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1. 2 line LCD display Up button Select button Down button RUN button and LED Generator power available LED Generator supplying power to the building LED Utility supplying power to the building LED Utility power available LED OFF button and LED AUTO button and LED These LEDs operate only if a Model RXT transfer switch is connected 1 2 3 4 5 6 7 8 9 10 k GM77569 Figure 3 2 RDC2 User Interface Section 3 RDC2 Controller Operation 27 3 2 1 Controller Keypad The Run Off and Auto buttons control the generator set as described in Figure 3 3 Use the Select Up arrow and Down arrow buttons to navigate through the menus and change settings if necessary See Section 2 4 for operation instructions Button Function 3 2 2 LED Indicators LEDs above the RUN OFF and AUTO buttons indicate the mode of operation as shown in Figure 3 3 The RDC2 controller also has a set of power system LEDs below the pushbuttons The power system LEDs indicate which power sources are available and which source is supplying power to the building based on the position of the Model RXT transfer switch See Figure 3 2 Note The power system LEDs operate only if a Model RXT transfer switch is connected They will not operate if a Model RDT or RSB transfer switch is used Starts the generator set The engine start time delay is ignored
2. Check PCV valve hose and fittings Replace PCV valve if equipped Check belts and belt tension Inspect vacuum lines and fittings LUBRICATION SYSTEM Check engine oil level Change engine oil and filter AIR INTAKE SYSTEM Inspect and clean air cleaner element Replace air cleaner element Check air induction for leaks Check intake manifold for vacuum leaks COOLING SYSTEM Check coolant level Inspect and clean radiator exterior Replace engine coolant Inspect coolant hoses ELECTRICAL SYSTEM Check battery charge and fluid level x Inspect electrical system Clean battery cables EXHAUST SYSTEM Inspect exhaust manifold for leaks Inspect exhaust piping for leaks Inspect catalyst inlet and outlet if equipped Check HEGO oxygen sensor connections FUEL SYSTEM Replace fuel filter S Check fuel shutoff valve for leaks and function Check fuel regulator pressure Test fuel lines for leaks Inspect drain vaporizer for oil buildup IGNITION SYSTEM Check spark plug wires Clean secondary ignition coil wires Replace distributor cap and rotor 3 0 5 7 L Replace spark plugs X Replace spark plug wires Check engine coolant condition and protection hoses and clamps annually prior to cold weather More frequent int
3. 0 00 c cece eee 51 4 6 2 Cooling System Inspection 00 cece 52 4 6 3 Draining Cooling System 0 0 cece ee 52 4 6 4 Flushing and Cleaning 0 0 cece eee ete eee eee aes 52 4 65 Filling Cooling System 00 cece cette 52 47 Ignition System ia needa eddies Cni be Ma edat DS 53 4 8 Battery a voce UTE bate ERIT ew PETI HE a ede dre d Pere E Ron EE 54 4 9 Storage Procedure issuer sk xd uer evel a e v TIN PIS 55 Section 5 Troubleshooting 000 ccc eee een hn 57 DT Introduction esee ket net Mapes PATE fige t e bertil 57 5 2 Controller Service Access 0 ttt enn 57 5 3 Fault Messades edo enti Av be XV iA uei qu ilem d swivel 57 5 4 Circuit Protection cose ever kx e 57 5 4 1 Line Circuit Breaker ssssssssssseee ee 57 5 4 2 FUSES o6jsll E DPI ad RERUM de EHE ee 57 5 4 3 Controller Internal Circuit Protection 0 00 cece eee 57 5 5 Generator Set Troubleshooting 00 cece eee eee 58 5 6 Controller Troubleshooting ssssssseeess eI 59 Appendix A Abbreviations ooooocoonccccnn eee hh hh nnn 61 4 Table of Contents TP 6810 6 12 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
4. A NY Engine gt Eng Speed Metering E 1800 RPM Genset Status Standby Voltage 240V Freq 60 0Hz Engine 95F Oil 40 PSI Y 12 3V Engine Runtime 27 4h Y Date 02DEC2011 Time HR MNpm Y Next Exercise 09 00p 09Dec2011 Y Next Maintenance 150 h or Mar2012 Y SW Version 4 03 lt Return Ol A Z ES Oil Pressure 40 PSI y Coolant Temp 73F i Oil Temp 73 F Battery Return Figure 3 10 Engine Metering Menu tp6809 Figure 3 9 Overview Menu TP 6810 6 12 Section 3 RDC2 Controller Operation 33 3 10 Generator Metering Menu Voltage Calibration The generator metering menu displays the generator DANGER kaS voltage and frequency See Figure 3 11 The voltage calibration mode can be entered from the generator metering menu Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel The voltage calibration mode can be entered from the Generator Metering menu Contact a Kohler authorized distributor dealer for service The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration if nece
5. Lights when generator power is available Building on Generator Power switch Lights when the building load is connected to generator power through the RXT transfer These LEDs operate only if a Model RXT transfer switch is connected Figure 3 4 RDC2 Controller LED Operation 28 Section 3 RDC2 Controller Operation TP 6810 6 12 3 2 3 LCD Display The controller is equipped with a two line x 16 character backlit liquid crystal diode LCD display with adjustable contrast When the generator is running the controller automatically scrolls through the displays shown in Figure 3 5 When the system is in AUTO the LCD display scrolls through the status messages shown in Figure 3 6 When a fault or warning condition exists the controller will show the corresponding message See Section 2 6 for more information on fault and warning messages Controller menus display power system information including status information for the engine generator and optional RBUS accessories exercise settings and event history Some menus allow changes to the controller settings See Sections 3 6 through 3 19 for menu diagrams Active Alert Y Genset Status Running f Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure 40 psi Y 12 3V Battery Engine Runtime 27 4h Y Date 02DEC2011 Time HR MNpm Sample data shown tp
6. Operation Residential Light Commercial Generator Sets KOHLER POWER SYSTEMS Model 38RCL 48RCL Controller RDC2 NATIONALLY REGISTERED TP 6810 6 12a California Proposition 65 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 6810 6 12 Table of Contents Product Identification Information 00 cece eee eee hh nn 2 Safety Precautions and Instructions 0 0 cece cece eee nnn 5 Introduction 2a estos a
7. Stops the generator set The cooldown time delay is ignored During the engine crank cycle pressing OFF will stop the crank cycle Press OFF to clear faults and reset the controller AUTO Places the generator set in Automatic standby mode Down arrow Up arrow Figure 3 83 Pushbutton Operation LED Operation Use to navigate through menus and change settings This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller Lights when the generator set has been started locally by pressing the RUN button Remote start and stop commands are ignored not run Lights for 2 seconds then flashes every 2 seconds when the generator set and controller are off Remote start stop commands have no effect The exercise cycle will In Auto mode OFF LED flashes quickly to indicate a fault shutdown Attention required Identify and correct the fault condition before resetting the controller Lights when the generator is in automatic standby mode Generator set will respond to engine start and stop commands from the controller for example exercise start and stop commands an ATS or OnCue Time delays operate as described in Section 2 4 Utility Power Available Lights when utility power is available Building on Utility Power Switch Lights when the building load is connected to utility power through the RXT transfer Generator Power Available
8. industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 219 bytes Kohler communication protocol kilogram Appendix 61 kg cm kgm kg m kHz kJ km kOhm KQ kPa kph kV kVA kVAR kW 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 meter 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 22 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 MO
9. 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 Disconnectthe power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery 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 electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous
10. Y E Return Reset Calib Yes Figure 3 15 ATS Status Menu with Calibration TP 6810 6 12 Section 3 RDC2 Controller Operation 37 3 15 ATS Configuration Menu Note The ATS Configuration menu appears only if a Model RXT transfer switch is connected Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays and change the settings if necessary Changing ATS Configuration Settings To enable editing press the select button The value flashes to indicate that it can be changed Press the up and down arrow buttons to change the value Press the Select button to save the value shown Use the up and down arrow buttons to move to the next value to be changed Repeat the adjustment process until all values are correct Press the down arrow until Return is displayed Press the select button to return to the main menu 38 Section 3 RDC2 Controller Operation ATS gt Configuration A Normal Freq 60 0 Hz j Normal Voltage 240 0 V Emerg Freq 60 0 Hz i Emerg Voltage 240 0 V Emerg Engine Start 3 sec Transfer From Normal 3 sec f Transfer From Emerg 120 sec 1 Return Figure 3 16 ATS Configuration Menu tp6810 TP 6810 6 12 3 16 Date and Time
11. for conditions that may indicate a blown fuse Obtain replacement parts and service from an authorized Kohler distributor dealer Fan Fuses Three 30 amp fan fuses are located in the fan fuse and relay box See Section 1 Service Views for location Engine Fuses Engine fuses are located in the engine fuse box See the service views in Section 1 for the fuse box location e Fuse F1 5 amps e Fuse F2 ECM 10 amps e Fuse M3 battery charging alternator 70 amps e Fuse F4 ignition 15 amps e Fuse F6 starter 20 amps 5 4 3 Controller Internal Circuit Protection The controller is equipped with internal circuit protection Press OFF to reset Section 5 Troubleshooting 57 5 5 Generator Set Troubleshooting Figure 5 2 contains generator set troubleshooting diagnostic and repair information Check for loose connections before replacing parts Problem The generator set does not crank Possible Cause Battery weak or dead Corrective Action Recharge or replace the battery Battery connections reversed or poor Check the connections Blown fuse s Replace the fuse Contact an authorized Kohler distributor dealer for service if fuse blows repeatedly Generator set is OFF Press the RUN button to start the engine or press AUTO to allow remote starting The generator set cranks but does not start starts hard lacks power or operates erratically Air cleaner clogged Clean and or
12. 12 Genset Run Time Menu ooo 35 TP 6810 6 12 Table of Contents 3 Table of Contents continued 3 13 Genset System Menu 0 oo 36 3 14 ATS Status Menu ize iau e RR deine RR dad deeded gee Lees 37 3 15 ATS Configuration Menu sssssssseees eee e eens 38 3 16 Date and Time Menu 0 0 ect e ene eee 39 3 17 Networking Information Menus 0000 cece cette teen eens 40 3 17 1 Networking Status Submenu 0 eee 41 3 17 2 Networking Configuration Submenu OnCue Password 42 3 17 3 RBUS Information Submenu 0 es 43 3 17 4 Remote Devices Submenu 0c ees 44 3 18 Programmable Interface Module PIM Menus 00e eee e eee 45 3 19 Load Control Module LCM Menus s seen I 46 Section 4 Scheduled Maintenance ooooooocccccnncc eens 47 4 1 General Maintenance 0c 47 4 2 Service Schedule rnanan eaa a o e eee nes 48 4 3 Lubrication System o oooocococoooorn eet tenn eens 49 4 3 1 Oil Specifications licis 49 43 2 Oll Gheck 1 b bes dd bal eddy eU by ERR USES 49 4 3 3 OiL Additions ii o ka a ea a a l emebsCw dels 49 43 4 Oil and Filter Change sssssssess eens 49 4 4 AiPGleaner s cm iex adds 50 4 5 EXhaust SySteM xis xiwenpbhid4shbedd d due deed det pb dapidus 51 4 6 Cooling System issssssssssseese e tte eeeeneeee 51 4 6 1 Checking and Filling Coolant
