the RDC2 DC2 controller are lost Setthe exerciser after installing and connecting the battery See Section 1 9 Set Exerciser TP 6809 11 13 1 6 Fuel System A WARNING _ LI 4 w 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 flex
66. cation Connection to Generator Set Terminal Block TP 6809 11 13 Section 1 Installation Instructions 21 Engine start connection for other transfer switches or a remote start stop switch Note Do not use the Kohler Model RRT transfer switch with Model RCL generator sets Other Kohler transfer switches inckuding Model RDT RSB and Model K MPAC transfer switches can be used with the Kohler generator sets covered in this document These transfer switches contain separate ATS controls that do not communicate with the RDC2 controller These transfer switches use a set of contacts to signal the engine generator to start When the normal source fails and the generator set is in AUTO mode the transfer switch contacts close to signal the generator set to start and run After the normal source returns the contacts open to signal the generator set to stop The engine start terminals are usually located near the transfer switch contactor with an engine start decal identifying the terminals Use the transfer switch wiring diagrams to identify the engine start terminals prior to making connections Generator Set Connect the transfer switch engine start contacts or a remote manual engine start switch to the engine start terminals 3 and 4 on the generator set Size the wire according to the transfer switch connection and the length of run Use separate conduit for the DC engine start leads and the AC generator set load cab
67. cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected 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 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 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 e Light headedness dizziness e Physical fat
68. ction box At installation the neutral can be grounded at the generator set or lifted from the ground stud and isolated if the installation requires an ungrounded neutral connection at the alternator The generator set will operate properly with the neutral either bonded to ground or isolated from ground at the alternator 1 4 4 Battery Chargers An engine driven battery charging alternator charges the battery whenever the generator set operates Engine driven systems can quickly restore the charge used in a normal cranking cycle 18 Section 1 Installation Instructions Whenthe engine is not operating a very low charge rate from an AC powered battery charger is usually sufficient to maintain a full charge on the batteries The RDC2 controller contains a built in battery charger to maintain the generator set s engine starting battery Be sure to provide AC power for the integral battery charger as instructed in Section 1 4 5 1 4 5 Power Supply Power must be supplied to the generator set location for the battery charger and optional accessories The power source must comply with both state and local codes The power to the accessories must be available at all times i e the circuit must be powered by the utility source and backed up by the generator set Connect power to the leads in the utility power connection area shown in Figure 1 10 See the wiring diagrams in Section 4 for connection details See Figure 1 9 for the power r
69. e glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F Acoolant solution with less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not mix long life coolant and conventional coolants Do not use alcohol or methanol antifreeze or mix them with the specified coolant 3 Check the oil level before operating the engine 4 Operate the engine with the radiator s pressure cap removed until the thermostat opens and the radiator upper hose becomes hot 5 Stop the engine and allow it to cool 6 Add coolant to the radiator to just below the overflow tube on the filler neck See Figure 1 23 7 Replace the radiator s pressure cap 32 Section 1 Installation Instructions 8 Maintain the coolant level in the coolant overflow bottle between the High and Low markings See Figure 1 23 for the coolant overflow bottle location Note Block Heater Damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater Coolant Capacity L gal Engine 15 4 4 1 17 4 4 6 17 4 4 6 Engine with Block Heater 16 9 4 5 18 9 5 0 18 9 5 0
70. e new factor and then compare the voltmeter reading with the voltage displayed on the controller 7 If the voltage readings do not match check your calculations Check the calibration factor and both 48 Section 3 Generator Reconnection voltage readings again Repeat the procedure using the new values if necessary Note Ifyou would like to simplify the calculation set the calibration factor to 1 0000 and then repeat the calibration procedure from step 3 8 Repeat the procedure for voltage across L2 L3 and L3 L1 if necessary Three phase only 9 Press OFF to stop the generator set Vmeter Vcontroi X Fold Fnew V meter Voltmeter reading Vcontroi Voltage displayed on controller Fgld Genset Calibration Factor Voltage L1 L2 from SiteTech before calibration Frew New value to enter for Genset Calibration Factor Voltage L1 L2 in SiteTech Example Voltmeter reading 241 2 Controller display 240 Old calibration factor from SiteTech 1 0063 New calibration factor 241 2 240 x 1 0063 1 0113 Figure 3 8 Voltage Calibration Factor TP 6809 11 13 Kohler SiteTech Device Testing dh Start Exercise Update Firmware gt Cut Show All ud x 68 Stop Exercise Change Pa i 3 Copy d Expand All Add 5 Power Gauges Apply Discard Device E Reset Faults lani Chain ste FF collapse Al Changes Changes Setup Views Clipboard Genset Calibration Factor Voltage L1 L2 1 006300
