Related Manuals for Kohler 38RCL
Summary of Contents for Kohler 38RCL
- Page 1 Operation Residential/Light Commercial Generator Sets Model: 38RCL 48RCL 60RCL Controller: RDC2 TP-6810 11/13b...
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Page 2: Product Identification Information
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 Controller Identification Product identification numbers determine service parts. Record the product identification numbers in the spaces Record the controller description from the generator set below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice. -
Page 3: Table Of Contents
Table of Contents Product Identification Information ............. Safety Precautions and Instructions . - Page 4 Table of Contents, continued 3.12 Genset Run Time Menu ..........3.13 Genset System Menu .
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Page 5: Safety Precautions And Instructions
Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be Explosion. Can cause severe injury or death. aware of potential dangers and act safely. - Page 6 metal surface away from the battery. To minimize the risk of fire or explosion. or fall asleep. Alert others to the avoid sparks, do not disturb the battery Equip the compartment or nearby area possibility carbon monoxide charger connections while the battery with a fully charged fire extinguisher.
- Page 7 Hazardous Voltage/ Explosive fuel vapors can cause Grounding electrical equipment. severe injury or death. Take Hazardous voltage cause Moving Parts additional precautions when using the severe injury or death. Electrocution following fuels: is possible whenever electricity is DANGER present. Ensure you comply with all Propane (LP)—Adequate ventilation applicable codes...
- Page 8 Engine block heater. Hazardous Servicing the generator set when it WARNING voltage can cause severe injury or is operating. Exposed moving parts death. The engine block heater can can cause severe injury or death. cause electrical shock. Remove the Keep hands, feet, hair, clothing, and engine block heater plug from the test leads away from the belts and electrical outlet before working on the...
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Page 9: Introduction
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. - Page 10 G4-211 Specification Sheet, 60RCL G4--233 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, 48/60RCL Engine Mechanical TP-6104 Service Manual, Engine ECM Diagnostics TP-6724 Service Manual, Alternator, 38RCL...
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Page 11: Service Assistance
Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product. - Page 12 Notes Service Assistance TP-6810 11/13...
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Page 13: Section 1 Service Views
29. Pressure cap (engine coolant fill) 14. Line circuit breaker 30. Coolant overflow tube 15. Generator set master control buttons (on RDC2 controller) 16. RDC2 controller 31. Coolant overflow bottle Figure 1-1 38/48RCL Service Views for Maintenance (38RCL shown) TP-6810 11/13 Section 1 Service Views... - Page 14 SERVICE SIDE GM85088 ADV-8545 Cooling System Detail NON-SERVICE SIDE 1. Air cleaner 17. RDC2 controller 2. Nameplate location 18. Cooling air inlet (remove this panel to access coolant drain) 3. Oil check (dipstick) 19. Access to coolant fill 4. Engine ECM and EPR (electronic fuel pressure regulator) 20.
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Page 15: Section 2 Generator Set Operation
Section 2 Generator Set Operation 2.1 Operating Area 2.2 Prestart Checklist To ensure continued satisfactory operation perform the WARNING 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. -
Page 16: Exercising The Generator Set
2.3 Exercising the Generator Set 2.4.5 Engine Cooldown The engine cooldown time delay allows the engine to Operate the generator set without load every week or run after the loads have been removed. every other week for 20 minutes. Perform all of the prestart checks before starting the exercise procedure. -
Page 17: Automatic Operation With Model Rdt Or Rsb Transfer Switches
RDT or RSB Transfer Switches recommended exercise mode and is the factory-default exercise setting. If a Kohler Model RDT or RSB transfer switch is used, the engine start contacts from the ATS must be The Unloaded Cycle exercise runs the engine for... -
Page 18: Unloaded Full-Speed Exercise
ATS connection. The controller verifies that the generator set. To set a loaded exercise, follow the Model RXT ATS interface board is connected. procedure in Section 2.5.8 and select Exercise Type: Loaded. Battery voltage. Battery voltage is checked before exercise to verify engine starting capability. Battery For a loaded exercise with a transfer switch other than a voltage provides a measurement of battery health. -
Page 19: Changing The Exercise Setting
2. Press Select button to save the year and move to 2. Press the Select button to go to the main menu. the month. See Figure 2-2. 3. Use the arrow and select buttons to set the month 3. Press the down arrow button to step to the Genset and the day. - Page 20 Status Overview ----> Displays 1.2 h Engine ----> ----> Metering Configuration Generator----> Date ----> Metering and Time Genset ----> Network ----> Information Information ----> Genset ----> Status Run Time Genset ----> Load ----> System Control Event Log----> ----> Status tp6810 Figure 2-2 RDC2 Main Menu Section 2 Generator Set Operation TP-6810 11/13...