13. 22 2 6 1 Warnings eese mc need dad eni a ae IU ade 22 2 02 Sh tdOWlnS educan deta ERR ER eru Rc Ru V latas 22 2 6 8 ATS Communication Errors sees 22 2 6 5 Resetting the Controller after a Fault Shutdown 22 2 6 5 EventibOg iis Sate px i EAE RIGEN RR AR CREAR 25 2 7 Model RXT Transfer Switch Operation 0 cece eee 25 2 7 1 Source Availability clie 25 2 7 2 ATS Control Sequence of Operation oooocccccccccco 26 2 23 Mime Delays occ vhs E Ven E mt om dos 26 2 7 4 ATS Load Control Relay Time Delay ssseeeeeeeees 26 Section 3 RDC2 Controller Operation oooocccccccoccnnn nnn nnn 27 3 1 RDC2 Generator Set Transfer Switch Controller oooocccoo ooo 27 3 2 Controls and Indicators ooooooocoorrccn etn 27 3 2 1 Controller Keypad o ooocococcooocco e 28 3 2 2 LED Indicators ios iria tral e DER Peg 28 3 23 LOD Display i see eR RR PERO UI RP whee cd 29 3 3 Controller Power sssssssssseee Ihn 30 3 4 Battery Charging 00 c cece rr 30 3 5 Changing Settings aasan anneanne 30 3 6 Controller Menus cocoa ra pr ias 32 3 77 Main Menu rta AAA 32 3 8 Overview Menu ooocccccccccccc hee 33 3 9 Engine Metering Menu sssssssssssssss s 33 3 10 Generator Metering Menu sssssssssssss eet e eens 34 3 11 Generator Set Information Menu s sess 35 3
14. Blown fuse s Replace the fuse If the fuse blows again contact an authorized Kohler distributor dealer Overspeed shutdown Reset the controller If the overspeed fault occurs again contact an authorized Kohler distributor dealer Generator set is OFF Press the RUN button to start the engine or press AUTO to allow remote starting Remote stop command received from a remote switch ATS or OnCue Check the remote switch position Engine malfunction Contact an authorized Kohler distributor dealer Fans run after engine shuts down The fans continue to run for 2 minutes after the engine shuts down to evacuate the engine compartment Figure 5 2 General Troubleshooting Chart 58 Section 5 Troubleshooting None TP 6810 6 12 5 6 Controller Troubleshooting Figure 5 3 contains basic troubleshooting information for the RDC2 controller Problem Possible Cause Controller LCD Low or no battery voltage display is off Corrective Action Check connections Check generator set battery See Figure 5 2 Controller display Backlight turns off after about 1 minute with no backlight is off activity Backlight will turn on when a button is pressed or the generator set starts Loss of Bad connections communication to accessory modules Check wiring and connections Verify that cable size and length of run comply with the instructions in the Installation manual Low
15. Changing the Exercise Setting Setthe date and time on the controller before setting the exercise schedule Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks Follow the procedure below and see the flowchart in Figure 2 3 to setthe exercise time and date mode and frequency Procedure to Change the Exercise Setting 1 Press the AUTO button on the controller 2 Press the Select button to go to the main menu See Figure 2 2 3 Press the down arrow button to step to the Genset System menu 4 Pressthe Select button to enter the Genset system menu See Figure 2 3 TP 6810 6 12 5 Use the down arrow button to step to the next Exercise menu 6 Press the Select button The setting flashes to show that it can be changed For example the hour flashes to show that the hour can be changed 7 Press the UP or Down arrow buttons to change the setting 8 Press the Select button to save the setting and move to the next For example save the hour setting and move to minutes 9 Repeat steps 5 through 8 to change the next item on the line until the desired settings are displayed 10 Press Select to save after all settings have been selected Settings will stop flashing 11 Ifthe generator setis connected to a Kohler Model RXT transfer switch the exercise can be changed to a loaded exercise Set the Exercise Mode to loaded full speed unloaded full speed or unloaded cyc
16. Menu The date and time will typically be set at controller power up To change the date time or time format 12 hour or 24 hour use the Date and Time menu See Figure 3 17 Date and Time Date A 02Dec2011 NA Time 12 34pm Time Format 12hr 24hr Return 1p6810 To change the date and time press the Select button See Figure 3 7 for instructions Figure 3 17 Date and Time Menu TP 6810 6 12 Section 3 RDC2 Controller Operation 39 3 17 Networking Information Menus System RBUS is a proprietary RS 485 communication protocol Use the networking menus to view and adjust communication settings for systems with remote RBUS The Networking Information menu leads to submenus devices such as a PIM or LCM and for systems that use for network and RBUS communication settings the Kohler OnCue Home Generator Management Networking gt Networking gt Information Status x a See Figure 3 19 Networking gt See Figure 3 20 Configuration RBUS gt Information Return See Figure 3 21 tp6810 Figure 3 18 Networking Information Menu 40 Section 3 RDC2 Controller Operation TP 6810 6 12 3 17 1 Networking Status Submenu The Networking Status submenu contains settings for OnCue See the OnCu
17. Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 TP 6810 6 12 China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 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 803315972 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 863 701 7131 Service Assistance 11 Notes 12 Service Assistance TP 6810 6 12 Figure 1 1 OMANDAARWN Section 1 Service Views o INN Nameplate location Engine fuses Engine ECM and EPR electronic fuel pressure regulator Oil check dipstick See cooling system detail Exhaust outlet Enclosure locking tool shipping location only Spark plugs Block heater connection valve Block heater optional Fuel inlet 1 in NPT Fuel solenoid valves two required for UL 2200 Customer load lead access Customer connection access panel Line circuit breaker Generator set master control buttons on RDC2 controller TP 6810 6 12 Ex E R 3 E 3 R 3 A E E pue GM83070 ADV 8494 Cooling Syst
18. RDC2 Controller 1 Press the Select button to enter the main menu Overview Display 12h 2 Press the down arrow button until the desired menu is displayed See Figure 3 8 Date and Time are used for this example Date gt Press Display and Time 3 Press the Select button to enter the Date and Time menu Date 05Dec2011 Display 4 To change the date and time settings press the Select button again The year will flash Displ Date isplay pay 05Dec2011 5 Press the up or down arrow buttons to change the year ZN Date Display pay 05Dec2012 DA 6 When the correct year is shown press the Select button The year is saved and the next setting month flashes Display Date pay 05Dec2012 7 Repeat steps 5 and 6 using the arrow and select buttons to set the month and the date Figure 3 7 Changing Settings TP 6810 6 12 8 When the correct date is shown press the Select button The saved date is shown Display Date 2 pay 03Jan2012 9 Press the down arrow button to step to the next menu Press Time Display 01 49pm 10 Repeat steps 5 and 6 using the arrow and select buttons to set and save the time Note To change from am to pm press the up arrow ke
19. Rec conn cont CPVC crit CSA CT Cu cUL CUL cu in cw CWC 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 Deutsche 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 Environ
20. Replace the spark plug Section 4 Scheduled Maintenance 53 10 Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap See Figure 4 10 Position the side electrode directly over the center electrode Figure 4 10 Spark Plug Gap Adjustment 11 Reinstall the spark plug Do not bump the electrode against the cylinder head Rotate the spark plug clockwise until you feel resistance 12 Use a torque wrench to torque each spark plug to 25 Nm 18 ft lbs Otherwise hand tighten the spark plug until you feel resistance 13 Use a ratchet wrench to final tighten an additional 1 4 turn Do not overtighten as doing so may strip the threads or alter the electrode gap setting 14 Checkthe spark plug wire connector in the boot for accumulated dirt grease and other debris and clean as necessary 15 Firmly push the spark plug boot onto the spark plug 16 Reconnect the generator set engine starting battery negative lead last 17 Reconnect the power for the battery charger 54 Section 4 Scheduled Maintenance 4 8 Battery Consult the battery manufacturer s regarding battery care and maintenance instructions 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 Battery electrolyte is a diluted sulfuric acid Battery acid can caus
21. Section 3 RDC2 Controller Operation TP 6810 6 12 3 17 3 RBUS Information Submenu The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol following optional modules o This includes the Networking gt Information Networking gt Status A Ed ESI Networking gt Configuration l e Model RXT transfer switch e Programmable e Load Control M RBUS Information 1 Modules Connected 3 Return MIA Remote gt Devices y Net Cycle Time Interface Module PIM odule LCM See Figure 3 22 123ms Module Timeouts 1234 Module Errors 1234 Figure 3 21 RBUS Information Submenu TP 6810 6 12 lt Return Section 3 RDC2 Controller Operation 43 3 17 4 Remote Devices Submenu Check the status of remote devices communicating through RBUS Device types can include e Model RXT ATS e Programmable interface module PIM e Load control module LCM S N XXXXXXXXX lt lt DeviceType gt gt gt S N XXXXXXXXX lt lt DeviceType gt gt y Device Status Connected a i Comm Errors 12345 i Comm Timeouts 12345 Y Mod
22. black deposits on the insulator shell bore Excessive oil entering combustion chamber through worn rings and pistons excessive clearance between valve guides and stems or worn or loose bearings Replace the spark plug Carbon fouled spark plug Black dry fluffy carbon deposits on insulator tips exposed shell surfaces and electrodes Incorrect spark plug weak ignition clogged air intake overrich fuel mixture or excessive no load operation Clean and regap the spark plug Lead fouled spark plug Dark gray black yellow or tan deposits or a glazed coating on the insulator tip Caused by highly leaded fuel Replace the spark plug Pre ignition damaged spark plug Melted electrodes and possibly blistered insulator Metallic deposits on insulator suggest internal engine damage Wrong type of fuel incorrect timing or advance too hot a plug burned valves or engine overheating Replace the spark plug Overheated spark plug White or light gray insulator with small black or gray brown spots with bluish burned appearance on electrodes Engine overheating wrong type of fuel loose spark plugs too hot a plug low fuel pressure or incorrect ignition timing Replace the spark plug Worn spark plug Severely eroded or worn electrodes Figure 4 9 Engine Evaluation Using Spark Plug Condition TP 6810 6 12 Caused by normal wear and failure to replace spark plug at prescribed interval
23. 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 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 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 fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or s
