Related Manuals for Kohler 30RCL
Summary of Contents for Kohler 30RCL
- Page 1 Operation Residential/Light Commercial Generator Sets Models: 24RCL 30RCL 38RCLB Controller: RDC2 TP-6905 7/18c...
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Page 2: Product Identification Information
State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator. Product Identification Information... -
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 .
- Page 5 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.
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Page 6: Safety Precautions And Instructions
metal surface away from the battery. To minimize the risk of fire or explosion. possibility carbon monoxide avoid sparks, do not disturb the battery Equip the compartment or nearby area poisoning. Seek medical attention if charger connections while the battery with a fully charged fire extinguisher. - Page 7 Hazardous Voltage/ Propane (LPG)—Adequate ventilation CAUTION is mandatory. Because propane is Moving Parts heavier than air, install propane gas detectors low in a room. Inspect the DANGER detectors manufacturer’s instructions. Natural Gas—Adequate ventilation is Welding the generator set. mandatory. Because natural gas rises, cause severe electrical...
- Page 8 Hot Parts Notice Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. NOTICE WARNING Reconnect battery correctly, Canadian installations only. positive to positive and negative to standby service connect the output of negative, to avoid electrical shock and the generator set to a suitably rated damage to the battery charger and transfer switch in accordance with...
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Page 9: Introduction
Genset Model Information in this publication represents data available Spec Number at the time of print. Kohler Co. reserves the right to Serial Number change this publication and the products represented Material Number without notice and without any obligation or liability... - Page 10 Service Manual, KG2204/KG2204T Engine Mechanical TP-6902 Service Manual, Engine ECM Diagnostics TP-6903 Parts Catalog, KG2204/KG2204T Engine TP-6904 Parts Catalog, 24RCL, 30RCL, 38RCLB Generator Set TP-6908 Operation Manual, OnCuer Plus Software TP-6928 Operation/Installation Manual, RXT ATS TP-6807 Operation/Installation Manual, RDT ATS...
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Page 11: Service Assistance
Visit the Kohler Co. website at KohlerPower.com. (86) 10 6518 7952 Fax: (86) 10 6518 7955 Look at the labels and decals on your Kohler product East China Regional Office, Shanghai or review the appropriate literature or documents Phone: (86) 21 6288 0500 included with the product. - Page 12 Notes Service Assistance TP-6905 7/18...
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Page 13: Section 1 Service Views
Section 1 Service Views SERVICE SIDE GM90230 ADV-8641 Cooling System Detail NON-SERVICE SIDE 1. Oil check (dipstick) 17. RDC2 controller 2. Oil fill location (on valve cover) 18. Fan fuses 3. See cooling system detail 19. Cooling air inlet (remove this panel to access coolant drain) 4. - Page 14 17. Cooling air inlet (remove this panel to access coolant drain) 35. Oil cooler hoses 18. See cooling system detail 36. Oil cooler (at bottom of radiator) Figure 1-2 30RCL and 38RCLB Service Views for Maintenance Section 1 Service Views TP-6905 7/18...
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Page 15: Section 2 Generator Set Operation
Section 2 Generator Set Operation 2.1 Operating Area Notice Do not locate patios, decks, play areas, or animal WARNING 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. - Page 16 DANGER WARNING Hazardous voltage. Will cause severe injury or death. Sulfuric acid in batteries. This equipment must be installed and Can cause severe injury or death. serviced qualified electrical Wear protective goggles personnel. clothing. Battery acid may cause blindness and burn skin. Grounding electrical equipment.
- Page 17 Drive Belt. Check the belt condition of the water pump Check that there are no combustible materials near and battery charging alternator belt. the exhaust outlet. Check that the exhaust outlet is unobstructed. Exhaust System. Check for exhaust leaks and blockages.
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Page 18: Exercising The Generator Set
2.3 Exercising the Generator Set The engine cooldown time delay is set to 5 minutes. The engine stops before the cooldown time delay expires if Operate the generator set without load every week or the temperature drops below the cooled-down every other week for 20 minutes. -
Page 19: Automatic Operation With Other Transfer Switches
Transfer Switches The Unloaded Cycle exercise runs the engine for If a Kohler Model RDT transfer switch is used, the 20 minutes in the cycle shown in Figure 2-1 and engine start contacts from the ATS must be connected described below. -
Page 20: Unloaded Full-Speed Exercise
2.5.4 Shutdown During Exercise Communication integrity tests. J1939, RBUS, Ethernet, and USB are monitored for messages The following advanced diagnostic operation applies to indicating that the controller and wiring are reliable. RDC2 controllers with firmware versions 5.04 and Engine speed. Engine speed is measured at low higher. -
Page 21: Changing The Exercise Setting
4. The time is displayed with the hour flashing. Use 3. Press the down arrow button to step to the Genset the up or down arrow key to step to the current hour System menu. and am or pm setting. 4. - Page 22 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-6905 7/18...