- Page 21 Genset ----> System Voltage: 240 V System System Freq: 60 Hz VR Voltage Adj: 240.0V System Phase: Single System Battery: 12 V See Section 2.5.8, Changing Next Exercise * Next Exercise the Exercise Setting HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY Exercise Mode: Exercise Mode: None/Unloaded Full Sp/...
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Page 22: Faults
2.6 Faults the transfer switch has been lost. Check the connection to the ATS interface board. Selected fault conditions are shown in Figure 2-5. Fault conditions are classified as warnings or shutdowns. If a 2.6.4 Resetting the Controller after a fault occurs that is not listed in the table, contact an Fault Shutdown authorized distributor/dealer for service. - Page 23 Reduce the load. Shtdwn generator set shuts down to protect the alternator from damage caused by overheating the windings. (38RCL only) ATS Com Error Ats Communication Error. Warning is displayed Check communication wiring between if RXT interface connection is lost. See transfer switch interface board and Section 2.6.3.
- Page 24 Total Power Measured load is greater than 102% of the Reduce the load. High ShtDwn generator set power rating for more than 1 minute. (38RCL only) Figure 2-5 Controller Fault Messages Section 2 Generator Set Operation TP-6810 11/13...
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Page 25: Event Log
2.7 Model RXT Transfer Switch 2.6.5 Event Log Operation The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are The RDC2 generator set/transfer switch controller numbered 1--1000, with 1 being the most recent. Each manages automatic transfer switch (ATS) functions event is displayed with the date and time of the event, when connected to a Kohlerr Model RXT transfer switch... -
Page 26: Ats Control Sequence Of Operation
2.7.2 ATS Control Sequence of 2.7.3 Time Delays Operation Time delays are factory-set to the values shown in Figure 2-8. An authorized distributor/dealer can adjust See Figure 2-8 for time delay settings. time delays using a personal computer and Kohlerr SiteTecht software. -
Page 27: Section 3 Rdc2 Controller Operation
RDC2 generator set/transfer switch controller. The RDC2 controls the following power system components: Model 38RCL, 48RCL, or 60RCL generator set Model RXT automatic transfer switch (ATS) Load control module (LCM) or load shed kit Programmable interface module (PIM) RDC2 Controller features include: 1. -
Page 28: Controller Keypad
3.2.1 Controller Keypad 3.2.2 LED Indicators The Run, Off, and Auto buttons control the generator set LEDs above the RUN, OFF, and AUTO buttons indicate as described in Figure 3-2. Use the Select, Up arrow, the mode of operation as shown in Figure 3-2. and Down arrow buttons to navigate through the menus The RDC2 controller also has a set of power system and change settings, if necessary. -
Page 29: Lcd Display
3.2.3 LCD Display The display contrast is adjustable. Navigate to the Genset System menu and step down to the Contrast The controller is equipped with a two-line x 16 character screen. Press the Select button, and then use the up backlit liquid crystal diode (LCD) display with adjustable and down arrow buttons to adjust the contrast. -
Page 30: Controller Power
Note: If no buttons are pushed, the controller exits the Have controller setup and adjustment performed only by menus and returns to the generator set status an authorized Kohler distributor/dealer or authorized display after 5 minutes. representative. Section 3 RDC2 Controller Operation... - Page 31 Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select button. The saved date is shown. Overview ----> Press: Display: Date: 1.2 h Press: Display: 03Jan2012 2.