71. ead a 76 mm 3 in thick layer of gravel to support the concrete mounting pad For the mounting pad dimensions see the generator set dimension drawing in Section 4 c Lay a 100 4 in thick concrete pad on the gravel layer Include mounting bolts and stub ups for the fuel supply and electrical conduit See the dimension drawing in Section 4 for the mounting bolt and stub up locations 1 3 5 Mount the Generator Set 1 Place the generator set on the concrete mounting pad Secure the generator set with mounting bolts anchored in the concrete pad 2 Remove the shipping bracket which is attached to the skid under the engine and labeled with a hang tag 3 Remove the enclosure doors and alternator end panel to gain access to the junction box and other generator set components during installation Remove the covers to access the AC and DC connection terminal blocks Section 1 Installation Instructions 15 1 4 Electrical System Before installing the generator set provide for electrical connections through conduit to the transfer switch and other accessories for the generator set Route DC leads in separate conduit from AC conductors Carefully install the selected generator set accessories Route wiring to the generator set through flexible connections Comply with all applicable codes when installing a wiring system See the dimension drawings in Section 4 for the recommended stub up location AC circuit protection
72. eath 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 inthe 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 Safety Precautions and Instructions 5 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 eguipment 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 4 connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solu
73. ems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per the manufacturer s instructions 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 A CAUTION 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 op
74. ent Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution 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 Section 3 Generator Reconnection 39 3 2 Four Lead Single Phase Generator Sets Figure 3 1 shows the factory connection for the single phase 120 240 V 60 Hz generator set Four lead single phase models are not reconnectable 100 120 200 240V 60HZ LO NEUTRAL GRD L1 L2 O GROUND LOAD SIDE FACTORY TWO POLE CIRCUIT BREAKER 3 2 4 1 STATORLEADS 100 120 200 240 VOLT 3 WIRE ADV 5857 A Figure 3 1 Single Phase Factory Connection 120 240 V 60 Hz 40 Section 3 Generator Reconnection 3 3 12 Lead Three Phase Generator Sets Three phase 12 lead generator sets are reconnectable to the voltages and phases shown on the generator set specification sheet See Figure 3 2 or Figure 3 3 and use the following procedure to reconnect the generator tothe desired voltage configuration change the system voltage setting and adjust the output voltage Note The current transformers CTs shown
75. ent The type of fuel the distance it must travel from gas meter tank to fuel shutoff solenoid and the amount consumed by the engine must be considered when determining fuel line pipe size In addition to actual fuel consumption consider the following pressure loss factors e Pipe length e Other appliances on the same fuel supply e Number of fittings Measure the pipe length from the primary gas pressure regulator to the pipe connection on the generator set fuel inlet Add 2 4 m 8 ft to the measured length for each 90 degree elbow Use the pipe size indicated in Figure 1 19 for the total length of pipe Figure 1 19 is based on gas pressures of 3 4 kPa 0 5 psi 13 8 in water column or less and a pressure drop of 0 12 kPa 0 018 psi 0 5 in water column with a 0 60 specific gravity and with a normal amount of restriction from fittings The LPG flow has been corrected for specific gravity to determine the pipe sizes shown in the table Flexible connections Rigid mount the piping but protect it from vibration Use flexible connections spanning a minimum of 152 mm 6 in between the stationary piping and the engine fuel inlet connection Nominal Iron Pipe Size in Rate Full Load Pipe Length m ft LPG cfh cfh corrected 12 2 183 244 30 5 40 60 80 100 Figure 1 19 Fuel Pipe Sizes TP 6809 11 13 Section 1 Installation Instructions 29 1
