Kohler 48RCL Operation
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Kohler 48RCL Operation

Residential/light commercial generator sets
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Operation
Residential/Light Commercial Generator Sets
Model:
38RCL
48RCL
48RCLA
60RCL
Controller:
RDC2
TP-6810 7/16d

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Summary of Contents for Kohler 48RCL

  • Page 1 Operation Residential/Light Commercial Generator Sets Model: 38RCL 48RCL 48RCLA 60RCL Controller: RDC2 TP-6810 7/16d...

  • Page 2: Product Identification Information

    State of California to to cause cancer, birth defects, or other cause cancer, birth defects, or other reproductive harm. reproductive harm. Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator. Product Identification Information Product identification numbers determine service parts.

  • 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

    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. 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 Grounding electrical equipment. is mandatory. Because propane is Hazardous voltage cause Moving Parts heavier than air, install propane gas severe injury or death. Electrocution detectors low in a room. Inspect the is possible whenever electricity is WARNING detectors manufacturer’s...
  • Page 8 Short circuits. Hazardous Servicing the generator set when it WARNING voltage/current can cause severe is operating. Exposed moving parts injury or death. Short circuits can can cause severe injury or death. cause bodily injury and/or equipment Keep hands, feet, hair, clothing, and damage.

  • Page 9: Introduction

    Refer to the Installation Manual for installation instructions. Information in this publication represents data available Genset Model at the time of print. Kohler Co. reserves the right to Spec Number change this publication and the products represented Serial Number without notice and without any obligation or liability Material Number whatsoever.
  • Page 10 TP-6809 Operation Manual, Engine TP-6101 Service Manual, Generator Set TP-6811 Service Manual, 38RCL Engine Mechanical TP-6103 Service Manual, 48RCL, 48RCLA, and 60RCL Engine Mechanical TP-6104 Service Manual, Engine ECM Diagnostics TP-6724 Service Manual, Alternator, 38RCL TP-6353 Service Manual, Alternator, 48RCL,...

  • Page 11: Service Assistance

    Phone: (86) 10 6518 7950 KOHLERPower.com. (86) 10 6518 7951 (86) 10 6518 7952 Look at the labels and decals on your Kohler product Fax: (86) 10 6518 7955 or review the appropriate literature or documents included with the product.
  • Page 12 Notes Service Assistance TP-6810 7/16...

  • 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 Service Views, 38RCL, 48RCL (38RCL shown) TP-6810 7/16 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.

  • Page 15: Section 2 Generator Set Operation

    Section 2 Generator Set Operation 2.1 Operating Area 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 WARNING openings in the building within 1.5 m (5 ft.) of the generator set exhaust outlet in any direction.
  • Page 16 WARNING WARNING Hazardous voltage. Moving parts. Can cause severe injury or death. Sulfuric acid in batteries. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures Wear protective goggles are in place. clothing. Battery acid may cause blindness and burn skin.

  • Page 17: Exercising The Generator Set

    Note: Block heater damage. The block heater will fail When utility power is restored, the transfer switch if the energized heater element is not immersed transfers the load back to utility, runs the generator set in coolant. Fill the cooling system before turning with no load to cool down the engine, and then stops the on the block heater.

  • Page 18: Automatic Operation With Model Rxt Transfer Switch

    Transfer Switches recommended exercise mode and is the factory-default exercise setting. If a Kohler Model RDT transfer switch is used, the engine start contacts from the ATS must be connected The Unloaded Cycle exercise runs the engine for to engine start leads 3 and 4 on the generator set.

  • Page 19: Unloaded Full-Speed Exercise

    Ramps down and runs at reduced speed for Oil pressure. Oil pressure is verified to ensure 5 minutes to cool down the engine before shutting proper lubrication of critical engine components. down automatically. 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.

  • Page 20: Power Failure During Exercise

    2.5.5 Power Failure During Exercise 9. Press Select. The controller exits the exercise menu. If the utility power is lost during an unloaded exercise, the ATS transfers to the emergency source, the exercise 10. Press the Auto button and verify that the AUTO is ended and the control remains in the AUTO mode.
  • Page 21 12. Set the exercise frequency (weekly or every two After a scheduled exercise run, the next exercise time weeks). Weekly exercises are recommended. and date will be updated automatically based on the Exercise Frequency setting. 13. Press the down arrow button to step to the Return menu.
  • Page 22 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-...

  • Page 23: 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 24 Warning (W) or Shutdown (SD) Condition Fault Check AC Sens Lost W (1 sec.) AC Sensing Lost. In Auto mode, generator Contact an authorized output AC sensing is lost. Starts 10 seconds distributor/dealer for service. SD (3 sec.) after crank disconnect. Warning: after 1 second if no output detected after crank disconnect.
  • Page 25 Warning (W) or Shutdown (SD) Condition Fault Check Exer Not Sch Exercise Not Scheduled. No exercise has been See Section 2.5 for instructions to set scheduled on the RDC2 controller. the exerciser. Generator Governed frequency exceeds 110% of the Contact an authorized Frequency High system’s frequency setpoint for more than 10 distributor/dealer for service.

