Kohler 38RCL Manual
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Kohler 38RCL Manual

Residential/light commercial generator sets
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Service
Residential/Light Commercial Generator Sets
Models:
38RCL
48RCL
48RCLA
60RCL
Controller:
RDC2
TP-6811 7/16d

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Table of Contents
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Summary of Contents for Kohler 38RCL

  • Page 1 Service Residential/Light Commercial Generator Sets Models: 38RCL 48RCL 48RCLA 60RCL Controller: RDC2 TP-6811 7/16d...
  • Page 2 Kohler strongly recommends that only factory-authorized distributors or dealers install and service the generator.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Table of Contents, continued Section 5 Troubleshooting ..............Introduction .

  • 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 Remove all jewelry before servicing the Combustible materials. A fire can Carbon monoxide detectors. equipment. Discharge static electricity cause severe injury death. Carbon monoxide can cause severe from your body before touching Generator set engine fuels and fuel nausea, fainting, or death. Install batteries by first touching a grounded vapors are flammable and explosive.
  • Page 7 Fuel System Hazardous Noise DANGER CAUTION WARNING Hazardous voltage. Will cause severe injury or death. This equipment must be installed and Hazardous noise. Explosive fuel vapors. serviced qualified electrical Can cause hearing loss. Can cause severe injury or death. personnel. Never operate the generator set Use extreme care when handling, without a muffler or with a faulty...
  • Page 8 Disconnecting the electrical load. Short circuits. Hazardous Testing live electrical circuits. Hazardous voltage cause voltage/current can cause severe Hazardous voltage or current can severe injury or death. Disconnect injury or death. Short circuits can cause severe injury or death. Have the generator set from the load by cause bodily injury and/or equipment trained and qualified personnel take...
  • Page 9 Heavy Equipment Hot Parts Notice NOTICE WARNING WARNING Canadian installations only. standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. Hot coolant and steam. NOTICE Can cause severe injury or death. Unbalanced and elevated weight.
  • Page 10 Notes Safety Precautions and Instructions TP-6811 7/16...

  • Page 11: Introduction

    Information in this publication represents data available service manuals are also available. The following table at the time of print. Kohler Co. reserves the right to lists the available manual part numbers. change this publication and the products represented...

  • Page 12: 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 13: Section 1 Specifications

    Solid State, Volts/Hz Insulation: NEMA MG1 1.3 Engine Service Material Class H Temperature rise 130_C, Standby Model 38RCL generator sets are equipped with 4-cycle, Bearing: quantity, type 1, Sealed six-cylinder, liquid-cooled General Motors engines. Coupling Flexible Disc Amortisseur windings Full...

  • Page 14: Service Views

    31. Engine compartment temperature sensor 15. Line circuit breaker 32. Fans (qty. 3) 16. Generator set master control buttons (on RDC2 controller) 17. RDC2 controller 33. Coolant overflow bottle Figure 1-1 Service Views, Model 38RCL Section 1 Specifications TP-6811 7/16...
  • Page 15 GM83070 ADV-7962 Cooling System Detail 1. Air cleaner 17. Line circuit breaker 2. Nameplate location 18. Generator set master control buttons (on RDC2 controller) 3. Oil check (dipstick) 19. RDC2 controller 4. Engine ECM and EPR (electronic fuel pressure regulator) 20.
  • Page 16 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 17: Section 2 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-6811 7/16 Section 2 Scheduled Maintenance...

  • Page 18: Service Schedule

    2.2 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 19: Lubrication System

    2.3 Lubrication System 2.3.3 Oil Additions Adding some oil between oil changes is normal. The 2.3.1 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 20: Air Cleaner

    6. Reset the maintenance timer on the RDC2. a. In the Overview menu, step down to the Next Maintenance screen. A--273699 A--253104 38RCL 48RCL b. Press the Select button. c. Press the Up arrow button so that Reset Maint Timer? Yes is displayed.

  • Page 21: Exhaust System

    Check that the exhaust outlet is unobstructed. cause severe nausea, fainting, or death. Check the exhaust gas color. If the exhaust is blue or black, contact your local authorized Kohler distributor/ exhaust system must leakproof and routinely inspected. dealer. Visually inspect for exhaust leaks (blowby). Check Generator set operation.

