Kohler 48RCLB Operation
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Kohler 48RCLB Operation

Residential/light commercial generator sets
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Operation
Residential/Light Commercial Generator Sets
Model:
48RCLB
60RCLA
Controller:
RDC2
TP-7102 3/20c

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Summary of Contents for Kohler 48RCLB

  • Page 1 Operation Residential/Light Commercial Generator Sets Model: 48RCLB 60RCLA Controller: RDC2 TP-7102 3/20c...

  • 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 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, Explosion. maintained. To prevent accidents be aware of potential dangers and act Can cause severe injury or death.
  • Page 6 metal surface away from the battery. To Combustible materials. A fire can If experiencing any of these symptoms avoid sparks, do not disturb the battery cause severe injury death. and carbon monoxide poisoning is charger connections while the battery Generator set engine fuels and fuel possible, seek fresh air immediately is charging.
  • Page 7 Hazardous Voltage/ Explosive fuel vapors can cause Disconnecting the electrical load. severe injury or death. Take Hazardous voltage will cause severe Moving Parts additional precautions when using the injury or death. Disconnect the following fuels: generator set from the load by turning DANGER off the line circuit breaker or by Propane (LPG)—Adequate ventilation...
  • Page 8 Hot Parts Notice Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install NOTICE WARNING a transfer switch in standby power Canadian installations only. installations to prevent the connection standby service connect the output of of standby and other sources of power.

  • 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 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, 48RCLB G4-276 Specification Sheet, 60RCLA G4-277 Installation Manual, Generator Set TP-7101...

  • Page 11: Service Assistance

    Visit the Kohler Co. website at KOHLERPower.com. Fax: (65) 6264-6455 China Look at the labels and decals on your Kohler product North China Regional Office, Beijing or review the appropriate literature or documents Phone: (86) 10 6518 7950 included with the product.
  • Page 12 Notes Service Assistance TP-7102 3/20...

  • Page 13: Section 1 Service Views

    Section 1 Service Views SERVICE SIDE GM103966 ADV-8954 Cooling System Detail NON-SERVICE SIDE 1. Nameplate location 17. Generator set master control buttons (on RDC2 controller) 2. Engine ECM and EPR (electronic fuel pressure regulator) 18. RDC2 controller 3. Oil check (dipstick) 19.
  • Page 14 Notes Section 1 Service Views TP-7102 3/20...

  • 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 Disabling the generator set. Accidental starting can Battery electrolyte is a diluted sulfuric acid. Battery acid cause severe injury or death. Before working on the can cause severe injury or death. Battery acid can cause generator set or equipment connected to the set, disable the blindness and burn skin.

  • Page 17: Exercising The Generator Set

    2.4 Generator Set Operation To ensure continued satisfactory operation perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in 2.4.1 Local Starting and Stopping the service schedule. In addition, some checks require verification after the unit starts.

  • Page 18: Automatic Operation With Other Transfer Switches

    If a Kohler Model RDT transfer switch is used, the high limit during the cooldown cycle. engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set.

  • Page 19: Unloaded Full-Speed Exercise

    2.5.1 Unloaded Cycle Exercise with or low charging battery is displayed and the exercise does not start. Complete System Diagnostics Coolant level check. The coolant level is checked. An unloaded cycle exercise runs the generator set without signalling the transfer switch to transfer the Communication integrity tests.

  • Page 20: Exerciser Reset

    For a loaded exercise with a transfer switch other than a 2. Next, the date is displayed with the year flashing. Kohlerr Model RXT, program the exercise at the Use the up or down arrow key to step to the current transfer switch controller.
  • Page 21 2. Press the Select button to go to the main menu. 11. If the generator set is connected to a Kohlerr Model See Figure 2-2. RXT transfer switch, the exercise can be changed to a loaded exercise. Set the Exercise Mode to 3.
  • 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-7102 3/20...

  • Page 29: 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 48RCLB and 60RCLA 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 and backlit liquid crystal diode (LCD) display with adjustable down arrow buttons to adjust the contrast.

  • Page 32: 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-7102 3/20...
  • 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: 12Jan2018...

  • 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:...

  • 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

    - - > 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 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 02Feb2018...

  • 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 (Oncuer 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 DANGER WARNING Hazardous voltage. Moving parts. Will cause severe injury or death. Accidental starting. Operate the generator set only when Can cause severe injury or death. all guards and electrical enclosures are in place. Disconnect the battery cables before working generator...

  • Page 50: Service Schedule

    Have an authorized injury or death. Vaporized fuels are highly explosive. Use Kohler distributor/dealer perform generator set service. extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment Engine Service.
  • Page 51 Service Schedule Reference Daily or Before Each Use Check oil level and add oil if necessary. See Section 4.3 Check coolant level and add coolant if necessary. w See Section 4.6 Check for fluid leaks. Check battery connections for tightness and signs of corrosion. See Section 4.8 Check for fuel leaks, hissing, or gas odors.

  • Page 52: Lubrication System

    Open the oil fill cap and pour in a small amount of oil using a funnel or Kohler recommends KOHLERr Genuine Oil, 10W- 40 other suitable pouring device. See Section 1, Service or equivalent.
  • 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) 48RCLB and 60RCLA Figure 4-3 Oil Capacity TP-7102 3/20 Section 4 Scheduled Maintenance...

  • Page 54: Air Cleaner

    4.4 Air Cleaner Air Cleaner Service Procedure A dry-type air cleaner silences and filters the intake air. WARNING See Figure 4-4. The air intake silencer assembly connects to the intake manifold via a rubber hose. Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working generator...

  • Page 55: Exhaust System

    Check the exhaust gas color. If the exhaust is blue or within minutes of breathing fresh air. black, contact your local authorized Kohler distributor/ dealer. Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death.

  • 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

    4.7 Spark Plugs 4.6.4 Flushing and Cleaning For optimum protection, drain, flush, and refill the WARNING cooling system at the interval listed in the service schedule. Flushing and Cleaning Procedure 1. Flush the system with clean water. Accidental starting. Can cause severe injury or death. 2.
  • Page 58 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.
  • 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

    Kohler distributor/ dealer for service. If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler 5.4.1 Load Circuit Breaker distributor/dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the...

  • 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-7102 3/20...

  • 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-7102 3/20 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-7102 3/20...
  • Page 70 Notes TP-7102 3/20...
  • Page 72 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-7102 3/20c For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2018 Kohler Co. All rights reserved.

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60rclaRdc2

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