76. equirements for the battery charger and accessories Power Requirement Amps Volts Equipment Watts Battery charger standard integral to RDC2 controller Block heater optional Battery heater optional Figure 1 9 Power Requirements TP 6809 11 13 1 4 6 Connect AC and DC Wiring Note Have a licensed electrician make the following electrical connections All connections must comply with state and local codes Size the wire according to the length of run and 115 of the circuit current amperage based on 75 C wire rating or less as directed by the National Electrical Code NEC in ANSI NFPA 70 See Section 1 4 1 for additional information about wire selection GM78527 Access panel remove to access connections 120VAC connection leads and ground screw Installer to punch access openings Low voltage connection terminal block Ethernet cable connection for OnCue Ground GRD lug 7 Load lead access opening 8 Load lead connections to line circuit breaker 9 Neutral lug Figure 1 10 Generator Set Connections TP 6809 11 13 The generator set is equipped with a field connection terminal block located in the access area below the junction box Leads have been factory installed from the junction box to the terminal block for easy field wiring See Figure 1 10 Make all AC and DC customer connections inside the customer connection box Do not remove the end panel or make connection
77. erating generator set TP 6809 11 13 Hazardous Voltage Moving Parts A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place WARNING 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 A CAUTION 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
78. he distributor lifting contractor should choose one of the following methods to liftthe generator set depending upon the location circumstances and the generator set s weight and size Single Spreader Bar and Skid Lifting Bar Method Refer to Figure 1 3 Double Spreader Bar and Skid Lifting Bar Method Refer to Figure 1 4 1 Lifting holes Figure 1 2 Typical Enclosure with Lifting Holes TP 6809 11 13 Figure 1 3 Single Spreader Bar and Skid Lifting Bar Method enclosure not shown SPREADER BAR 20 TP 5700 2 L11 Figure 1 4 Double Spreader Bar and Skid Lifting Bar Method enclosure not shown Section 1 Installation Instructions 13 1 3 Location and Mounting 1 3 1 Location Factors The manufacturer recommends mounting the generator set on concrete at ground level For above ground installations including roof installations weight considerations are especially important The building engineer must determine whether the structure can support the weight of the generator set The location of the generator set must e Support the weight of the generator set and related equipment such as batteries radiators and mounting pad s Keep in mind that the mounting pad weight may exceed the weight of the generator set e Meet applicable fire rating codes and standards e Minimize the risk that people will come into contact with hot generator set surfaces e Position the generator set over
79. heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second International Building Code integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 210 bytes Kohler communication protocol kilogram Appendix 67 kg cm kgm kg m3 kHz kJ km kOhm ka kPa kph kV kVA kVAR m3 m3 hr m min mA man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilograms per square centimeter kilogram meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature me
80. ible 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 Fuelleakage 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 Gas fuel systems operate on either LP vapor or natural gas Refer to the generator set specification sheet and Section 1 6 3 for more detailed information on fuel requirements Note Thefuel system installation must comply with the National Electrical Code9 NEC and applicable local codes Maximum Fuel Flow 1 6 1 Fuel Lines Gas lines Never use fuel piping to ground electrical equipment The gas supplier is responsible for installation repair and alteration to gas piping Use Schedule 40 black iron pipe for gas piping Copper tubing may be usedifthefuel does not contain hydrogen sulfide or other ingredients that react chemically with copper Line size Size piping according to the requirements of the equipm
81. ide the following information from the original nameplate e Model Number e kVA e Spec Number e Amps e Serial Number e Volts e Fuel original and new e Hz e kW Section 1 Installation Instructions 31 1 7 Cooling System The generator set is equipped with a unit mounted radiator common cooling system Add cooloant before starting the generator set or energizing the block heater The system s major components include two electric fans a circulating water pump a radiator and a thermostat The pump circulates water through the engine until it reaches operating temperature Then the engine thermostat opens allowing water circulation through the radiator The thermostat restricts water flow as necessary to prevent overcooling The fans blow air through the radiator across the cooling surface Follow the instructions below to fill the cooling system 1 Close the radiator s coolant drain valve and tighten the hose clamps Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled 2 Fill the radiator with the recommended coolant mixture of 50 ethylene glycol based long life coolant and 50 clean softened water to inhibit rust corrosion and prevent freezing See Figure 1 22 for coolant capacity and Figure 1 23 for coolant fill location Do not replace the pressure cap at this time Note A coolant solution of 50 ethylen