  • Page 26: 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 27: 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 28 Notes Section 2 Generator Set Operation TP-6810 7/16...

  • Page 29: Section 3 Rdc2 Controller Operation

    Switch Controller Figure 3-1 illustrates the keypad, display, and indicators on the controller’s user interface. Model 38RCL, 48RCL, 48RCLA and 60RCL generator sets are equipped with the RDC2 generator set/transfer switch controller. The RDC2 controls the following power system components:...

  • Page 30: 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 31: 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 32: 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 33 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.

  • Page 34: 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 35: 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 36: Generator Metering Menu

    Voltage Calibration The voltage calibration mode can be entered from the The generator metering menu displays the generator Generator Metering menu. Contact a Kohler-authorized voltage and frequency. See Figure 3-10. distributor/dealer for service. The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration, if necessary.

  • Page 37: 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 38: 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 39: 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 40: 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 41: 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 42: Networking Information Menus

    3.17 Networking Information Menus The Networking Information menu leads to submenus for network and RBUS communication settings. Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or load management device, and for systems that use the Kohlerr OnCuer Plus Home Generator Management System.

  • Page 43: 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 OnCuer Plus Software Operation Manual for information about the appropriate To enable or disable DHCP and change the IP settings, network settings for OnCuer Plus.

  • Page 44: 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 (OnCuer Plus Password) For the initial OnCue Plus setup, you will be required to reset the OnCue password on the RDC2 controller, and The networking Configuration menu includes settings then enter it into the OnCue Plus software.

  • Page 45: 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 46: 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.

  • Page 47: 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 Generator Management module (PIM).

  • Page 48: 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 49: Section 4 Scheduled Maintenance

    Section 4 Scheduled Maintenance 4.1 General Maintenance WARNING WARNING Hazardous voltage. Moving parts. Can cause severe injury or death. Operate the generator set only when Accidental starting. all guards and electrical enclosures Can cause severe injury or death. are in place. Disconnect the battery cables before working generator...
  • Page 50 A successful test depends on the ability of the solution to bubble. Maintenance and Service Parts. Obtain maintenance and service parts from an authorized Kohler The engine and generator set may use both American distributor/dealer.

  • Page 51: 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 52: 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 53 3. Fill with oil. See Figure 4-1 for oil selection and Figure 4-3 for oil capacity. Model Oil Capacity, L (qt.) 4.7 (5.0) 38RCL, 48RCL, 48RCLA, and 60RCL Figure 4-3 Oil Capacity 4. Check for leaks. a. Press the OFF button on the RDC2 generator set controller.

  • Page 54: Air Cleaner

    4.4 Air Cleaner WARNING A--273699 A--253104 38RCL 48RCL Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

  • Page 55: Exhaust System

    Check the exhaust gas color. If the exhaust is blue or black, contact your local authorized Kohler distributor/ Carbon monoxide detectors. Carbon monoxide can dealer.

  • Page 56: Cooling System

    4.6 Cooling System 4.6.2 Cooling System Inspection To prevent generator shutdown or damage because of WARNING overheating: Keep the cooling air inlets clean and unobstructed Inspect the radiator’s exterior for obstructions and remove dirt and foreign material with a soft brush or Hot coolant and steam.

  • Page 57: Flushing And Cleaning

    Filling Cooling System WARNING Coolant Capacity, L (gal.) Generator Set With Block Heater Model 38RCL 15 (4.0) 15.6 (4.2) 48RCL 17 (4.5) 17.6 (4.7) 48RCLA 20.8 (5.5) 21.4 (5.7) Accidental starting. Can cause severe injury or death. 60RCL 20.8 (5.5) 21.4 (5.7)
  • Page 58 Model Spark plug gap 12. Use a torque wrench to torque each spark plug to 38RCL, 48RCL, 48RCLA, and 15 Nm (11 ft. lbs.). Otherwise, hand-tighten the 0.9 mm (0.035 in.) 60RCL spark plug until you feel resistance.
  • Page 59 Problem/Condition Means of Identification Possible Cause/Solution Gap-bridged spark Built-up deposits and gap between electrodes Oil or carbon fouling. Clean and regap the spark plug closing. plug. Oil-fouled spark plug Wet, black deposits on the insulator shell, bore, Excessive oil entering combustion chamber and electrodes.

  • Page 60: 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 61: 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 62: Storage Procedure

    4.9 Storage Procedure 5. Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs. WARNING 6. 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.

  • Page 63: 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 64: 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 65: 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 66 Notes Section 5 Troubleshooting TP-6810 7/16...

  • Page 67: 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 7/16 Appendix 67...
  • Page 68 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 69 Notes TP-6810 7/16...
  • Page 70 Notes TP-6810 7/16...
  • Page 72 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER authorized installation, service, and sales dealer in TP-6810 7/16d the US and Canada: Original Instructions (English) Call 1-800-544-2444 or visit KOHLERPower.com E 2012, 2013, 2015, 2016 by Kohler Co. All rights reserved.

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38rcl48rcla60rcl

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