24. coolant drain valve to drain the cooling system When draining the coolant remove the radiator s pressure cap which will allow the entire system to drain and will prevent air pockets from forming and restricting coolant passage to the block 1 De energize the block heater if equipped 2 Remove the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow through the engine block 3 Open the coolant drain valve and allow the system to drain 4 If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease go to Section 4 6 4 Flushing and Cleaning Ifthe cooling system does not have mineral deposits refill the cooling system as instructed in Section 4 6 5 Filling Cooling System 52 Section 4 Scheduled Maintenance 4 6 4 Flushing and Cleaning For optimum protection drain flush and refill the cooling system at the interval listed in the service schedule Flushing and Cleaning Procedure 1 Flush the system with clean water 2 Drain clean and flush the coolant overflow bottle 3 Refill the cooling system as_ instructed in Section 4 6 5 4 6 5 Filling Cooling System Coolant Capacity L qts With Block Heater 16 5 17 5 19 20 Generator Set 15 16 17 5 18 5 Figure 4 6 Coolant Capacity Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder hea
25. discharge damage Electrostatic discharge ESD damages electronic circuit boards Prevent electrostatic discharge damage by wearing an approved grounding wrist strap when handling electronic circuit boards or integrated circuits An approved grounding wrist strap provides a high resistance about 1 megohm not a direct short to ground TP 6810 6 12 This manual provides operation instructions for Model 38RCL and 48RCL residential light commercial generator sets equipped with the RDC2 generator set transfer switch controller This generator set is approved for use in stationary applications in locations served by a reliable utility power source Have the generator set installed by an authorized Kohler distributor dealer or service technician Refer to the Installation Manual for installation instructions Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment maintenance requirements are very important for safe and efficient operation Inspect the
26. of 5096 ethylene 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 use alcohol or methanol antifreeze or mix them with the specified coolant Section 4 Scheduled Maintenance 51 4 6 2 Cooling System Inspection To prevent generator shutdown or damage because of overheating e Keep the cooling air inlets clean and unobstructed e Inspect the radiator s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins e Check the hoses and connections for leaks and replace any cracked frayed or spongy hoses e Check the condition and tension of the radiator water pump belt s e Check the rubber seal of the radiator s pressure cap and replace a cracked or deteriorated cap Remove dirt and other debris from the pressure cap and filler neck The pressure cap raises the boiling point of the coolant enabling higher operating temperatures If the cap leaks replace it with the same rating type of cap Find the pressure cap rating in Figure 4 5 Pressure cap 97 kPa 14 psi 71 C 160 F Thermostat Figure 4 5 Pressure Cap and Thermostat Rating 4 6 3 Draining Cooling System The radiator contains a
27. of selected loads to the generator set to prevent simultaneous starting of large motors after transfer to the emergency source Recommended for delayed starting of air conditioners Figure 2 8 Time Delays 26 Section 2 Generator Set Operation TP 6810 6 12 Section 3 RDC2 Controller Operation 3 1 RDC2 Generator Set Transfer Switch Controller Model 38 RCL and 48RCL generator sets are equipped with the RDC2 generator set transfer switch controller The RDC2 controls the following power system components e Model 38RCL or 48RCL generator set e Model RXT automatic transfer switch ATS e Load Control Module LCM e Programmable Interface Module PIM RDC2 Controller features include e Two line x 16 character backlit LCD display with adjustable contrast e OFF AUTO and RUN generator set master control buttons e Generator set status indicating LEDs OFF AUTO RUN e Up Down and Select buttons for navigation through menus and adjustments e Power system indicator LEDs to show utility and generator source status and to show which source utility or generator is supplying power to the building 3 2 Controls and Indicators Figure 3 1 illustrates the RDC2 controller Figure 3 2 shows the keypad display and indicators on the controller s user interface TP 6810 6 12 1 User Interface See Figure 3 2 2 Service access USB connection and aux winding breaker Figure 3 1 RDC2 Controller
28. or no battery voltage Check battery connections Check generator set battery See Figure 5 2 LCM relays do not Bad connections operate Check wiring and connections Verify that cable size and length of run comply with the instructions in the Installation manual Low or no battery voltage Check battery connections Check generator set battery See Figure 5 2 Date is flashing Controller power was disconnected and then reconnected Figure 5 3 RDC2 Troubleshooting Chart TP 6810 6 12 Check battery connections See Figure 5 2 Check utility power connection for the built in battery charger Reset the time date and exercise schedule See Section 2 5 6 Setting the Exerciser at Power Up Section 5 Troubleshooting 59 Notes 60 Section 5 Troubleshooting TP 6810 6 12 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP alt Al 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 cc CCA CCW CEC cert cfh ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertisin
29. 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 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 6810 6 12 Accidental Starting A WARNING Pa or 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
30. 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 connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnectthe negative lead last when reconnecting the battery Followthese precautions to prevent starting ofthe generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Bo RE Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation TP 6810 6 12 Section 4 Scheduled Maintenance 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 Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pull
31. set The load is transferred back to the utility source before the generator set shuts down Note With a loaded exercise power to the building is lost for up to 10 seconds during load transfer 18 Section 2 Generator Set Operation For aloaded exercise controlled by the RDC2 controller a Model RXT transfer switch must be connected to the generator set To set a loaded exercise follow the procedure in Section 2 5 7 and select Exercise Type Loaded For a loaded exercise with a transfer switch other than a Kohler Model RXT program the exercise at the transfer switch controller Refer to the transfer switch operation manual for instructions 2 5 4 Power Failure During Exercise If the utility power is lost during an unloaded exercise the ATS transfers to the emergency source the exercise is ended and the control remains in the AUTO mode If the utility power is lost during a loaded exercise the exercise is ended The ATS remains in the emergency position and the control goes into the AUTO mode The generator set continues to run and supply power to the load for the duration of the utility power outage When Utility power is restored the ATS will re transfer to the utility source through normal timing sequences 2 5 5 Exerciser Reset To reset the exerciser to run at a different day and or time or to change the exercise mode follow the procedure in Section 2 5 6 to change the exerciser settings 2 5 6 Setting the Exe
32. severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING 7 Gh 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 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 6 Safety Precautions and Instructions Equip the
33. 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 TP 6810 6 12 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 4 9 Storage Procedure Follow the procedure below when storing your generator set for a long period 3 months or more 1 Start and run the generator set until it reaches operating temperature or about 15 minutes 2 Stop the generator set 3 Change the oil and oil filter see Section 4 3 4 Oil and Filter Change 4 Check the engine coolant Section 4 6 protection see Note Use antifreeze capable of with
34. time of the event and the event description Procedure to View Event History 1 Press Select to enter the main menu 2 Press the down arrow to step down to the event log 3 Press Select to display the most recent event 4 Press the down arrow to step to the next event 5 Use the up and down arrow buttons to view events 6 Press the Select button to exit the event log To stop viewing the event history before the last event press the select button to return to the main menu Date MO DA YEAR Event Log gt __ time HR MN event number W S I engine hours event name Press UP and Down arrow M buttons to scroll through events v ZN Date MO DA YEAR time HR MN event number W S I engine hours event name Press Select button at any time to return to the main menu Event codes W Warning S Shutdown Informational Notice Figure 2 6 Event Log TP 6810 6 12 2 7 Model RXT Transfer Switch Operation The RDC2 generator set transfer switch controller manages automatic transfer switch ATS functions when connected to a Kohler Model RXT transfer switch through the ATS interface board Refer to the Model RXT Operation Installation Manual for information about the transfer switch operation 2 7 4 Source Availability The Model RXT transfer switch supplies voltage sensing data to the RDC2 controller through the ATS interface board If the source voltage falls below the unde
35. 0 V SN System Freq 60 Hz Y VR Voltage Adj 240 0V Y System Phase Single System Battery 12V Next Exercise HR MN PM MM DD YY Next Exercise HR MN PM MM DD YY re E See Section 2 5 7 Changing the Exercise Setting Exercise Mode Unloaded Cycle Exercise Mode None Unloaded Full Sp Unloaded Cycle Loaded Full SP T Y Y Exercise Freq Weekly Exercise Freq Weekly Every Other Week Y u Meas System English I Contrast 50 Y Return f the exerciser has not been set No Exercise Sch will be displayed Figure 2 3 Procedure to Set the Exerciser TP 6810 6 12 1p6809 Section 2 Generator Set Operation 21 2 6 Faults Selected fault conditions are shown in Figure 2 5 Fault conditions are classified as warnings or shutdowns If a fault occurs that is not listed in the table contact an authorized distributor dealer for service If a programmable interface module PIM is connected to the generator set controller additional faults can be activated by customer supplied equipment See TT 1584 Installation Instructions for the Programmable Interface Module for available inputs and outputs 2 6 1 Warnings The contro
36. 15Dec2011 Y Exercise Mode Unloaded Cycle Exercise Freq Weekly Meas System English Contrast 50 y Return Figure 3 14 Genset System Menu tp6810 TP 6810 6 12 3 14 ATS Status Menu ATS menus appear if a Model RXT transfer switch is connected to the generator set If no transfer switch is connected or another model ATS is connected to the engine start connections Remote ATS is displayed on the ATS Status screen ATS Status o y A The ATS Status menu displays Model RXT transfer switch and source information The voltage shown in these menus can be calibrated Contact an authorized distributor or dealer for service if calibration is required Note If there is no Model RXT transfer switch connected to the generator set ATS Position Normal Remote ATS is displayed and the other screens on this page do not appear A LLA Normal Status Not Acceptable A v Emerg Status Standby Single phase Three phase y y Voltage Voltage L1 L2 t Frequency 60 0 Hz 240V t Voltage L2 L3 A 240 V p Voltage L3 L1 240V Frequency 60 0 Hz Reset Calibration Reset Calib No