82. igue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e 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 Fuel System A WARNING 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 TP 6809 11 13 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 syst
83. in Figure 3 3 are not used on Model 48RCL or 60RCL generator sets Note Equipment damage Verify that the voltage ratings ofthe transfer switch line circuit breakers and other accessories match the selected line voltage Reconnection Procedure 1 Press the OFF button on the RDC2 controller 2 Disconnect engine starting battery negative lead first 3 Disconnect utility power to the generator set 4 Selectdesired voltage connection See Figure 3 2 for the 38RCL or Figure 3 3 for the 48RCL and 60RCL Connect the leads according to the diagram for desired phase and voltage 5 Reconnect generator set engine starting battery negative lead last 6 Follow the instructions in Section 3 4 to enter the RDC2 Genset System menu Check the system voltage frequency and phase settings and change them if necessary 7 Connect a digital multimeter DVM to the generator set output 8 Press RUN to start the generator set 9 Use a voltmeter to check for the correct voltage output from the generator set Follow the instructions in Section 3 5 to calibrate the voltage on the RDC2 controller if necessary 10 Press OFF to stop the generator set 11 Reconnect utility power to the generator set 12 Press AUTO to place the generator set in automatic mode TP 6809 11 13 12 LEAD ALTERNATOR 4 WIRE LOW WYE 12 LEAD ALTERNATOR 4 WIRE HI WYE 60 HZ 120 208V 60 HZ 277 480V 50 HZ 220 380V 60 HZ 127 220V 50 H
84. ircuits 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 A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected 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 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 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 Section 1 Installation Instructions 11 Tools Required e Multimeter for measuring voltage and current e Frequency meter ma
85. les and battery charger leads See Figure 1 12 Connect the engine start leads from the transfer switch or remote start switch to terminals 3 and 4 onthe terminal block Route the engine startleads through separate conduit from the AC power and load leads Close the remote start contacts to start and run the generator set Open the contacts to signal the generator set to stop The generator set controller must be in AUTO mode for remote start stop ATS Models RDT or RSB 1 Customer connection terminal block See Figure 1 10 for location Check the decal on the generator set for terminal block connections 2 Engine start leads 3 and 4 See the ATS manual for cable size specifications Figure 1 12 Engine Start Connections with Transfer Switch Models RDT or RSB 22 Section 1 Installation Instructions TP 6809 11 13 1 4 8 Communication Cable Specifications RBUS Connections A and B For the RBUS communication connections A and B to the Model RXT transfer switch optional PIM and or optional LCM or load shed kit use 20 AWG shielded twisted pair communication cable Belden 49402 two pair or Belden 8762 single pair or equivalent cable is recommended For outdoor installations including those with buried cables and or conduit use outdoor rated Belden 1075 or equivalent 20 AWG shielded twisted pair communication cable PWR and COM Connections For the PWR and COM connections from the gene
86. libration after controller replacement or generator set reconnection and adjust if necessary The RDC2 controller can be calibrated using the controller keypad and menus or using a personal computer with Kohler SiteTech software 46 Section 3 Generator Reconnection 3 5 4 Calibration using the RDC2 Controller Keypad and Menus The controller s voltage calibration can be adjusted using the controller keypad See Figure 3 7 and follow the procedure below Note A digital voltmeter is required for these adjustments 1 With the generator set off connect a digital multimeter to measure output voltage across L1 and L2 Set the meter to measure AC volts 2 Startthe generator set by pressing the RUN button on the RDC2 controller 3 On the RDC2 controller press the Select button and then use the arrow buttons to navigate to the Generator Metering menu on the RDC2 controller 4 Press the Select button to display Volts L1 L2 Compare the number displayed with the voltmeter reading 5 Ifthe correct voltage is not displayed follow these steps to adjust it a Pressthe Select button The voltage will flash b Pressthe up or down arrow button to adjustthe voltage to match the voltmeter reading c Press Select to save the voltage setting The voltage stops flashing d Wait for the voltmeter reading to stabilize This may take 30 to 60 seconds 6 For three phase models press the Down arrow button and repeat the