  • Page 22: Ignition System

    2.6 Ignition System 7. 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 WARNING firing tip. See Figure 2-7 to evaluate engine condition by color/condition of a problem spark plug.
  • Page 23 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 24: Battery

    2.7 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 25: Checking Electrolyte Level

    2.7.1 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 26: Fuel System Maintenance

    2.8 Fuel System Maintenance Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized WARNING to 6--8 ounces per square inch (10--14 inches water column).

  • Page 27: Section 3 Controller

    Detail, mini-B connector firmware. SiteTech software available Kohler-authorized distributors and dealers. See the SiteTech Operation Manual, TP-6701, for general software operation instructions. Figure 3-1 USB Cable 1. USB cable connection to PC 2. USB cable connection to controller...

  • Page 28: Controller Parameters

    See the SiteTech Operation number and serial number will need to be entered by the Manual, TP-6701, for general software operation installer. For the genset model number, select 38RCL, instructions. 48RCL, 48RCLA, or 60RCL from the dropdown list.
  • Page 29 ECM Model RBUS Devices Do not change the ECM Model setting (located in the A maximum of three RBUS devices, including one Genset Personality Profile group). Changing the ECM Model RXT transfer switch, one programmable model to the wrong setting can damage the controller. interface module (PIM), and/or one load management device, can be connected to the generator set.
  • Page 30 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Identity Vendor Read Only Kohler Company Identity Product Read Only RDC 2 Identity Firmware Version Read Only Engine Metering Engine Speed R/min Read Only Engine Metering Engine Target Speed...
  • Page 31 Generator Metering Generator Current Average Read Only Generator Metering Generator Frequency Read Only Factory set per Genset Info Genset Model Number Select 38RCL, 48RCL, 48RCLA, or unit. See 60RCL Section 3.3.2 (Dropdown list) Genset Info Genset Serial Number 0--20 characters...
  • Page 32 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Genset Personality Engine Crank Disconnect Speed 300 --1000 Profile Genset Personality Engine Idle Speed 600 -- 3000 1350 Profile Genset Personality Engine Run Speed 1000 -- 3900 1800 Profile Genset Personality Engine Coolant Temperature No effect.
  • Page 33 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Genset Personality Personality Power Rating 50 Hz No effect. Profile 173 346 Genset Personality Personality Power Rating 50 Hz No effect. Profile Delta Genset Personality Personality Fixed Voltage 60 Hz No effect.
  • Page 34 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Genset System Genset Maximum Percent 0 -- 120 70.0 Configuration Capacity Genset System Generator Overloaded Percent 0 -- 120 85.0 Configuration Genset System Under Frequency Shed Level 0 -- 5 Configuration Genset System Base Load Add Time...
  • Page 35 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Voltage Regulator Voltage Regulator Volts Per 1-- 10 Hertz Slope Voltage Regulator Voltage Regulator Volts Per 42 -- 62 Hertz Cut In Frequency Voltage Regulator Voltage Regulator Gain 1 -- 255 Engine Timing Engine Start Delay 0 -- 300...
  • Page 36 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Digital Input A1 Digital Input A1 Value Read Only False Digital Input A1 Digital Input A1 Enabled True or False True Digital Input A1 Digital Input A1 Event See dropdown list Fuel Pressure in SiteTech.
  • Page 37 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Digital Output B9 Digital Output B9 Value Read Only False Load Mgmntw Digital Output B9 Digital Output B9 Event Read Only 65003 Load Mgmntw Digital Output B10 Digital Output B10 Value Read Only False Load...
  • Page 38 0.0.0.0 OnCue 255.255.255.255 Plus Network Configuration Static DNS Server 2 0.0.0.0 -- 0.0.0.0 OnCue 255.255.255.255 Plus Network Configuration Server Host Name devices.kohler.com devices.kohler. OnCue Plus Network Status IP Address Read Only 0.0.0.0 OnCuer Plus Network Status Subnet Mask Read Only 0.0.0.0...
  • Page 39 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes Network Status DNS Server 1 Read Only 0.0.0.0 OnCue Plus Network Status DNS Server 2 Read Only 0.0.0.0 OnCue Plus Network Status MAC Address Read Only OnCue Plus Network Status Connected Server IP Address Read Only 0.0.0.0...
  • Page 40 Adjustment Default Set- Range * ting SiteTech Group Parameter Units Notes RXT, RBUS Devices B2 RBUS Devices B2 Firmware Read Only Version PIM, or Load RBUS Devices B2 RBUS Devices B2 Connected Read Only Mgmntw RBUS Devices B3 RBUS Devices B3 Serial Read Only Number RBUS Devices B3...