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Page 32: Controller Menus
3.6 Controller Menus 3.7 Main Menu The following sections show the RDC2 controller menus Press the Select button once to bring up the main menu. and submenus. Use the Select button and the up and Overview is displayed. See Figure 3-7. Press the down down arrow buttons to navigate the menus as shown in arrow button to step to the next menu, Engine Metering. -
Page 33: Overview Menu
3.8 Overview Menu 3.9 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3-9. This menu displays status information only. No settings can be changed Overview ----> Active Alert from this menu. 1.2 h (if any) Eng Speed: Engine ---->... -
Page 34: Generator Metering Menu
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 necessary. See Figure 3-10. -
Page 35: Generator Set Information Menu
Kohlerr SiteTecht software is required to enter manufacturer’s recommendation for changing the oil. the generator set model number and serial numbers on Refer to Section 4, Scheduled Maintenance, for a replacement controller. Contact an authorized Kohler maintenance instructions. distributor/dealer for service. After... -
Page 36: Genset System Menu
240 V System factory set and should not require changes to the system settings in the field. A Kohler authorized distributor or dealer can adjust System Freq: these settings, if necessary. If the generator set is 60 Hz 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... -
Page 37: Ats Status Menu
3.14 ATS Status Menu The ATS Status menu displays Model RXT transfer switch and source information. ATS menus appear if a Model RXT transfer switch is The voltage shown in these menus can be calibrated. connected to the generator set. If no transfer switch is Contact an authorized distributor or dealer for service if connected, or another model ATS is connected to the calibration is required. -
Page 38: Ats Configuration Menu
3.15 ATS Configuration Menu Note: The ATS Configuration menu appears only if a ATS ----> Normal Freq: Model RXT transfer switch is connected. Configuration 60.0 Hz Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary. -
Page 39: Date And Time Menu
3.16 Date and Time 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 3-16. Date and Date: Time 02Dec2011... -
Page 40: Networking Information Menus
3.17 Networking Information Menus System. RBUS is a proprietary RS-485 communication protocol. Use the networking menus to view and adjust The Networking Information menu leads to submenus communication settings for systems with remote RBUS for network and RBUS communication settings. devices such as a PIM or LCM, and for systems that use the Kohlerr OnCuer Home Generator Management Networking---->... -
Page 41: Networking Status Submenu
3.17.1 Networking Status Submenu If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the The Networking Status submenu contains settings for IP parameters are displayed. OnCuer. See the OnCue Software Operation Manual for information about the appropriate network settings To enable or disable DHCP and change the IP settings, for OnCue. -
Page 42: Networking Configuration Submenu (Oncue Password)
3.17.2 Networking Configuration OnCue Password Submenu (OnCue Password) For the initial OnCue setup, you will be required to reset the OnCue password on the RDC2 controller, and then The networking Configuration menu includes settings enter it into the OnCue software. To reset the password, used for communication with the Kohlerr OnCuer follow the instructions in Figure 3-19. -
Page 43: Rbus Information Submenu
3.17.3 RBUS Information Submenu Model RXT transfer switch The RBUS Information menu contains settings for Programmable Interface Module (PIM) remote modules that communicate with the RDC2 Load Control Module (LCM) controller using RBUS protocol. This includes the following optional modules: Networking---->... -
Page 44: Remote Devices Submenu
3.17.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: Model RXT ATS Programmable interface module (PIM) Load control module (LCM) <---- Return S/N: XXXXXXXXX S/N: XXXXXXXXX <<*DeviceType*>> <<*DeviceType*>> Device Status: Connected Comm. Errors: 12345 Comm. -
Page 45: Programmable Interface Module (Pim) Menus
3.18 Programmable Interface A personal computer running Kohlerr SiteTecht software is required to change the input and output Module (PIM) Menus settings. Contact an authorized distributor or dealer for service. The PIM status menu displays the status of inputs and outputs connected to the programmable interface The Kohlerr OnCuer Home Management System can module (PIM). -
Page 46: Load Control Menus