87. onnection A typical standby system has an automatic transfer switch connected to the generator set output to automatically transfer the electrical load to the generator set if the normal source fails The normal power source is typically utility power When normal power returns the switch transfers the load back to the normal power source and then signals the generator set to stop Connect the ATS or remote start stop switch Connect the load leads from the generator set to the Emergency source lugs on the ATS Connect the RBUS or engine start connections as described below Route low voltage communication leads through separate conduit from the AC power and load leads All connections must comply with applicable state and local codes TP 6809 11 13 Kohler Model RXT Automatic Transfer Switch The RDC2 controller is designed to control the Kohler Model RXT transfer switch as well as the generator set Follow the installation instructions to connect the transfer switch interface board to the appropriate terminals on the generator set The RDC2 controller uses a Kohler propietary communication protocol to communicate with the transfer switch When connected to a Kohler Model RXT transfer switch the RDC2 controller provides the following features e Monitors and displays utility voltage and frequency e Schedule loaded exercises from the RDC2 generator set controller e Set the ATS system voltage and frequency e Allows calibra
88. ons 2 Splice 3 Connect all of the shield leads on this end to GROUND at the generator set Figure 1 17 Multiple Connections to the Generator Set 26 Section 1 Installation Instructions TP 6809 11 13 Generator Set Notes e See Figure 1 10 for terminal block location on generator set Check the decal on the generator set for terminal block connections e See Figure 1 13 for maximum total cable length with 12 or 14 AWG wire e See Figure 1 14 for communication connection A and B PWR and COM details Connect the cable shield to ground at the generator set Figure 1 18 Accessory Module Connections two cable runs with one and two modules shown 1 4 10 Other Accessories See Section 2 for information about available accessories Install and connect optional accessories Follow the installation instructions provided with the accessory kits TP 6809 11 13 Section 1 Installation Instructions 27 1 5 Engine Starting Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING 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 gases Explosion can cause severe injury or de
89. ontroller s battery charger Connectto a circuitthat is supplied by the utility source and backed up by the generator See Section 1 4 5 for more information about the utility power requirement 5 For transfer switch communication and or engine start connection see Section 1 4 7 6 For connection of the optional programmable interface module PIM and or load control module LCM see Section 1 4 9 7 Install an AC receptacle for the optional block heater if equipped Power to this receptacle must be available when the generator set is not running 20 Section 1 Installation Instructions 8 Ifthe OnCue Generator Management System will be used with the generator set run category 5E network cable from the generator set to the customer s router or modem Note Installation of the network cable at the time of generator set installation is highly recommended Installingthe Ethernet cable now will make connection much easier if you choose to add OnCue later a Route the network cable with other low voltage signal wiring for example the RBUS communication leads or engine start leads to the transfer switch in separate conduit from the AC load leads Ifthe network cable is longer than 100 meters 328 ft use a repeater or switch b Use an RJ45 inline coupler to connect the Ethernet cable to the cable in the customer connection box The inline coupler is included with the OnCue kit 1 4 7 Automatic Transfer Switch C
90. ore dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board Category 5 network cable circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour TP 6809 11 13 cfm CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL DVR E2PROM E emer ECM EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ER ES ESD est E Stop etc cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also De
91. r com or another website 4 After verifying the connection through the network cable disconnect the network cable from the laptop and turn the laptop wireless connections back on 38 Section 2 Accessories Connect to the Ethernet cable in the customer connection area of the generator set See Figure 2 6 Use an RJ45 inline coupler provided with the OnCue kit to connect the customer s Ethernet cable to the cable in the customer connection box 1 Connect to Ethernet cable in customer connection box Figure 2 6 Network Connection for OnCue TP 6809 11 13 Section 3 Generator Reconnection 3 1 Voltage Reconnection The reconnection procedure explains voltage reconnections only Do not attempt to change the frequency e g from 60 Hz to 50 Hz in the field The following instructions explain the reconnection of 12 lead generator sets In all cases follow the National Electrical Code NEC guidelines Reconnect the stator leads of the generator set if a different output phase or voltage is desired Refer to the following procedure and the connection schematics Follow all safety precautions at the front of this manual and in the text while performing this procedure Note Order voltage reconnection decal 246242 from an authorized service distributor dealer and affix decal to generator set after reconnecting to a voltage different than