  • Page 41: Controller Firmware

    Active Alert controller firmware. Kohlerr distributors can download 1.2 h (if any) the latest software from the Kohler Power Resource Center website. Controller firmware is also available for download on the Kohler dealer portal. Genset Status A personal computer (laptop), a USB cable, and Kohlerr...

  • Page 42: Controller Replacement

    If a controller settings file was created at installation or at some other time when the controller was known to be operating correctly, a personal computer (laptop) with Kohler SiteTech software can be used to load the settings onto the new controller. Hazardous voltage.
  • Page 43 GM66569 GM81217 1. Controller screws (qty. 2) 2. Nameplate location 3. Utility power entry point 4. Customer connection access panel 1. P6 Ethernet connection for OnCuer Plus 2. P1 Figure 3-6 Controller and Access Panel 3. Field circuit breaker (Not connected). Note: Newer RDC2 controllers to not have a field circuit breaker.

  • Page 44: Controller Setup

    Figure 3-8 Voltage and Phase Connections parameters shown in Figure 3-9. Parameter Controller Menu SiteTech Group Settings Genset Model Number 38RCL, 48RCL, 48RCLA, or 60RCL Genset Information Genset Info Genset Serial Number From nameplate; see Figure 3-6. Natural Gas or Fuel Type [...
  • Page 45 Genset M/N: Genset ----> 48RCL Information Genset S/N: ######## Controller S/N: ######## <---- Return tp6810 Figure 3-10 Generator Set Information Menu, RDC2 Genset ----> Fuel Type: System Voltage: See Note. Natural Gas 240 V System Next Exercise 06:30p 15Dec2011 System Freq: 60 Hz Exercise Mode: Unloaded Cycle...
  • Page 46 tt6811 1. Genset model and serial numbers 2. System settings 3. Fuel type (controller firmware version 3.5 or higher) Figure 3-12 Controller Setup Using SiteTecht Section 3 Controller TP-6811 7/16...

  • Page 47: Voltage Calibration

    3.7 Voltage Calibration 3.7.1 Calibration using the RDC2 Controller Keypad and Menus WARNING The controller’s voltage calibration can be adjusted using the controller keypad. See Figure 3-13 and follow the procedure below. Note: A digital voltmeter is required for these Hazardous voltage.
  • Page 48 Generator ----> Metering Three-phase Single-phase Volts L1--L2: Volts: Calibrate Calibrate 240 V 240V Volts L2--L3: Frequency: Calibrate 240 V 60.0 Hz To Calibrate Voltage: 1. Press Select when the voltage is Volts L3--L1: displayed. The voltage flashes. Calibrate 240 V 2.

  • Page 49: Calibration Using Sitetech

    3.7.2 Calibration Using SiteTech voltage readings again. Repeat the procedure using the new values, if necessary. Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 controller. Note: If you would like to simplify the calculation, set the Connect a personal computer (laptop) to the controller calibration factor to 1.0000 and then repeat the using a USB cable and follow this procedure to use...
  • Page 50 1. Voltage calibration factor Figure 3-15 Voltage Calibration Factor in SiteTecht Section 3 Controller TP-6811 7/16...

  • Page 51: Setting The Oncue Password

    3.8 Setting the OnCue Password 4. Press Select. Reset OnCue Password is displayed. If the Kohlerr OnCuer Plus Generator Management 5. Press and HOLD the Select button until Reset System is used to monitor the generator set, reset the OnCue Password? No appears. The word No will OnCue password as described below.
  • Page 52 Notes Section 3 Controller TP-6811 7/16...