3.19 Load Control Menus The test function cycles the relays in the order of their priority. The generator set may be connected to a Load Control For detailed information about load control operation, Module (LCM) or a Model RXT transfer switch equipped refer to TT-1574, provided with the LCM kit, or TT-1609, with a Load Shed kit. -
Page 47: Section 4 Scheduled Maintenance
Do not touch hot engine parts. The engine and exhaust system components become extremely Maintenance and Service Parts. Obtain maintenance hot during operation. and service parts from an authorized Kohler distributor/dealer. TP-6810 11/13 Section 4 Scheduled Maintenance... -
Page 48: Service Schedule
4.2 Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set. Every Every Every Every Every Every 100 Hr. 150 Hr. 400 Hr. 1000 Hr. 1500 Hr. 2000 Hr. Req’d Operation Daily... -
Page 49: Lubrication System
4.3 Lubrication System 4.3.3 Oil Additions Adding some oil between oil changes is normal. The 4.3.1 Oil Specifications amount varies with generator set usage. Open the oil fill cap and pour in a small amount of oil using a funnel or Use oil that displays the American Petroleum Institute other suitable pouring device. -
Page 50: Air Cleaner
Model Oil Capacity, L (qt.) cleaner element. Follow the procedure described 4.7 (5.0) 38RCL, 48RCL, and 60RCL below. Figure 4-3 Oil Capacity Air Cleaner Service Procedure 4. Check for leaks. A dry-type air cleaner silences and filters the intake air. -
Page 51: Exhaust System
Maintain the coolant level in the coolant overflow bottle Check the exhaust gas color. If the exhaust is blue or between the High and Low markings. See Section 1, black, contact your local authorized Kohler distributor/ Service Views, for the coolant overflow bottle location. dealer. -
Page 52: Cooling System Inspection
Generator Set With Block Heater Model neck. The pressure cap raises the boiling point of the 38RCL 15.5 (16.4) 17.0 (18.0) coolant, enabling higher operating temperatures. If 48RCL 17.5 (18.5) 19.0 (20.1) -
Page 53: Ignition System
4.7 Ignition System Note: Do not sandblast, wire brush, scrape, or otherwise service spark plugs in poor Service the spark plugs at the interval specified in the condition. Obtain a new plug for best service schedule using the following procedure. results. -
Page 54: Battery
4.8 Battery 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. Consult battery manufacturer’s instructions Position the side electrode directly over the center regarding battery care and maintenance. -
Page 55: Storage Procedure
Battery short circuits. Explosion can cause severe injury 5. Keep spark plugs in their holes or seal spark plug or death. Short circuits can cause bodily injury and/or holes with suitable threaded metal plugs. equipment damage. Disconnect the battery before generator set installation or maintenance. - Page 56 Notes Section 4 Scheduled Maintenance TP-6810 11/13...
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Page 57: Section 5 Troubleshooting
5.4.2 Fuses If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler Always identify and correct the cause of a blown fuse distributor/dealer. Maintain a record of repairs and before restarting the generator set. Refer to Figure 5-1, adjustments performed on the equipment. -
Page 58: Generator Set Troubleshooting
Battery connections reversed or poor. Check the connections. crank. 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. -
Page 59: Controller Troubleshooting
5.6 Controller Troubleshooting Figure 5-2 contains basic troubleshooting information for the RDC2 controller. Problem Possible Cause Corrective Action Controller LCD Low or no battery voltage. Check connections. display is off. Check generator set battery. See Figure 5-1. Controller display Backlight turns off after about 1 minute with no Backlight will turn on when a button is pressed or backlight is off. - Page 60 Notes Section 5 Troubleshooting TP-6810 11/13...
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Page 61: Appendix A Abbreviations
(2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6810 11/13 Appendix 61... - Page 62 kg/cm kilograms per square normally closed remote terminal unit centimeter National Electrical Code room temperature vulcanization kilogram-meter NEMA National Electrical read/write kg/m kilograms per cubic meter Manufacturers Association Society of Automotive kilohertz NFPA National Fire Protection Engineers Association kilojoule scfm standard cubic feet per minute newton meter kilometer...
- Page 64 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: TP-6810 11/13b Call 1-800-544-2444 or visit KOHLERPower.com E 2012, 2013 by Kohler Co. All rights reserved.