37. 6810 Figure 3 5 Autopaging Displays Generator Running TP 6810 6 12 The display contrast is adjustable Navigate to the Genset System menu and step down to the Contrast screen Press the Select button and then use the up and down arrow buttons to adjust the contrast See Section 3 5 Changing Settings and Section 3 11 Generator Set System Menu The display backlight turns off after about a minute of no activity The backlight turns on when a button is pressed or when the generator set starts Genset Status Standby 12 3V Engine Runtime 27 4h Y Date 02DEC2011 Time HR MNpm Y Next Exercise 09 00p 09Dec2011 Y Next Maintenance 150 h or Mar2012 Battery Sample data shown tp6810 Figure 3 6 Autopaging Displays Automatic Mode Section 3 RDC2 Controller Operation 29 3 3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built in battery charger Note To disconnect controller power disconnect the battery and the utility power to the generator set If controller power is disconnected and reconnected you will be prompted to set the time date and exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move on to the next Repeat until all settings are saved and the controller
38. Bus ID 12 Y Firmware Ver 122 i Connected MM DD YY 12 12 O LE LM moe EUR MES Return gt Figure 3 22 Remote Devices Submenu 44 Section 3 RDC2 Controller Operation Return Connected Displays date time device was connected Disconnected Displays date time of the last successful communication 3 18 Programmable Interface Module PIM Menus The PIM status menu displays the status of inputs and outputs connected to the programmable interface module PIM This is a status display menu only Input and output settings cannot be changed from the RDC2 controller s user interface PIM Status A lt Return A personal computer running Kohler SiteTech software is required to change the input and output settings Contact an authorized distributor or dealer for service The Kohler OnCue Home Management System can be used to turn outputs on and off See the OnCue Software Operation Manual for instructions Input 1 In Active MIA Input 2 In Active t Output 1 In Active t Output 2 In Active y Output 3 In Active f Output 4 In Active t Output 5 In Active Y Output 6 In Active x Y Return tp6810 Figure 3 23 Programmable Int
39. G Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Carbon monoxide detectors Carbon monoxide can cause severe nausea fainting or death Install carbon monoxide detectors on each level of the building 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 Atthe interval specified in the service schedule inspect the exhaust system components exhaust manifold exhaust outlet exhaust line exhaust clamps and muffler for cracks leaks and corrosion Exhaust System Inspection Points e Checkfor corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed e Check the exhaust gas color If the exhaust is blue or black contact your local authorized Kohler distributor dealer e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed e Check that all covers and doors are undamaged in place and locked e Check for the installation and operation of carbon monoxide CO detectors on each level of any building near the generator set TP 6810 6 12 4 6 Cooling System A WARNING y Ho
40. S interface board on the transfer switch Also see Section 2 7 Model RXT Transfer Switch Operation The RDC2 controller must be in AUTO mode for automatic transfer switch operation Automatic Start The RDC2 controller receives utility source voltage sensing data from the Model RXT transfer switch 1 If the utility source voltage falls below an acceptable level the controller starts the engine start time delay 2 If the utility source is not restored before the time delay expires the generator set starts 3 After the Normal to Emergency time delay the ATS is signaled to transfer the load to the emergency source TP 6810 6 12 Automatic Stop 1 When the utility source is restored the Emergency to Normal time delay starts 2 When the Emergency to Normal time delay expires the load is transferred to the utility 3 The generator set stops 2 4 7 Automatic Operation with Model RDT or RSB Transfer Switches If a Kohler Model RDT or RSB transfer switch is used the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set The RDC2 generator set controller must be in AUTO mode to respond to remote start stop signals from an ATS or remote switch Press the AUTO button on the RDC2 controller to put the generator set into automatic mode Automatic Start The engine start contacts on the ATS close to signal the generator set to start and remain closed while the ge
41. V 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 62 Appendix NC NEC NEMA NFPA 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 overcrank 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 co
42. age caused by overheating the windings 38RCL only Reduce the load ATS Com Error Ats Communication Error Warning is displayed if RXT interface connection is lost See Section 2 6 3 Check communication wiring between transfer switch interface board and generator set ATS PhaseRot ATS Phase Rotation Mismatch Transfer switch phase rotation does not match ATS will not transfer Correct the ATS connection Refer to the ATS Installation manual wiring diagrams and labels on the transfer switch Aux Input Auxiliary Input An optional customer connected input is closed Digital input from optional PIM Check customer supplied equipment Batt Chg Fit Battery charger fault Input to PIM from an external battery charger not the built in battery charger Check external battery charger Battery Voltage High Engine starting battery voltage rises above 125 of the battery voltage setting for more than 10 seconds Inhibited during the engine crank cycle Clears when the battery voltage returns to an acceptable level Check the battery rating and condition Check the battery charger operation Battery Voltage Low Engine starting battery voltage falls below the battery voltage setting typically 12 5 volts for more than 90 seconds when the engine is not running Inhibited during the engine crank cycle Clears when the battery voltage returns to an acceptable level Check th
43. ah ees tat tae eed iaa RR RPM nla Sle NNUS UNA T Pedals ai E E MR eee 9 Service Assistance cere da e afe ura 11 Section Service VIEWS iii tas 13 Section 2 Generator Set Operation oooooooccccnncnnnnn nnn nnn 15 2 1 Operating Areas e ER RN ENS NUES RENNES 15 2 2 Prestart Checklist sic Ree ida aeu era 15 23 Exercising the Generator Set 0 0 cece ete esses 16 2 4 Generator Set Operation sssusa anann nre 16 2 4 1 Local Starting and Stopping 0 eee eee 16 2 4 2 Automatic Starting and Stopping 0 16 2 4 8 Remote Starting and Stopping ccc eee eee 16 2 44 Engine Start Crank Cycle oooocccccccccccccccrc 16 2 45 Engine Cooldown 00 cece n 16 2 4 6 Automatic Operation with Model RXT Transfer Switch 16 2 4 7 Automatic Operation with Model RDT or RSB Transfer Switches 17 2 5 EXGEIGISO ataca rd Reacts bag Hee a ety 17 2 5 1 Unloaded Cycle Exercise with Complete System Diagnostics 17 2 5 2 Unloaded Full Speed Exercise 00 c cece eee eee 18 2 5 3 Loaded Full Speed Exercise with RXT only 0000eeee ee 18 2 5 4 Power Failure During Exercise 0 cc eet 18 2 5 5 Exerciser Reset vsede any fees at read 18 2 5 6 Setting the Exerciser at Power up 0 00 eee 18 2 5 7 Changing the Exercise Setting 0 cece eee eee eee 19 2 6 Faults et waters EDDA Se Cup eedem edu
44. changes are allowed from this menu The Next Maintenance menu shows the number of hours of generator set operation until maintenance is required The estimated date for the next scheduled maintenance is also displayed The maintenance reminder intervals are based on the engine manufacturer s recommendation for changing the oil Refer to Section 4 Scheduled Maintenance for maintenance instructions After changing the oil and performing other recommended maintenance go to the Overview menu to reset the maintenance timer See Section 4 3 4 for instructions to reset the maintenance timer Eng Runtime 27 4h A I Eng Starts Genset Run Time 1 Next Maintenance 150 h or Mar2012 Return Figure 3 13 Generator Set Run Time Menu Section 3 RDC2 Controller Operation 35 3 13 Genset System Menu The genset system menu displays the system information shown in Figure 3 14 Generator sets are factory set and should not require changes to the system settings in the field A Kohler authorized distributor or dealer can adjust these settings if necessary If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason see Section 3 5 for instructions to enable editing and change the system settings Note Use caution when navigating the controller menus In some menus pressing t
45. ctions Contact an authorized distributor dealer for service MainPwrOverL Shutdown Main power overload An over current fault on the 70 controller power output short circuit Contact an authorized distributor dealer for service Not in Auto The generator set is not in Automatic standby mode Remote start and stop commands from a transfer switch or remote switch will be ignored Press AUTO to place the generator set in Automatic mode when appropriate Over Crank Three unsuccessful starting attempts Check the fuel supply spark plug and battery Check for loose connections Contact an authorized distributor dealer for service Speed Sensor Fault Engine speed sensor has failed or engine stalled Contact an authorized distributor dealer for service Total Power High ShtDwn Measured load is greater than 102 of the generator set power rating for more than 1 minute 38RCL only Figure 2 5 Controller Fault Messages 24 Section 2 Generator Set Operation Reduce the load TP 6810 6 12 2 6 5 Event Log The event log displays up to 1000 controller faults and notices starting with the most recent event Events are numbered 1 1000 with 1 being the most recent Each event is displayed with the date and time of the event the number of the event a code to indicate whether the event was a warning W shutdown S or informational notice 1 the engine hours at the
46. d hold the select button to enable editing disable DHCP and then step to the next parameters and enter the information If an error occurs while setting a parameter an error message is displayed and then the controller exits the edit mode Previous settings are preserved Networking gt Networking Information Status J OnCue Password For the initial OnCue setup you will be required to reset the OnCue password on the RDC2 controller and then enter itinto the OnCue software To resetthe password follow the instructions in Figure 3 20 Note The password is displayed for only 10 seconds Be sure to write down the password and serial number A new password is generated each time the reset password procedure is performed If the password is reset after the OnCue system has been set up the connection will be lost Enter the new password in OnCue to reconnect Networking Reset OnCue Reset OnCue Configuration Password Password No X a Reset OnCue Password Yes UP arrow for YES Down arrow for NO Press Select to enter YES or NO as displayed New C password is displayed for approximately 10 seconds Enabled x S N 1234567 New PW 12345 v Return IVa DHCP tp6804 Figure 3 20 Network Configuration Submenu 42