  • Page 53: Section 4 Cooling System

    Section 4 Cooling System 4.1 General WARNING WARNING Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, Accidental starting. stop the generator set and allow it to Can cause severe injury or death. cool. Then loosen the pressure cap to relieve pressure.

  • Page 54: Clean Radiator Fins And Inspect Hoses

    4.2 Clean Radiator Fins and Inspect Hoses To prevent generator set from shutting down or becoming damaged due to overheating, keep the cooling air inlets clean and unobstructed at all times. Inspect the exterior of the radiator for obstructions; remove all dirt and foreign material with a soft brush or cloth (to avoid damaging radiator fins).

  • Page 55: Cooling System Inspection

    4.4 Cooling System Inspection 4.6 Draining Cooling System To prevent generator shutdown or damage because of The radiator contains a coolant drain valve to drain the overheating: cooling system. When draining the coolant, remove the radiator’s pressure cap, which will allow the entire Keep the cooling air inlets clean and unobstructed.

  • Page 56: Filling Cooling System

    Coolant Capacity, L (gal.) overflow tube on the filler neck. See Section 1, Generator Set With Block Heater Model Service Views, for the overflow tube location. 38RCL 15 (4.0) 15.6 (4.2) 6. Replace the radiator’s pressure cap. 48RCL 17 (4.5) 17.6 (4.7)

  • Page 57: Cooling Fans

    4.10 Cooling Fans temperature returns to an operating temperature below 46_C (115_F), the fan returns to low-speed operation. 4.10.1 Fan Operation Note: The engine compartment fan continues to run for 2 minutes after the engine stops to evacuate The generator cooling system includes three electric residual engine and exhaust system heat.

  • Page 58: Fan Troubleshooting Guide

    4.10.2 Fan Troubleshooting Guide Symptom Corrective Action All electric fans are not Check fan fuses. operating Check that fan system positive power supply is properly connected to the positive (+) battery terminal. Individual fan is not operating Check fan fuses. Check fan for obstruction.

  • Page 59: Section 5 Troubleshooting

    Section 5 Troubleshooting 5.1 Introduction b. R1 contact energizes the starter solenoid and provides cranking power to the engine. Corrective action and testing in many cases requires 3. Ignition knowledge of electrical systems and electronic circuits. Have an authorized distributor/dealer or trained service a.

  • Page 60: Circuit Protection

    Kohlerr SiteTecht software. WARNING 5.4 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly, contact an authorized Kohler distributor/ dealer for service. Explosive fuel vapors. Can cause severe injury or death. 5.4.1...

  • Page 61: Controller Service Access

    5.6 Controller Service Access 5.7 Fault Messages Section 3.3.1 lists controller settings. Some settings can Note: Read all safety precautions at the beginning of be changed from the controller keypad. All other this publication before performing any work on adjustable settings require a personal computer (laptop) the generator set.
  • Page 62 The generator set shuts down disconnecting non-essential to protect the alternator from damage equipment. Check wiring and caused by overheating the windings. troubleshoot connected (38RCL only) equipment. Check for phase imbalance. Check for very high power factor loads. ATS ComError Warning...
  • Page 63 Fault Message Action Description/ Comments Check CAN Shutdown Shutdown The ECM shut down the engine and Troubleshoot engine reported an unknown fault code. operation per the engine service manual. Chk DateTime Warning Warning DC power to the controller has been Verify the time and date interrupted and the date and time may settings to ensure proper...
  • Page 64 Fault Message Action Description/ Comments Check Engine Speed Low Shutdwn Shutdown The controller shut down the generator, Troubleshoot engine after crank disconnect, because engine operation per the engine speed, as calculated from AC service manual. frequency, was below the low speed setting for 3 seconds or more.
  • Page 65 Fault Message Action Description/ Comments Check Maint Req’d Warning Warning Engine run time, or calendar days, has Change the oil and perform exceeded the maintenance reminder other service according to the setting. service schedule in Section 2.2. Reset the maintenance timer after service.
  • Page 66 Total Power High ShtDwn Measured load is greater than 102% of Reduce the load by the generator set power rating for more disconnecting non-essential than 1 minute. (38RCL only) equipment. Check wiring and troubleshoot connected equipment. Check for phase imbalance.