92. r switch must be connected To set a loaded exercise on a generator set connected to a transfer switch other than a Model RXT use the transfer switch controller to set the exercise Refer to the transfer switch operation manual for instructions The controller must be in automatic mode for the exerciser to operate as scheduled Press AUTO to place the generator set controller into automatic mode Section 1 Installation Instructions 33 1 10 Operation Tests week to keep the generator set in good operating condition See TP 6710 Operation Manual for WARNING instructions to set the date and time and set the exerciser 4 Press the RUN button on the generator set controller to start the generator set Hazardous voltage Moving parts 5 Use a digital voltmeter DVM to check the output Can cause severe injury or death voltage from the generator set If voltage calibration is required refer to Section 3 5 for instructions Operate the generator set only when all guards and electrical enclosures are in place 6 Press OFF to stop the engine Then press AUTO on the RDC2 controller 1 Verify that all guards are in place Install the enclosure s end panels and nonservice side door 7 Installthe enclosure sservice side door Verify that all enclosure doors and panels are installed Lock 2 Check the items in the Prestart Checklist in the the enclosure doors to prevent unauthorized generator set operation manual access
93. rator setto the RXT PIM and or LCM use the second pair in the two pair communication cable for short runs or use 12 14 AWG cable for longer runs as shown in Figure 1 13 The maximum cable length depends on the number of optional modules connected A module can be a Model RXT transfer switch a load control module LCM or load shed kit or a programmable interface module PIM See Figure 1 13 for the maximum cable lengths for 1 2 or 3 modules per cable run Note the shield connections shown in Figure 1 14 Maximum length per run meters ft Cable Size for PWR and COM Connections 20 AWG Belden 9402 or equivalent two pair Indoor or Outdoor Installation Indoor Number of Modules ATS PIM and LCM per Run 1 Module 200 2 Modules 31 100 3 Modules 67 20 AWG Belden 1075A or equivalent two pair Outdoor 200 31 100 67 14 AWG 152 500 400 12 AWG 500 152 500 500 Use 12 or 14 AWG cable for PWR and COM connections only For RBUS connections A and B always use shielded twisted pair communication cable Figure 1 13 Total Cable Lengths with Accessory Modules TP 6809 11 13 Section 1 Installation Instructions 23 1 4 9 System Connections with Accessory Modules See Figure 1 14 through Figure 1 18 for connection options with up to three accessory modules Accessory modules can include one Model RXT transfer switch
94. s WOUi 135340 0 8 SVH 135 13S 3 1 40 QN3 19 3 JHL WOH4 1334 ISV3 l LY SI ONINAdO 3H4NLONYLS YVTIWIS HO HOOQ LN3A MOQNIM LS3HV3N FHL 31V9389NOD 41dOdd 3U3HM SVJHV u3HlO YO 9011 4 Sv3uv AVld LV Q3LOJHIQ LON SI LSNVHX3 2 3W8NLONHLS FHL OL HO WOH4 AVMY Q3WIV SI LSNVHX3 I S3NI 130109 1 19 6 jlON 335 8 JION 335 3JION 335 000 ais 32 835 6 JION 335 8 JlON 335 ALON 335 8 JION 335 3unionuls Q3ldn5350 3HNLONHLS Q3ldf220 310N 335 N 200 3015 331 835 E 41ON 335 34NLONHLS 31 20 48NLONHLS 03 2330 Drawing 60RCL ADV 8545 Sheet 2 of 2 imension Figure 4 11 D 61 Section 4 Diagrams and Drawings TP 6809 11 13 Y6ST W9 waga VIF ERI zez S 6655 0 8 8 SRO i 34 0 S WwAOMddV ON 083 ONIAIM Avsovid 10 097 SNOOWII m 193538 289 NOUNGAM HO NOISJA 40 TW ory ww 539 o rox MOM O2 83116 HLM Ni 09 Ni Ld3OX3 GASN 38 LON GNY AnisdoHd 02 UTIHOM SI NYLIQ ANY NOIS3O NI ONMAYMO SIKI HSINI4 32 38 oso F XX G 8G AQV Np 4 2 7 5379 oko FR VSN vvOCG IM NATHOM SWALSAS N3MOd 2 335 SNOILO3NNOO p 34V SJONYATIOL 4 o aa 1H
95. s inside the junction box Refer to the wiring diagrams in Section 4 8 7 Connection details Access panel removed Section 1 Installation Instructions 19 Generator Set Connections Use separate conduit for the power cables and the low voltage communication or engine start leads Local codes and the length of run as well as the transfer switch wire size requirements will determine the wire size needed for the AC leads Note Some codes require the use of a disconnect switch Check the code requirements for your location and install a disconnect switch if required 1 Route the load leads into the junction box through the access opening in the bottom of the box Connectthe load leads from the line circuit breaker in the generator set junction box to the transfer switch emergency power connection points See Figure 1 10 and refer to transfer switch installation manual for ATS connection instructions 2 Connect the neutral LO and ground GRD leads from the ATS and the main panel to the corresponding lugs in the connection box See Section 1 3 5 for grounding information 3 Cutor punch openings in the side of the connection box for the 120 VAC power supply leads and the low voltage connections See Figure 1 10 Use separate conduit for the power leads and the low voltage leads 4 Connect utility power for the c