47. d to crack Wait until engine has cooled 1 Close the radiator s coolant drain valve and tighten the hose clamps 2 Fill the radiator with the recommended coolant mixture of 5096 ethylene glycol and 5096 clean softened water to inhibit rust corrosion and prevent freezing The coolant capacity is shown in Figure 4 6 3 Operate the engine with the radiator cap removed until the thermostat opens and the upper radiator hose becomes hot 4 Stop the engine and allow it to cool 5 Add coolant to the radiator to just below the overflow tube on the filler neck See Section 1 Service Views for the overflow tube location 6 Replace the radiator s pressure cap 7 Maintain the coolant level in the coolant overflow bottle between the High and Low markings See Section 1 Service Views for the coolant overflow bottle location 8 Re energize the block heater if equipped TP 6810 6 12 4 7 Ignition System Service the spark plugs at the interval specified in the service schedule using the following procedure 1 2 Problem Condition Gap bridged spark plug Press the OFF button on the RDC2 controller Disconnect the power to the battery charger Disconnect the generator set engine starting battery negative lead first Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling Do not pull the wire Pulling on the wire rather than the boot may damage the wire or te
48. default exercise setting The Unloaded Cycle exercise runs the engine for 20 minutes in the cycle shown in Figure 2 1 and described below e Runs at reduced speed for 10 minutes to warm up and exercise the engine e Ramps up and runs at full speed for 3 minutes Engine diagnostics are performed during this full speed portion of the cycle which provides the best test of engine and alternator power backup capability Diagnostic tests at full speed can identify potential problems with the power output and alert the operator before an emergency event e Ramps down and runs at reduced speed for 5 minutes to cool down the engine before shutting down automatically a tr 5 D o o o c Ww Full Speed Diagnostics Engine Cooldown Exercise Figure 2 1 Unloaded Exercise Cycle System Diagnostics During the unloaded cycle exercise the controller monitors the following data The controller display indicates an unloaded exercise run during the diagnostics unless a fault is detected as described below Section 2 Generator Set Operation 17 e ATS connection The controller verifies that the Model RXT ATS interface board is connected e Battery voltage Battery voltage is checked before exercise to verify engine starting capability Battery voltage provides a measurement of battery health If the controller detects low battery voltage low battery or low charging battery is displayed and the exercise does not
49. e Software Operation Manual for information about the appropriate network settings for OnCue o If DHCP is enabled IP parameters are not displayed If DHCP is disabled i e if a static IP address is used the IP parameters are displayed To enable or disable DHCP and change the IP settings go to the Networking Configuration menu See Section 3 17 2 Networking gt Networking gt Information Status OnCue Status Connected EE A ai DHCP Enabled 1 IP Address 123 456 789 123 Subnet Mask 123 456 789 123 Gateway 123 456 789 123 DNS 1 123 456 789 123 f DNS 2 123 456 789 123 Y Ethernet Status Disconnected Y OnCue Server 123 456 789 123 Figure 3 19 Network Status Submenu TP 6810 6 12 Return tp6804 Section 3 RDC2 Controller Operation 41 3 17 2 Networking Configuration Submenu OnCue Password The networking Configuration menu includes settings used for communication with the Kohler OnCue Home Generator Management System For most applications DHCP is enabled and the IP settings cannot be changed from the controller keypad If DHCP is enabled IP parameters are not displayed If DHCP is disabled i e if a static IP address is required then the IP parameters can be modified For applications that require static IP addresses press an
50. e battery rating and condition Check the battery charger operation Charge or replace the battery CAN comm fault Engine CAN communications fault Check wiring to ECM Check power to ECM Engine Coolant Temperature High Engine coolant temperature exceeds the maximum temperature for more than 5 seconds Function becomes active after crank disconnect Check for blocked air inlets and exhaust outlets Engine Oil Pressure Low The engine ECM indicates low oil pressure for more than 5 seconds Function becomes active 30 seconds after crank disconnect 30 second inhibit Note The low oil pressure shutdown does not protect against low oil level Check the engine oil level regularly as recommended in Section 4 Check for leaks in the lubrication system Check the oil level and add oil if the level is low EngineSpeed High Engine speed exceeds 115 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service EngineSpeed Low TP 6810 6 12 Engine speed drops below 85 of the normal running speed for more than 3 seconds Reduce the load Contact an authorized distributor dealer for service Section 2 Generator Set Operation 23 Fault Warning W or Shutdown SD Condition Check Exer Not Sch W Exercise Not Scheduled No exercise has been scheduled on the RDC2 controller See Section 2 5 for instructio
51. e 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 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
52. ed fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels TP 6810 6 12 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 CAUTION Hazardous noise Can cause hearing loss Never operate the generat
53. efficient 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 SAE scfm SCR S sec Sl SI EO sil SMTP SN 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 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 e
54. em Detail RDC2 controller Cooling air inlet remove this panel to access coolant drain Access to coolant fill Oil fill on valve cover Air cleaner Fan fuses Battery Oil drain valve Lube oil filter Block heater connection valve Coolant drain Radiator Pressure cap engine coolant fill Coolant overflow tube Fans qty 3 Coolant overflow bottle 38 48RCL Service Views for Maintenance 38RCL shown Section 1 Service Views 13 Notes 14 Section 1 Service Views TP 6810 6 12 Section 2 Generator Set Operation 2 1 Operating Area A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected 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 fatigue 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 aslee
55. equipment 5 2 Controller Service Access A USB port is located in the controller s service access area Some controller settings can be adjusted using a laptop computer with Kohler SiteTech software See TP 6701 SiteTech Software Operation Manual for more information Use a USB cable with a mini B connector to connect the controller to your PC Remove the service access door to access the USB port See Figure 5 1 1 USB port for service 2 Mini breaker N A for these models Figure 5 1 Controller Service Access cover removed 5 3 Fault Messages The RDC2 controller displays fault messages to aid in troubleshooting Fault messages descriptions and recommended checks are listed in Figure 2 5 TP 6810 6 12 Section 5 Troubleshooting Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 6 4 5 4 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly contact an authorized Kohler distributor dealer for service 5 4 1 Line Circuit Breaker Theline circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load Ifthe circuit breaker trips reduce the load and switch the breaker back to the ON position 5 4 2 Fuses Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Figure 5 2 Troubleshooting Chart
56. erface Module PIM Status Menu TP 6810 6 12 Section 3 RDC2 Controller Operation 45 3 19 Load Control Module LCM Menus The Load Control menu displays the status of the Load Control Module LCM inputs and outputs and allows a test of the LCM output relays Generator current is displayed as a percent of the maximum generator capacity The load control module adds and sheds loads based on the generator current The test function cycles the relays in the order of their priority For detailed information about the LCM operation refer to TT 1574 provided with the LCM kit o Load gt Control Generator Current VE Load Control 1 i Return 123 IN o Test Outputs Push Select blinking A WA Input 1 In Active Input 2 In Active y Output 1 Add Shed t Output 2 Add Shed y Output 3 Add Shed 1 Output 4 Add Shed 1 Output 5 Add Shed 1 Output 6 Add Shed 1 lt Return tp6810 Figure 3 24 Load Control Module LCM Status Menu 46 Section 3 RDC2 Controller Operation TP 6810 6 12 4 1 General Maintenance A WARNING AS S Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator
57. ervals may be required in dusty or dirty operating conditions Seasonal or as required 8 More frequent intervals may be required with dirt in fuel system 48 Section 4 Scheduled Maintenance TP 6810 6 12 4 3 Lubrication System 4 3 1 Oil Specifications Use oil that displays the American Petroleum Institute API Starburst certification mark FOR GASOLINE ENGINES on the container Do not use straight weight oils recommended for industrial or stationary engines CC or CD classification oils even when labeled Heavy Duty or For Natural Gas Engines are not acceptable Multi viscosity oils are recommended Figure 4 1 shows the recommended Society of Automotive Engineers SAE viscosity designation for a given operating temperature Ambient Temperature Engine Oil Type SAE 10W 30 18 C 0 F and above Below 18 C 0 F SAE 5W 30 Figure 4 1 Engine Oil Selection 4 3 2 Oil Check Check the oil level in the crankcase every 24 hours of operation or before the engine is started each day Do not check the oil level while operating the unit Stop the generator set and keep the generator set level to get an accurate reading To check the oil level remove the dipstick and wipe the end clean Reinsert the dipstick and wait at least 30 seconds Remove the dipstick and check the level Maintain the oil level between the Full and Add marks on the dipstick as shown in Figure 4 2 See Section 1 Service Views for the dipstick l
58. et Maint Timer Yes is displayed d Pressthe Select button The next maintenance interval and date will be displayed 50 Section 4 Scheduled Maintenance 4 4 Air Cleaner Atthe interval specified in the service schedule inspect and clean or replace the air cleaner element Clean the element more frequently in dirty dusty conditions Check the element for accumulated oil or dirt that could cause poor performance Replace a damaged air cleaner element Follow the procedure described below Air Cleaner Service Procedure A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a rubber hose Refer to Figure 4 4 during this procedure 1 Cover 2 Housing 3 Pressure tap 1 8 in NPT 4 Wing nut Figure 4 4 Air Cleaner 1 Remove the wing nuts to open the housing and remove the air silencer element 2 Tap the element lightly against a flat surface to dislodge loose surface dirt Do not clean the element in any liquid or use compressed air as these will damage the filter element 3 Examine the element and housing for damage Replace the element or housing if necessary 4 Wipe the cover and housing with a clean rag to remove dirt Make sure the sealing surfaces fit correctly 5 Replace the cover and secure using the wing nut TP 6810 6 12 4 5 Exhaust System A WARNIN