  • Page 67: Status Messages

    5.8 Status Messages The following messages are displayed to show system digital input is activated; the optional Programmable status. Notices are displayed in the Event History in Interface Module (PIM) is required for display of those SiteTech when active but do not appear on the controller messages as noted in the table.
  • Page 68 Status Message Action Description/ Comments Check Minor Fault Notice The digital output for Minor Fault (PIM) is Check customer equipment active (contacts closed), indicating either connected to the PIM module. the digital input for Ground Fault Check cranking battery Indicator Warning (PIM) is active (low) or condition.
  • Page 69 Status Message Action Description/ Comments Check Load Shed 5 Status Info Notice The digital output for LoadPriority5Shed Remove loads as required. is active (contacts closed), indicating the Check building wiring for 5th priority load shed (load management proper load distribution. device ) has been activated.

  • Page 70: Generator Set Troubleshooting

    5.9 Generator Set Troubleshooting following tables contain generator service manuals. For issues with generator output troubleshooting, diagnostic, and repair information. voltage, refer to the alternator service manual in addition Check for loose connections and incorrect controller to the items mentioned in the tables below. See the List settings before replacing parts.
  • Page 71 Problem Possible Cause Corrective Action Reference Generator set Air cleaner clogged. Clean and/or replace the air cleaner. Generator set operation manual engine starts hard. Recharge or replace the battery. Weak battery. Check for DC voltage on lead CHO to the W/D Section 8 battery.
  • Page 72 Problem Possible Cause Corrective Action Reference Generator set Air cleaner clogged Replace element. Section 2.4 operates Inadequate cooling (hot engine Inspect air inlet and outlet. — erratically only) Check the coolant level. Section 4, Cooling System Check the cooling fan fuses, relays, and operation.
  • Page 73 Problem Possible Cause Corrective Action Reference Engine power loss Refer to the Engine Service Manual for Engine S/M troubleshooting and repair instructions. Generator set overloaded Reduce the load. — Low output or excessive drop If the system is equipped with the load Load management in voltage.

  • Page 74: Controller Troubleshooting

    5.10 Controller Troubleshooting Figure 5-6 contains basic troubleshooting information for the RDC2 controller. Problem Possible Cause Corrective Action Reference Controller LCD Low or no battery voltage Check controller connections. W/D, Section 8 display is off. Check DC power to the RDC2 controller.

  • Page 75: Section 6 Component Testing And Adjustment

    Section 6 Component Testing and Adjustment 6.1 Theory of Operation The generator set utilizes a rotating-field alternator to produce AC voltage. There are two types of alternator available: single phase (see Figure 6-1) and three phase (see Figure 6-2). The alternator is excited by a permanent magnet brushless exciter, providing superior motor starting capability, fault current, transient performance, and longevity.

  • Page 76: Low To No Voltage Operation

    6.2.1 Low to No Voltage Operation 5. If the alternator is able to produce greater than rated voltage while manually excited, the problem This section covers the operation of the alternator most likely lies in the stationary portion of the excitation and troubleshooting information for low or no alternator excitation control system.

  • Page 77: Erratic Voltage Regulation

    6.2.2 Erratic Voltage Regulation To further isolate the cause of an overvoltage condition: Dramatic variations in the alternator voltage (more than 1. Remove the connector from P4 on the RDC2 5 VAC) while the generator is operating at a steady load controller.
  • Page 78 Figure 6-5. 1. Remove the junction box panels from the generator unit remove phototransistor board cover (38RCL) or the LED optic board and holder (48RCL, 48RCLA, and 60RCL). See Figure 6-3 or Figure 6-4. TP-6783-3 1. FRX activator board 2. Photo transistor 3.

  • Page 79: Voltage Connections

    If the output voltage remains high, there is a failure in the SCR assembly and phototransistor board 6.4 Additional Alternator Service (38RCL) or the FRX activator board (48RCL, 48RCLA, and 60RCL). Information 5. With the generator set running at no load,...