- Page 23 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/ Un-...
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Page 24: Faults
2.6 Faults 2.6.3 ATS Communication Errors When a Model RXT transfer switch is used, an ATS fault Selected fault conditions are shown in Figure 2-5. Fault indicates that the connection to the interface board on conditions are classified as warnings or shutdowns. If a the transfer switch has been lost. - Page 25 Fault (RDC2) Fault (OnCuer Condition Check Plus) AC Sens Loss AC Sensing AC Sensing Lost. In Auto mode, generator Contact an authorized Lost output AC sensing is lost. Detection begins 10 distributor/dealer for service. Warning seconds after crank disconnect. (1 sec.) Warning: after 1 second if no output detected Shutdwn after crank disconnect.
- Page 26 Fault (RDC2) Fault (OnCuer Condition Check Plus) CoolTemp Vhi Ect Higher Coolant temperature is extremely high. Check coolant level. Shutdwn Than Check radiator and fans for Expected 2 obstruction. Contact an authorized distributor/dealer for service and provide the fault code. CoolntTemp 0 Coolant Temp 0 The ECM reported a problem with the coolant...
- Page 27 Fault (RDC2) Fault (OnCuer Condition Check Plus) Genset S/N Unavailable Generator set serial number is unavailable. Contact an authorized Unaval Warning Genset Serial distributor/dealer for service. See Number section 3.11. Ground Fault Ground Fault The digital input for Ground Fault Warning is Check customer equipment Warning Warning...
- Page 28 Fault (RDC2) Fault (OnCuer Condition Check Plus) PrimLoopOpn Primary Loop Ignition coil 1 voltage is below normal or Check the battery voltage. Warning Open there is an open circuit. Contact an authorized distributor/dealer for service and provide the fault code. PrimLoopSht Primary Loop Ignition coil 1 voltage is abnormal.
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Page 29: 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 30: 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 31: Section 3 Rdc2 Controller Operation
3.2 Controls and Indicators Switch Controller Figure 3-1 illustrates the keypad, display, and indicators on the controller’s user interface. Model 24RCL, 30RCL, and 38RCLB generator sets are equipped with the RDC2 generator set/transfer switch controller. The RDC2 controls the following power system components:... -
Page 32: 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 33: 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 and backlit liquid crystal diode (LCD) display with adjustable down arrow buttons to adjust the contrast. -
Page 34: Controller Power
Note: If no buttons are pushed, the controller exits the menus and returns to the generator set status Have controller setup and adjustment performed only by display after 5 minutes. an authorized Kohler distributor/dealer or authorized representative. Section 3 RDC2 Controller Operation TP-6905 7/18... - Page 35 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: 03Jan2014 2.
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Page 36: 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 37: 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 38: 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 39: 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 40: Genset System Menu
----> System Voltage: 240 V System 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 System Freq: 3.5 for instructions to enable editing and change the... -
Page 41: 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 42: 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 43: 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 02Dec2014... -
Page 44: Networking Information Menus
3.17 Networking Information Menus Generator Management 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 load management device, and for systems that use the Kohlerr OnCuer Plus Home Networking---->... -
Page 45: 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 Plus. See the OnCue Plus Software Operation Manual for information about the appropriate To enable or disable DHCP and change the IP settings, network settings for OnCue Plus. -
Page 46: Networking Configuration Submenu (Oncue Plus Password)
3.17.2 Networking Configuration Note: Use the OnCue password shown on the controller display for OnCue Plus applications. Submenu (OnCue Plus Password) The networking Configuration menu includes settings For the initial OnCue Plus setup, you will be required to reset the OnCue password on the used for communication with the Kohlerr OnCuer Plus RDC2 controller, and then enter it into the OnCue Generator Management System. -
Page 47: 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 Shed Kit or RXT combined interface/load controller using RBUS protocol. This includes the management board following optional modules: Networking---->... -
Page 48: 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 Shed Kit or RXT combined interface/load management board The serial numbers for the PIM and load shed kit are printed on the circuit boards inside the enclosures. -
Page 49: 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 Plus Management System can be module (PIM). -
Page 50: Load Control Menus
3.19 Load Control Menus device adds and sheds loads based on the generator current. The Load Control menu displays the status of the load The test function cycles the relays in the order of their management inputs and outputs, and allows a test of the priority. -
Page 51: Section 4 Scheduled Maintenance
Section 4 Scheduled Maintenance 4.1 General Maintenance Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power. Operating the heater before WARNING installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater or nearby parts. - Page 52 Do not use a soap solution containing either ammonia or Maintenance and Service Parts. Obtain maintenance chlorine because both prevent bubble formation. A successful and service parts from an authorized Kohler test depends on the ability of the solution to bubble. distributor/dealer.