59. eys when the generator set is running Replace guards screens and covers before operating the generator set The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized Kohler distributor dealer perform generator set service Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the runtime hours shown on the RDC2 controller to determine when to schedule routine maintenance Service generator sets that are subject to extreme weather or dusty or dirty conditions more frequently Maintenance and Service Parts Obtain maintenance and service parts from an authorized Kohler distributor dealer Section 4 Scheduled Maintenance 47 4 2 Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set Initial Startup Sequence Operation Check GENERAL MAINTENANCE Check for fluid leaks Check all bolts and nuts for tightness
60. g 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 before 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 6810 6 12 cfm CG CID CL cm CMOS com coml Coml
61. he Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable Voltage Regulator VR Voltage Adjust The generator set voltage is factory set and typically does not require adjustment in the field If voltage adjustment is required contact a Kohler authorized distributor or dealer for service Refer to the generator set Installation Manual for instructions to adjust the voltage Setting the Exerciser Use the Genset System menus to set the generator set exerciser Refer to Section 2 5 for instructions to set the exerciser and for more information about exercising the generator set After a scheduled exercise run the Next Exercise time and date will be updated automatically based on the Exercise Frequency setting Adjusting the Display Contrast To adjust the display contrast use the down arrow button to step to the Contrast menu Press the Select button and then use the up and down arrow buttons to adjust the contrast Press the Select button to save the contrast setting 36 Section 3 RDC2 Controller Operation Genset System gt A System Voltage 240 V Y System Freq 60 Hz VR Voltage Adj 240 0V Y System Phase Three Delta Y System Battery 12V Y Next Exercise 06 30p
62. ime for the engine oil to drain completely h Close the oil drain valve i Replace the oil drain plug 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench b Clean the contact surface of the oil filter adapter c Apply a light coat of clean oil to the rubber seal of the new oil filter Section 4 Scheduled Maintenance 49 d Install the new oil filter following the instructions provided with the filter 3 Fill with oil See Figure 4 1 for oil selection and Figure 4 3 for oil capacity Model Oi Capaciy L Gt 38RCL and 48RCL 4 7 5 0 Figure 4 3 Oil Capacity 4 Check for leaks a Press the OFF button on the RDC2 generator set controller b Reconnect the generator set engine starting battery negative lead last c Reconnect the power for the battery charger d Start the generator set and check for leaks around the oil filter e Stopthe generator set and tighten the oil filter to stop any leaks f Reinstall the housing side panel 5 Stop the generator set Check the oil level Add oil as necessary to bring the level up to the Full mark Note Too high an oil level causes high oil consumption and engine carbonizing Too low a level damages the engine 6 Reset the maintenance timer on the RDC2 a In the Overview menu step down to the Next Maintenance screen b Press the Select button c Press the Up arrow button so that Res
63. le as shown in Figure 2 3 12 Set the exercise frequency weekly or every two weeks Weekly exercises are recommended 13 Press the down arrow button to step to the Return menu Press the Select button to return to the main menu 14 Check that the AUTO LED is lit The generator set must be in automatic mode for the exercise to run as scheduled After a scheduled exercise run the next exercise time and date will be updated automatically based on the Exercise Frequency setting Other transfer switches For a loaded exercise with a transfer switch other than a Kohler Model RXT program the exercise at the transfer switch controller Refer to the transfer switch operation manual for instructions Section 2 Generator Set Operation 19 Status Displays Overview W 12h Figure 2 2 RDC2 Main Menu 20 Section 2 Generator Set Operation 9 EN Engine Metering ATS gt Configuration Generator gt Y Metering Date gt and Time Genset gt Information Y Y Network gt Information Y Genset Run Time PIM gt Y Genset Status System Load gt ATS gt Status Control Event Log gt 1p6810 TP 6810 6 12 Genset System gt A System Voltage 24
64. lectrically 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 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 Connecting the battery and the battery charger Hazardous voltage can cau
65. ller displays a fault message but the generator set does not shut down on a warning The controller resets automatically after a warning condition is corrected 2 6 2 Shutdowns Under a fault shutdown condition the generator set shuts down automatically and the controller displays a fault message The OFF LED flashes See Figure 2 5 Shutdown switches such as the low coolant level switch or high engine temperature switch on the generator set will automatically reset when the problem is corrected However the fault condition at the controller does not clear until the controller is reset The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 6 4 to reset the controller after a fault shutdown 2 6 3 ATS Communication Errors When a Model RXT transfer switch is used an ATS fault indicates that the connection to the interface board on Overview gt 1 2h Fault Message the transfer switch has been lost Check the connection to the ATS interface board 2 6 4 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Check the fault message displayed on the controller and refer to Figure 2 5 to identify and correct the fault condition before proceeding Contact an authorized distributor dealer for service if necessary Press the OFF button to resetthe cont
66. mental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exh ext F FHM fl oz flex freq FS ft ft Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt 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 H x W xD height by width by depth IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP ISO J JIS k K kA KB KBus kg hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour 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
67. nerator set is running Automatic Stop The engine start contacts on the ATS open to signal the generator set to stop 2 5 Exercise The RDC2 controller can be set to automatically run the generator set at the same time and day every week or every other week Exercising the generator set every week or every two weeks is required in order to keep the engine and alternator in good operating condition Three exercise modes are available unloaded cycle unloaded full speed and loaded full speed See Sections 2 5 1 through 2 5 3 for information about the exercise modes A loaded exercise can be set at the RDC2 controller only if a Model RXT transfer switch is connected Note With the RDT and RSB transfer switches it is possible to have two exercise settings one unloaded exercise set at the generator set controller and another exercise set at the ATS controller If the exercise times overlap the ATS exercise setting takes priority TP 6810 6 12 If a Model RDT or RSB transfer switch is used refer to the instructions provided with the transfer switch to set a loaded exercise at the ATS if desired 2 5 1 Unloaded Cycle Exercise with Complete System Diagnostics An unloaded cycle exercise runs the generator set without signalling the transfer switch to transfer the electrical load from the utility source to the generator set The Unloaded Cycle exercise with diagnostics is the recommended exercise mode and is the factory
68. ngine 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 6810 6 12 TP 6810 6 12a 2012 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
69. ns to set the exerciser Generator Frequency High Governed frequency exceeds 110 of the system s frequency setpoint for more than 10 seconds Function becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service Generator Frequency Low Governed frequency falls below 90 of the system frequency setting for more than 10 seconds or 1 Hz below the system frequency setting for more than 60 seconds Function becomes active 10 seconds after engine start 10 second inhibit Reduce the load and restart the generator set Contact an authorized distributor dealer for service Generator VoltageL1 L2 High Generator Voltage High Output voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service Generator VoltageL1 L2 Low Generator Voltage Low Output voltage falls below 80 of the nominal system voltage for more than 10 seconds Reduce the load and restart the generator set Contact an authorized distributor dealer for service Lo Crank Vit Low cranking voltage Battery voltage falls below 60 6 of system battery voltage for more than 6 seconds while the starter is engaged Charge or replace the battery Locked Rotor No engine rotation is sensed during cranking Shuts down 3 seconds after the fault is detected Check the battery Check for loose conne
70. ocation Note Do not operate the set if the oil level is below the Add mark or above the Full mark on the dipstick 1 Full mark 2 Add mark Figure 4 2 Oil Level Check TP 6810 6 12 4 3 3 Oil Additions Adding some oil between oil changes is normal The amount varies with generator set usage Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device See Section 1 Service Views for the oil check and oil fill locations 4 3 4 Oil and Filter Change Change the oil according to the service schedule or before generator set storage Change the oil more frequently if the generator set operates under dirty dusty conditions Change the oil while the engine is still warm See Section 1 Service Views for oil fill oil check and oil filter locations Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner Note Reset the maintenance timer on the RDC2 controller after changing the oil Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Drain the oil a Press the OFF button on the RDC2 generator set controller b Disconnect the power for the battery charger c Disconnect the generator set engine starting battery negative lead first d Remove the housing side panel e Remove the plug from the oil drain fitting and install a drain hose f Open the oil drain valve on the engine g Allowt
71. ol Relay Time Delay 6 The transfer switch transfers to the emergency source The load control time delay allows delayed starting of large motor loads such as air conditioners preventing 7 The load control contact time delay times out simultaneous starting of large motors after transfer to the generator set The load control time delay is fixed at 8 The load control contact closes 5 minutes It is not adjustable Normal Source Returns The load must be connected to the load control output on the interface board of the Model RXT transfer switch 1 The emergency to normal time delay times out See the transfer switch operation and installation manual for connection instructions 2 The contactor transfers to the normal source 3 The engine cooldown time delay times out 4 The generator is signaled to stop Time Delay Setting Description Engine Start 3 seconds Time delay after utility source is lost until the engine start cycle begins Guards against starting the generator set because of a brief change in the utility source Transfer Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer to emergency source Transfer Emergency to Normal 2 minutes Time delay after the utility source returns until transfer back to normal Ensures that the the utility source is stable before transferring from the emergency source Load Control 5 minutes See Section 2 7 4 Allows delayed connection