  • Page 80: Voltage Adjustments Using Sitetech

    Excitation current control is performed by the patented SiteTech Group Parameter Kohler Hybrid Voltage Regulator. This regulator Genset System Configuration Genset System Voltage consists of a fast-reacting analog inner loop and a Voltage Regulator Average Voltage Adjustment slower digital outer loop.
  • Page 81 Genset ----> System Voltage: System Voltage: 240 V 240 V System System Freq: System Freq: 60 Hz 60 Hz Press the Up or Down arrow button VR Voltage Adj: VR Voltage Adj: to change the setting. 240.0V 240.0V Press the Select button to save the set- ting and move to the next screen.

  • Page 82: Volts/Hz Slope And Cut-In Frequency

    At a gain setting of 1, it will take 128 seconds to adjust except under unique circumstances and under direction the voltage output 1%. At a gain setting of 255, the from a Kohler factory representative. voltage adjustment rate is related to the difference between the target voltage and the measured voltage, If the slope of the Volts/Hz curve is set too low, the but could vary up to 3.1% per second.

  • Page 83: Frequency Adjustment

    6.6 Frequency Adjustment 6.6.2 Hunting/Surging The engine speed regulation gains reside in the engine The engine speed determines the generator output ECU and are not adjustable. Most Hunting or surging frequency; 60 Hz units operate at 1800 RPM and 50 Hz problems are caused by fuel supply pressures that are units run at 1500 RPM.
  • Page 84 1. Engine Speed Adjustment 2. Engine Run Speed Setting (changes automatically with Genset System Frequency) 3. Genset System Frequency Setting (50 or 60 Hz) Figure 6-11 Engine Speed and Frequency Adjustments in SiteTech Section 6 Component Testing and Adjustment TP-6811 7/16...

  • Page 85: Generator Set Switches

    6.7 Generator Set Switches Check the high engine compartment temperature sensor by performing the following test procedure. If the sensor does not function as described, replace it. WARNING Temperature Sensor Test Procedure 1. Press the OFF button on the controller to stop the generator set and allow the generator set to cool.

  • Page 86: Fuel Systems

    6.8 Fuel Systems generator set engine and is designed for a maximum inlet pressure of 2.7 kPa (6 oz./in. ) or 280 mm (11 in.) water column. This regulator is electronically controlled. WARNING Do not attempt to adjust the fuel mixture or engine speed by adjusting the regulators.

  • Page 87: Fuel Solenoid Valves

    6.8.1 Fuel Solenoid Valves 6.8.2 Checking the Fuel Pressure Connect a pressure gauge or manometer to the port on Two 12 VDC solenoid valves are mounted upstream of the bottom of the second (downstream) fuel solenoid the engine on the generator set skid. See Figure 6-14. valve to measure the fuel pressure to the engine.

  • Page 88: Fuel Conversion Procedures

    Use the RDC2 controller menus or a personal computer Natural Gas Connections: (laptop) with Kohler SiteTech software to change the fuel Disconnect lead 65 from N3. type. On controllers with firmware version 4.5 or higher, the fuel type is located in the Genset System menu.

  • Page 89: Section 7 Disassembly/Reassembly

    Section 7 Disassembly/Reassembly 7.1 Introduction 7.2 Initial Steps Perform the following steps before disassembling the WARNING generator set. 1. Disconnect AC power to the generator set by opening the upstream circuit breaker. Disconnect the engine starting battery, negative (--) lead first. Accidental starting.

  • Page 90: Enclosure

    7.3 Enclosure Note: When reassembling the enclosure, do not over-tighten the screws into the aluminum See Figure 7-1 or Figure 7-2 for an illustration of enclosure panels. enclosure parts. Remove enclosure panels as necessary to access the alternator. 1. Roof 2.
  • Page 91 8. End panel (design may vary) Note: Maximum torque for screws into aluminum GM85089_A enclosure panels: 5.7 Nm (50 in. lbs.). Figure 7-2 Enclosure, 38RCL, 48RCL, 48RCLA, and 60RCL (except 48RCL specification number GM78521-GA1; see Figure 7-1) TP-6811 7/16 Section 7 Disassembly/Reassembly...