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Page 53: Service Schedule
4.2 Service Schedule Procedure Visually Inspect Check Change Clean Test Section System Component or Procedure Frequency General Maintenance Fluid leaks Daily Engine oil level Daily Coolant level 4.6.1 Daily Obstructions or combustible materials near Weekly exhaust outlet Leaks, hissing, and gas odor Weekly Bolts and nuts for tightness Quarterly or 20 hours... -
Page 54: Lubrication System
4.3 Lubrication System 4.3.4 Oil and Filter Change WARNING 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. Accidental starting. - Page 55 [Torque = 25 Nm (18.4 ft. lbs.)]. 3. Fill with oil. Use 5W-30 for oil selection and Figure 4-2 for oil capacity. Model Oil Capacity, L (qt.) 4.2 (4.4) 24RCL, 30RCL, and 38RCLB Figure 4-2 Oil Capacity TP-6905 7/18 Section 4 Scheduled Maintenance...
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Page 56: Air Cleaner
4.4 Air Cleaner WARNING Accidental starting. 1. Air Cleaner Cover Can cause severe injury or death. GM90280 Disconnect the battery cables before Figure 4-3 Air Cleaners working generator set. Remove the negative (--) lead first 1. Release the retaining clips to open the cover and when disconnecting the battery. -
Page 57: Cooling System
Check the exhaust gas color. If the exhaust is blue or D Light-headedness, dizziness black, contact your local authorized Kohler distributor/ D Physical fatigue, weakness in dealer. joints and muscles D Sleepiness, mental fatigue, Visually inspect for exhaust leaks (blowby). -
Page 58: Checking And Filling Coolant
Remove Block Heater Engine Model dirt and other debris from the pressure cap and filler 24RCL, 30RCL, 38RCLB 13.2 (3.5) 13.7 (3.6) neck. The pressure cap raises the boiling point of the coolant, enabling higher operating temperatures. If... -
Page 59: Ignition System
softened water to inhibit rust/corrosion and prevent Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the freezing. The coolant capacity is shown in generator set or equipment connected to the set, disable the Figure 4-5. - Page 60 Model Spark Plug Gap 24RCL 0.9–1.0 mm (0.036–0.040 in.) 15. Use a torque wrench to tighten each spark plug to 30RCL and 38RCLB 0.7--0.8 mm (0.028--0.030 in.) the torque shown in Figure 4-9. Figure 4-6 Spark Plug Gap Model Spark Plug Torque 24RCL 18 Nm (13.3 ft.
- Page 61 Problem/Condition Means of Identification Possible Cause/Solution Gap-bridged spark Built-up deposits and gap between Oil or carbon fouling. Clean and regap the spark plug electrodes closing. plug. Oil-fouled spark plug Wet, black deposits on the insulator shell, Excessive oil entering combustion chamber through bore, and electrodes.
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Page 62: Battery
4.8 Battery 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 Consult battery manufacturer’s instructions set installation or maintenance. Remove all jewelry before regarding battery care and maintenance. servicing the equipment. -
Page 63: Checking Electrolyte Level
4.8.1 Checking Electrolyte Level Temperature Correction C F Check the electrolyte level of batteries with filler caps 71.1 + .032 monthly. Remove filler caps and verify that electrolyte + .030 level reaches bottom of filler holes. Refill as necessary 65.6 + .028 EXAMPLE NO. -
Page 64: Storage Procedure
4.9 Storage Procedure 4. Check the engine coolant protection; see Section 4.6. DANGER Note: Use antifreeze capable of withstanding the lowest possible temperatures. 5. Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs. Hazardous voltage. -
Page 65: Section 5 Troubleshooting
If the procedures in this manual do not explain how to in the event of a fault in the wiring between the generator correct the problem, contact an authorized Kohler and the load. If the circuit breaker trips, reduce the load distributor/dealer. -
Page 66: 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 67: 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 68 Notes Section 5 Troubleshooting TP-6905 7/18...
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Page 69: 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 exh. exhaust... - Page 70 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 72 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-6905 7/18c For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2014, 2015, 2016, 2018 by Kohler Co. All rights reserved.