72. or set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set TP 6810 6 12 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 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 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 E
73. over the full mark on the dipstick Section 2 Generator Set Operation 15 2 3 Exercising the Generator Set Operate the generator set without load every week or every other week for 20 minutes Perform all of the prestart checks before starting the exercise procedure See Section 2 5 for instructions to set the automatic exerciser 2 4 Generator Set Operation 2 4 1 Start Press the RUN button to immediately start the generator set Local Starting and Stopping Stop Press the OFF button The engine stops Run the generator set with no load for atleast 2 minutes to ensure adequate engine cooldown 2 4 2 Automatic Starting and Stopping An automatic transfer switch monitors the utility power and signals the generator set to start when utility power islost The ATS then transfers the load to the generator set When utility power is restored the transfer switch transfers the load back to utility runs the generator set with no load to cool down the engine and then stops the generator set engine The electric fans continue to run for two minutes after the engine shuts down to evacuate the engine compartment 2 4 3 Remote Starting and Stopping A remote switch connected to terminals 3 and 4 can be used to start and stop the generator set Close the switch to start and run the generator set Open the switch to stop the generator set Run the generator set with no load for atleast 2 minutes to ensure adequate engine cooldo
74. oving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Heavy Equipment Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid 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 Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armature become hot enough to cause severe burns 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 NOTICE Electrostatic
75. p 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 Keep the generator set area clear Maintain at least 0 9 m 3 ft of clearance on all sides of the generator set Verify that there are no windows air vents or other openings in the building within 1 5 m 5ft of the generator set exhaust outlet in any direction Notice Do not locate patios decks play areas or animal shelters near the generator set 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 TP 6810 6 12 2 2 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for obs
76. parts often and perform required maintenance at the prescribed intervals Obtain service from an authorized Kohler distributor dealer or service technician to keep equipment in top condition Model 48RCL Generator Set Figure 1 TP 6810 6 12 Introduction Nameplate Figure 2 shows a typical generator set nameplate Copy the model serial and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual See the service view in Section 1 for the nameplate location KOHLER KOHLER CO KOHLER WI USA ODEL SERIAL BUILD DATE M RPM FUEL VOLTAGE AMPS PHASE Kw KVA GEN MODEL BATT V INSUL NEMA CLASS _ 40 C AMB KW VARIES WITH BTU CONTENT OF FUEL GM12070 Figure 2 Nameplate Typical Introduction 9 List of Related Literature Figure 3 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 Installation Manual Generator Set TP 6809 Operation Manual Engine TP 6101 Service Manual Generator Set TP 6811 Service Manual 38RCL Engine Mechanical TP 6103 Service Manual 48RCL Engine Mechanical TP 6104 Service Manual Engine ECM Diagno
77. peak 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 notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air 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 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 spill
78. rciser at Power up When power is connected to the controller you will be prompted to set the date time and exercise schedule 1 At power up the date is displayed with the year flashing Use the up or down arrow key to step to the current year 2 Press Select button to save the year and move to the month 3 Use the arrow and select buttons to set the month and the day 4 The time is displayed with the hour flashing Use the up or down arrow key to step to the current hour and am or pm setting Note Check the am pm setting displayed If pm is displayed and you need to change it to am use the down arrow button to step down in time until the correct hour and am are displayed TP 6810 6 12 5 Press the Select button to save the hour and move to minutes 6 Use the up or down arrow button to change the minutes 7 Press Select to save the time and move to the next screen 8 Next Exercise is displayed Use the up down and select buttons to set the exercise time and date Be sure to set a time and date in the future 9 Press Select The controller exits the exercise menu 10 Press the Auto button and verify that the AUTO LED is lit The generator set must be in automatic mode for the exercise to run as scheduled The exercise will run every 7 days at the same time starting on the date set To change the exerciser to run every other week or on a different day and time use the following procedure 2 5 7
79. replace the air cleaner Battery weak or dead Recharge or replace the battery Battery connection poor Clean and tighten the battery connections Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary Fuel pressure insufficient Check the fuel supply and valves Engine fuse blown Replace the fuse If the fuse blows again contact an authorized Kohler distributor dealer Engine malfunction Contact an authorized Kohler distributor dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC circuit breaker tripping because of overload Reduce the load on the generator set AC circuit breaker tripping because of short circuit Contact an authorized Kohler distributor dealer for service Engine fuse blown Replace the fuse Contact an authorized Kohler distributor dealer for service if fuse blows repeatedly Low output or excessive drop in voltage Generator set overloaded Reduce the load Generator set stops suddenly Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact an authorized Kohler distributor dealer
80. returns to the main menu See Section 3 5 for more detailed instructions to change settings on the RDC2 See Section 2 5 for more detailed instructions to set the exerciser or change the exercise settings 3 4 Battery Charging The controller includes a built in battery charger to maintain the engine starting battery The RDC2 controller monitors the battery voltage and provides a constant 14 2 VDC voltage and maximum 2 5 amps to charge the battery The installer must connect 120 VAC 60Hz utility power provided from the building on a breaker protected circuit for the built in battery charger See the Installation Manual for instructions to connect the utility power for the battery charger 3 5 Changing Settings Some settings can be changed from the controller keypad The controller settings and generator set output are factory set and should not require field adjustment under normal circumstances Check and adjust the settings and or output when e The controller has been replaced e The voltage requires adjustment for a particular application e Troubleshooting generator set problems Have controller setup and adjustment performed only by an authorized Kohler distributor dealer or authorized representative 30 Section 3 RDC2 Controller Operation The following procedure explains how to change settings See Figure 3 7 for an example using the Date and Time settings Note Use caution when navigating the controller menu
81. rminal Loosen the spark plug with a ratchet and 5 8 in spark plug socket with a rubber insert to prevent spark plug damage Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber Remove spark plugs one at a time and examine Identify a normal spark plug in good operating condition by observing a light tan or gray deposit on firing tip See Figure 4 9 to evaluate engine condition by color condition of a problem spark plug Clean spark plugs by wiping them with a rag File the center electrode to keep it parallel to the side electrode Means of Identification closing Built up deposits and gap between electrodes Note Do not sandblast wire brush scrape or otherwise service spark plugs in poor condition Obtain a new plug for best results 9 Check the spark plug gap before installing any spark plug See Figure 4 7 and Figure 4 8 Attain a correct gap when the feeler or wire passes between the spark plug electrode It should pass easily but with some resistance or drag otherwise adjust as necessary moa Sparkplug gap 38 RCL and 48RCL 0 9 mm 0 035 in Figure 4 7 Recommended Spark Plug Gap 1 0 9 mm 0 035 in gap 2 Spark plug electrodes Figure 4 8 Spark Plug Gap Inspection Possible Cause Solution Oil or carbon fouling Clean and regap the spark plug Oil fouled spark plug and electrodes Wet
82. roller or follow the procedure below See Figure 2 4 Procedure to Reset the Controller after a Fault Shutdown 1 Press the Select button to go to the Overview menu 2 Press Select again The active fault is displayed 3 Press Select Confirm Clear Fault NO is displayed 4 Press the Up arrow button Confirm Clear Fault YES is displayed 5 Press the Select button to enter YES and clear the fault 6 Press the Select Button to return to the overview menu 7 Press AUTO to putthe generator set into automatic mode Fault Message Confirm Clear AB Fault NO Press Up arrow button Confirm Clear Fault YES Figure 2 4 Clearing a Fault 22 Section 2 Generator Set Operation TP 6810 6 12 AC Sens Lost Warning W or Shutdown SD Condition AC Sensing Lost In Auto mode generator output AC sensing is lost Starts 10 seconds after crank disconnect Warning after 1 second if no output detected after crank disconnect Shutdown after 3 seconds if voltage was present and then lost Contact an authorized distributor dealer for service Accy PwrOver Warning Accessory Power Overload An over current fault short circuit on the accessory controller power output Contact an authorized distributor dealer for service Alt Protect Shtdwn High generator current has been detected The generator set shuts down to protect the alternator from dam
83. rvoltage dropout setting the source is considered to have failed See Figure 2 7 Accuracy 5 90 of Pickup 90 of Nominal Undervoltage Dropout Undervoltage Pickup Figure 2 7 Voltage Sensing Parameters The RDC2 controller also has a set of power system LEDs below the pushbuttons The power system LEDs indicate which power sources are available and which source is supplying power to the building See Figure 3 2 Note The power system LEDs operate only if a Model RXT transfer switch is connected They will not operate if a Model RDT or RSB transfer switch is used Section 2 Generator Set Operation 25 2 7 2 ATS Control Sequence of 2 7 3 Time Delays Operation Time delays are factory set to the values shown in See Figure 2 8 for time delay settings Figure 2 8 An authorized distributor dealer can adjust time delays using a personal computer and Kohler Preferred Source Fails SiteTech software 1 The load control contact opens Time delays described in this section operate only when the controller is connected to a Kohler Model RXT 2 The engine start time delay times out transfer switch 3 The generator set is signaled to start The engine start and load transfer time delays prevent engine start and load transfer caused by brief variations 4 The generator starts and the emergency source in the utility power source becomes available 5 The normal to emergency time delay times out 2 7 4 ATS Load Contr