  • Page 92: Connection Box

    7.4 Connection Box Remove the connection box before removing the alternator. See Figure 7-3. 1. Remove the lower access panel. 2. Remove the controller mounting bolts, lift the controller carefully, and disconnect harnesses to the controller. Then remove the controller. 3.

  • Page 93: Other Components

    7.5 Other Components Note: The air cleaner is mounted above the engine on some models. Figure 7-4 shows components mounted to the exterior of the alternator junction box. Disconnect and remove as needed before disassembling the alternator. GM78526 GM78527 1. Air cleaner assembly (some models have the air cleaner mounted above the engine). Disconnect and remove if necessary. 2.

  • Page 94: Alternator

    7.6 Alternator The alternator is shown in Figure 7-5. Note: Refer to the alternator service manual for instructions to disassemble and reassemble the alternator. 1. Junction box top cover 2. Alternator adapter 3. Fan guard 4. Alternator assembly GM78543_B 5. Junction box Figure 7-5 Alternator Components (see alternator Service Manual for details) Section 7 Disassembly/Reassembly TP-6811 7/16...

  • Page 95: Section 8 Diagrams And Drawings

    Section 8 Diagrams This section contains wiring diagrams and schematics Drawing Description Drawing Number Page for the enclosed generator set. Figure 8-1 lists the Schematic Diagram: drawing numbers and page numbers. Sheet 1 ADV-8484, 1 of 3 Also see Section 1.7, Service Views, for drawings of the Sheet 2 ADV-8484, 2 of 3 generator set.
  • Page 96 Figure 8-2 Schematic Diagram, ADV-8484, Sheet 1 of 3 Section 8 Diagrams TP-6811 7/16...
  • Page 97 Figure 8-3 Schematic Diagram, ADV-8484, Sheet 2 of 3 TP-6811 7/16 Section 8 Diagrams...
  • Page 98 Figure 8-4 Schematic Diagram, ADV-8484, Sheet 3 of 3 Section 8 Diagrams TP-6811 7/16...
  • Page 99 Figure 8-5 Wiring Diagram, GM85226, Sheet 1 of 2 TP-6811 7/16 Section 8 Diagrams...
  • Page 100 Figure 8-6 Wiring Diagram, GM85226, Sheet 2 of 2 Section 8 Diagrams TP-6811 7/16...

  • Page 101: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per minute est. estimated ABDC after bottom dead center center of gravity E--Stop emergency stop alternating current cubic inch displacement etc. et cetera (and so forth) analog to digital centerline...
  • Page 102 Motoren--und Turbinen--Union rnd. round kilobyte (2 bytes) megawatt read only memory KBus Kohler communication protocol milliwatt rot. rotate, rotating kilogram microfarad revolutions per minute F kg/cm kilograms per square N, norm. normal (power source)

  • Page 103: Appendix B Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application: identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 104: Appendix C General Torque Specifications

    Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Torque Aluminum Measurement Grade 2 Grade 5 Grade 8 Size Grade 2 or 5 8--32 Nm (in. lb.) (16) (20) — 10--24 Nm (in.

  • Page 105: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 106: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X--465--17 1/4--20 x .38 X--6238--14...
  • Page 107 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Hex Head Bolts (Full Thread), Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), continued continued M931--05055--60 M5--0.80 x 55 M931--06040--60 M6--1.00 x 40 M933--12016--60...
  • Page 108 Metric, continued Part No. Dimensions Type Hex Nuts M934--03--50 M3--0.50 Standard M934--04--50 M4--0.70 Standard M934--04--B M4--0.70 Brass M934--05--50 M5--0.80 Standard M934--06--60 M6--1.00 Standard M934--06--64 M6--1.00 Std. (green) M6923--06--80 M6--1.00 Spiralock M982--06--80 M6--1.00 Elastic Stop M934--08--60 M8--1.25 Standard M6923--08--80 M8--1.25 Spiralock M982--08--80 M8--1.25 Elastic Stop...
  • Page 109 Notes TP-6811 7/16...
  • Page 110 Notes TP-6811 7/16...
  • Page 112 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-6811 7/16d Call 1-800-544-2444 or visit KOHLERPower.com E 2012, 2014, 2015, 2016 by Kohler Co. All rights reserved.

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