96. t Have the fuel supplier install a larger gas meter if necessary 3 Determine the fuel pipe size as described in Section 1 6 1 4 Have your fuel supplier install a manual fuel shutoff valve and rigid gas piping Bring the pipe to within 254 mm 10 in of the generator set fuel inlet location 5 Remove the enclosure door on the service side of the unit 30 Section 1 Installation Instructions 6 Connect the fuel supply a Apply pipe sealant that is approved for fuel connections to the threaded fuel connections b Use a section of flexible fuel line to connect the fuel supply to the 1 in NPT fuel inlet connection on the generator set See Figure 1 20 or the dimension drawing in Section 4 for the fuel inlet connection location c Open the manual fuel valves and leak test all fuel connections using soapy water Ifa leak is detected close the fuel valves disconnect the lines at the location of the leak clean the fittings and apply fresh pipe sealant Reconnect the lines and recheck for leaks 7 Verifythatthe fuel system is setup forthe fuel being used natural gas or LP See Section 1 6 4 Note After the system installation is complete check for fuel leaks with the generator set running GM78523 1 Fuel solenoid valves 2 2 Fuel inlet connection Figure 1 20 Fuel Supply Connection Location generator set enclosure not shown TP 6809 11 13 1 6 4 Fuel Conversion Procedures Note The Integrated
97. tdoors The exhaust systems on enclosed units are designed for outdoor installation only Note DO NOT install these generator sets inside a building Note Install carbon monoxide CO detector s on each level of any building adjacentto a generator set Locate the detectors to adequately warn the building s occupants of the presence of carbon monoxide Read and follow the safety precautions in this manual and observe the decals on the equipment Refer to the diagrams and drawings in Section 4 for dimensions and electrical connections during the installation procedure Read the entire installation procedure and obtain the accessories and tools needed before beginning installation Perform the steps in the order shown To install optional accessories follow the instructions provided with each kit TP 6809 11 13 Section 1 Installation Instructions A WARNING 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 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 c
98. ter milli 1 1000 mega 108 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQmilliohm MOhm MQmegohm MOV MPa mpg mph MS ms nat gas NBS metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards 68 Appendix NC NEC NEMA NFPA Nm NO no nos NPSC NPT NPTF NR ns OC OD OEM OF opt OS OSHA OV 02 Pp PC PCB pF PF ph 2 PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RBUS RDO ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot rpm RS RTDs normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcr
99. the nameplate A WARNING D KS 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 TP 6809 11 13 Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Movethe generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place 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 equipm
100. tion ofthe utility voltage and frequency at the generator set controller e Allows adjustment of transfer switch transfer time delays from the generator set controller Generator Set G B A 1 A 3 4 RBUS communication connections for a Kohler Model RXT transfer switch One Model RXT transfer switch can be connected to the generator set See Figure 1 11 Use shielded twisted pair cable to connect P10 1 through P10 4 on the transfer switch interface module to the generator set terminal block connections A B PWR and COM See Section 1 4 8 for communication cable recommendations and maximum cable length Note Connections 3 and 4 on the generator set are not used with the Model RXT transfer switch Interface Board on the Model RXT Transfer Switch 4 RXT WOO MMd 8 WOO MMd 8 sngM Old Note Generator set terminal block connections 3 and 4 are NOT USED with the Model RXT ATS Customer connection terminal block See Figure 1 10 for location Check the decal on the generator set for terminal block connections Connect one end of each cable shield to GROUND at the generator set See Figure 1 13 for cable specifications Leave the end of each cable shield disconnected at the last device If accessory modules PIM or LCM are connected see Section 1 4 9 Figure 1 11 Model RXT Transfer Switch Communi
101. tion 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 Engine Backfire Flash Fire A WARNING Gh 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 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 Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed 6 Safety Precautions and Instructions 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 A WARNING Carbon monoxide Can
102. ure 3 7 Voltage Calibration TP 6809 11 13 Reset Calibration No j Reset Calibration Yes tp6811 Section 3 Generator Reconnection 47 3 5 2 Calibration Using SiteTech Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 controller Connect a personal computer laptop to the controller using a USB cable and follow this procedure to use Kohler SiteTech software to calibrate the controller The voltage calibration factors are located in the Genset Calibration group in SiteTech Find the parameter labelled Genset Calibration Factor Voltage L1 L2 See Figure 3 9 Note A digital voltmeter is required for these adjustments 1 With the generator set off connect a digital multimeter to measure output voltage across L1 and L2 Set the meter to measure AC volts 2 Startthe generator set by pressing the RUN button on the RDC2 controller 3 Compare the voltage reading on the digital voltmeter to the voltage displayed by the controller 4 If the voltage displayed on the controller does not match the measured voltage use the equation in Figure 3 8 to calculate a new value for Genset Calibration Factor Voltage L1 L2 5 Type the new value for Genset Calibration Factor Voltage L1 L2 into SiteTech and click on Apply Changes See Figure 3 9 6 Allow a few seconds for the controller to adjust to th
103. utsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator EEPROM electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext I O IP ISO J JIS k K kA KB KBus kg exhaust external Fahrenheit female flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour
104. viations that may appear in this publication A amp ABDC AC AID ADC adj ADV Ah AHWT AISI ALOP alt AI ANSI AO APDC API approx APU AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CAT5 CB CC 66 CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International bef
105. wings in Section 4 Refer to the generator set dimension drawings for conduit and fuel line placement The drawings give dimensions for electrical and fuel connection rough ins and stub ups TP 6809 11 13 1 3 3 Vibration Isolation The generator set is equipped with neoprene vibration isolators Connections between the generator set or its mounting base and any conduits or fuel lines must include flexible sections to prevent breakage and to isolate vibration 1 3 4 Prepare Site Choose a location that is at least 0 9 m 3 ft from any building or structure and near the incoming gas service Allow a minimum of 2 4 m 8 ft clearance beyond the exhaust end ofthe generator set Planthe installation so that the exhaust outlets of the generator set are not directed toward the building or any openings where exhaust gas could be drawn into the building 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 1 Obtain a building permit and contact your local utility companies to mark the locations of underground pipes and cables 2 Prepare an area for mounting the generator set a Clear all combustible materials including plants and shrubs building materials and lawn TP 6809 11 13 furniture from an area at least 2 4 m 8 ft beyond the exhaust outlets of the generator set b Spr
106. write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer simple mail transfer protocol serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency user interface Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal uniform resource locator web address undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with write only without weight transformer TP 6809 11 13 TP 6809 11 13 Notes 69 70 Notes TP 6809 11 13 TP 6809 11 13b
107. y 6328861104 19111131 9NIMVH MIN wa SOISINTG 345 75 189806 971 T3431 NOISIAGN 804 ON LUYA 335 SOMO 3 1504803 NO 6 jlON 335 000 3015 33 359 L 340 335 9N11002 HOLVH3N39 3408 4 38 5 3 OL 1334 40 3ONVISIQ WAWINIW Y 3 3 OL 34N 38 IWIYJLYW 8 19 YVAN SNOILYTIVLSNI YO4 Iviu3lvW J31I8ILSNAWOO V 1333 15 3 lv 18 QINOHS JONVISIG SIHL 831 15 S3NIGUNI SVO ANY S3NION3 NOI LSNAWOJ AUVNOIIVIS 40 35 ANY NOIIVTTIVISNI JHL 803 SQUVONVIS LE VddN S3009 1v201 GNV 31VIS NO 1N30N3d3Q SI 38 123 815 V WOY 3ONVISIQ Q3QN3NWOO3H FHL ALON 8000 3015 331 835 6 JION 335 N Pam 310N 33S 8 JION 335 310N 335 WOHd4 1334 9 I1SV3 LV 3uv 2313 3unliNund Ollvd 91 3JAILISN3S 6 v3uv 13Avu9 NI SATGILSNGWOD HJHLO HO SBANHHS SINV Td ON 131100 LSNYHX3 WOHJ 14 v QN3LX3 OL 038 T3AVH9 8 Q33M 53015 NO 13SN39 QNOA38 9 9NIQN31X3 AYd 313HONOO YDIHL v 13S 40 QN3 LSNVHX3 Wodi 1334 01 1SY31 LV 38V S3MVINI HVTIWIS H3HLO QNV 33 8 3 Q3s010 34V STIVM IN3OVfOV NO SHOOQ SMOQONIM 3unionsuls WOUi 135340 0 8 SVH 135 13S 3 1 40 QN3 19 3 JHL WOH4 1334 ISV3 l LY SI ONINAdO 3H4NLONYLS YVTIWIS HO HOOQ LN3A MOQNIM LS3HV3N FHL 31V9389NOD 41dOdd 3U3
108. y be part of multimeter e Manometer for measuring fuel pressure e Torque wrench e Wrenches e Screwdrivers e Socket wrenches or nut drivers e Pliers e Safety glasses or goggles e Drill with bits and hole saw Installer Customer Supplied Items e One BCI group 24 size 12 volt battery with a minimum rating of 630 cold cranking amps CCA at 0 F Gravel or crushed stone Concrete mounting pad Cables and conduit Fuel supply line with shutoff valve and pipe sealant provided by fuel supplier e Carbon monoxide CO detector s Available Accessories e Battery Battery heater Block heater Flexible fuel lines Programmable Interface Module PIM See TT 1584 for installation instructions e Load Control Module LCM See TT 1574 for installation instructions e OnCue Home Generator Management System requires Ethernet cable connection to your router 12 Section 1 Installation Instructions 1 2 Lifting Generator Set A WARNING 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 The approximate weight of the generator set with enclosure is shown in Figure 1 1 Use equipment that is rated for the generator set s weight to lift the unit into place Lift the enclosure and generator set together as one unit Model Weight kg Ib 789 1740 862 1900

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