84. s and changing the settings In some menus pressing the Select button can enable editing of the controller settings Changing some settings to incorrect values can adversely affect generator set operation or render the unit inoperable Procedure to Change Settings 1 Press the Select button to enter the main menu 2 Pressthe down arrow button until the desired menu is displayed The Date and Time menu is used for the example in Figure 3 7 3 Press the Select button to enter the selected menu See Figure 3 7 4 Press the down arrow button to step through the parameters in the selected menu 5 To change a setting press the Select button The selected setting flashes 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 If there are additional adjustable settings on the screen the next setting flashes For example in the date menu the year month and day can be adjusted 8 Repeat steps 5 through 7 for each setting on the screen 9 Press the down arrow to step to the next screen 10 To exit press the down arrow button until Return is displayed Press the Select button to exit the menu 11 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 TP 6810 6 12 Changing Settings on the
85. se 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 Safety Precautions and Instructions 7 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 A WARNING A Airborne particles Can cause severe injury or blind ness Wear protective goggles and clothing when using power tools hand tools or compressed air 8 Safety Precautions and Instructions Servicing the generator set when it is operating Exposed m
86. 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 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose ofa 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 Safety Precautions and Instructions 5 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
87. ss the down arrow button to step to the next menu Engine Metering Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 3 8 The controller will exit the main menu after 5 minutes if no buttons are pressed To exit the main menu immediately press the controllers OFF or AUTO button Status Overview Displays 1 2h NZ Press the Up and Down arrow buttons to move between menus Press OFF or AUTO to exit the menus Engine Metering ATS gt Configuration Generator gt Metering Date gt Genset gt Information Genset Run Time Genset System and Time Network Information PIM Status Load gt Control ATS gt Event Log gt Status ATS configuration appears only if a Model RXT transfer switch is connected Figure 3 8 RDC2 Main Menu 32 Section 3 RDC2 Controller Operation TP 6810 6 12 3 8 Overview Menu 3 9 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3 10 This menu displays status information only No settings can be Overview gt Active Alert 12h if any changed from this menu
88. ssary See Figure 3 11 Generator gt Metering A Three phase VY Single phase Volts L1 L2 240 V y Y Volts L2 L3 Frequency 240 V 60 0 Hz Volts L3 L1 240 V Frequency 6 0 Hz Reset Reset 9 Calibration Calib No E A Reset Return Calib Yes 1p6810 Figure 3 11 Generator Metering Menu 34 Section 3 RDC2 Controller Operation TP 6810 6 12 3 11 Generator Set Information Menu The generator set model number and serial numbers are displayed No changes are allowed from this menu Model and serial numbers are factory set and should not require changes in the field except in the event that the controller is being replaced A personal computer running Kohler SiteTech software is required to enter the generator set model number and serial numbers on areplacement controller Contact an authorized Kohler distributor dealer for service 1 Genset gt Information Genset M N 48RCL Y Genset S N THHHHHHHE E Controller S N THHHHHHHE Return tp6810 Figure 3 12 Generator Set Information Menu TP 6810 6 12 3 12 Genset Run Time Menu The data shown in Figure 3 13 are displayed No
89. standing the lowest possible temperatures TP 6810 6 12 10 Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs Clean the exterior of the generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion Seal the air inlet exhaust pipe and fuel tank cap with tape Disconnect and remove the battery Place the battery in a warm dry location for the storage period Recharge the battery once a month to maintain a full charge Select a well ventilated not humid or dusty location to store the generator Cover the entire unit with a dust cover Note Run the generator set once a month whenever possible Section 4 Scheduled Maintenance 55 Notes 56 Section 4 Scheduled Maintenance TP 6810 6 12 5 1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems First check for simple causes such as a dead engine starting battery loose connections or an open circuit breaker The charts include a list of common problems possible causes of the problem and recommended corrective actions If the procedures in this manual do not explain how to correct the problem contact an authorized Kohler distributor dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and repairs or adjustments made to
90. start e Coolant level check The coolant level is checked e Communication integrity tests J1939 RBUS Ethernet and USB are monitored for messages indicating that the controller and wiring are reliable e Engine speed Engine speed is measured at low speed and full speed An overspeed or underspeed condition will result in a fault condition and shutdown e Generator output frequency and voltage Operating the generator at full speed allows the RDC2 controller to check the output power for correct voltage frequency and stability When the engine is running at full speed the controller verifies that the voltage and frequency are within acceptable limits A fault message is displayed if the voltage or frequency is out of range e Oil pressure Oil pressure is verified to ensure proper lubrication of critical engine components Pressure is monitored at both low and full speeds If the oil pressure is low low oil pressure is displayed and the generator set shuts down 2 5 2 Unloaded Full Speed Exercise The unloaded full speed exercise runs the generator set at full speed for 20 minutes without transferring the load To set an unloaded full speed exercise follow the procedure in Figure 2 3 and select Exercise Mode Unloaded Full 2 5 3 Loaded Full Speed Exercise with RXT only A loaded exercise starts the generator set ramps up to full speed and then transfers the electrical load from the utility source to the generator
91. stics TP 6724 Service Manual 38RCL Alternator TP 6353 Service Manual 48RCL Alternator TP 6783 Parts Catalog 38RCL Engine TP 6730 Parts Catalog 48RCL Engine TP 6731 Parts Catalog Generator Set TP 6812 Installation Instructions Load Control Module LCM TT 1574 Installation Instructions Programmable Interface Module PIM TT 1584 Operation Manual OnCue Software TP 6796 Operation Installation Manual RXT ATS TP 6807 Operation Installation Manual RDT ATS TP 6345 Installation Manual RSB Transfer Switch TP 6486 Operation Manual RSB Transfer Switch TP 6487 Figure3 Related Literature 10 Introduction TP 6810 6 12 Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest authorized Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler Power Systems website at KohlerPower com Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional
92. t 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 Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank 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 4 6 14 Checking and Filling Coolant Maintain the coolant level in the coolant overflow bottle between the High and Low markings See Section 1 Service Views for the coolant overflow bottle location Note Periodically check the coolant level by removing the radiator s pressure cap Do not rely solely on the level in the coolant overflow bottle Add fresh coolant until the level is just below the overflow tube opening Use a coolant mixture of 5096 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing A coolant solution
93. tructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information 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 Drive Belt s Check the belt condition of the water pump and battery charging alternator belt s Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components for cracks and corrosion exhaust manifold exhaust pipe exhaust clamps and silencer e Checkfor corroded or broken metal parts and replace them as needed e Check that there are no combustible materials near the exhaust outlet e Check that the exhaust outlet is unobstructed Carbon Monoxide Detectors Check for the installation and operation of carbon monoxide CO detectors on each level of any building near the generator set Oil Level Maintain the oil level at or near not
94. wn 2 4 4 Engine Start Crank Cycle The controller attempts to start the generator set three times three crank cycles 15 seconds crank and 15 seconds off If the generator set does not start in three attempts the system shuts down on an overcrank fault See Section 2 6 Pressing the OFF button during the crank cycle stops the cranking No other buttons are acknowledged during the crank cycle 16 Section 2 Generator Set Operation 2 45 Engine Cooldown The engine cooldown time delay allows the engine to run after the loads have been removed The engine cooldown time delay is setto 5 minutes The engine stops before the cooldown time delay expires if the temperature drops below the cooled down temperature level or if the temperature rises above the high limit during the cooldown cycle The electric fans continue to run for two minutes after the engine shuts down to evacuate the engine compartment If atransfer switch other than the Model RXT is used an additional engine cooldown time delay may be programmed on the transfer switch To allow the smart engine cooldown on the RDC2 controller to operate most efficiently set the cooldown time on the transfer switch controller to zero or the minimum time allowed Refer to the instructions provided with the transfer switch for more information 2 4 6 Automatic Operation with Model RXT Transfer Switch The Model RXT transfer switch connects to the RDC2 controller through the AT
95. y to increase the hour until the correct hour and pm is displayed 11 Repeat to set the time format to 12 hr or 24 hr 12 Press the down arrow button Return is displayed lt Return Press NZ Display 13 Press Select to return to the Date and Time menu Date gt Display and Time 14 Press the Up or Down arrow buttons to step to a different menu 15 Press Auto to signal the controller to exit the menus and return to the generator set status display Press O AUTO Genset State Display Standby Note If no buttons are pressed the controller returns to the status display after 5 minutes Section 3 RDC2 Controller Operation 31 3 6 Controller Menus The following sections show the RDC2 controller menus and submenus Use the Select button and the up and down arrow buttons to navigate the menus as shown in the diagrams Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable If a setting on the controller display is flashing edit mode has been enabled Press the OFF or AUTO button to exit the edit mode 3 7 Main Menu Press the Select button once to bring up the main menu Overview is displayed See Figure 3 8 Pre

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