Kohler 24RCL Manual
  1. Manuals
  2. Brands
  3. Kohler Manuals
  4. Inverter
  5. 24RCL
  6. Manual
Kohler 24RCL Manual

Kohler 24RCL Manual

Residential/light commercial generator sets
Hide thumbs Also See for 24RCL:
Table of Contents

Advertisement

Quick Links

Service
Residential/Light Commercial Generator Sets
Models:
24RCL
30RCL
38RCLB
Controller:
RDC2
TP-6907 5/16c

Advertisement

Table of Contents
loading

Related Manuals for Kohler 24RCL

Summary of Contents for Kohler 24RCL

  • Page 1 Service Residential/Light Commercial Generator Sets Models: 24RCL 30RCL 38RCLB Controller: RDC2 TP-6907 5/16c...

  • 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 WARNING CAUTION WARNING Hazardous voltage. Backfeed to the utility system can cause property damage, severe Hazardous noise. injury, or death. Explosive fuel vapors. Can cause hearing loss. Can cause severe injury or death. If the generator set is used for Never operate the generator set standby power, install an automatic Use extreme care when handling,...
  • Page 8 when standing in water or on wet Servicing the generator set when it Welding on the generator set. Can ground because these conditions is operating. Exposed moving parts cause severe electrical equipment increase the risk of electrocution. can cause severe injury or death. damage.
  • 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-6907 5/16...

  • 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

    Visit the Kohler Power Systems website at Phone: (86) 21 6288 0500 KohlerPower.com. Fax: (86) 21 6288 0550 Look at the labels and decals on your Kohler product India, Bangladesh, Sri Lanka or review the appropriate literature or documents India Regional Office included with the product.

  • Page 13: Section 1 Specifications

    Generator sets covered in this manual are equipped with a 2.2L (134.25 cu. in.) 4-cycle, four-cylinder, 1.6 Torque Specifications liquid-cooled Kohler engine. For engine service information and specifications not For alternator assembly torque specifications, refer to the alternator service manual.

  • Page 14: Service Views

    29. Pressure cap (engine coolant fill) 14. Fuel solenoid valves (qty. 2) or dual-solenoid fuel valve 30. Coolant overflow tube 15. Lube oil filter 16. Customer load lead access 31. Coolant overflow bottle Figure 1-1 24RCL Service Views Section 1 Specifications TP-6907 5/16...
  • Page 15 SERVICE SIDE GM92075 ADV-8663 Cooling System Detail NON-SERVICE SIDE 1. Oil check (dipstick) 19. Access to coolant fill (on roof) 2. Oil fill location (on valve cover) 20. Turbocharger 3. Exhaust outlet 21. Air-fuel mixer 4. Enclosure locking key (shipping location only) 22.
  • Page 16 Notes Section 1 Specifications TP-6907 5/16...

  • Page 17: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance 2.1 General Maintenance DANGER WARNING Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before Accidental starting. opening the enclosure. Can cause severe injury or death. Disconnect the battery cables before WARNING working generator set.
  • Page 18 Have an authorized Kohler distributor/dealer perform generator set service. Maintenance and Service Parts. Obtain maintenance and service parts from an authorized Kohler Engine Service. Perform generator set engine service distributor/dealer. at the intervals specified by the engine operation manual.

  • Page 19: Service Schedule

    2.2 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 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 20: Lubrication System

    Oil Capacity, L (qt.) amount varies with generator set usage. Open the oil fill 4.2 (4.4) 24RCL, 30RCL, and 38RCLB cap and pour in a small amount of oil using a funnel or Figure 2-2 Oil Capacity other suitable pouring device. See Section 1, Service Views, for the oil check and oil fill locations.

  • Page 21: Air Cleaner

    4. Check for leaks. dirty, dusty conditions. Check the element for accumulated oil or dirt that could cause poor a. Press the OFF button on the RDC2 generator performance. Replace a damaged air cleaner element. set controller. Follow the procedure described below. b.

  • Page 22: Exhaust System

    2.5 Exhaust System CAUTION WARNING Hazardous noise. Can cause hearing loss. Carbon monoxide. cause severe nausea, Never operate the generator set fainting, or death. without a muffler or with a faulty exhaust system. exhaust system must leakproof and routinely inspected. At the interval specified in the service schedule, inspect the exhaust system components (exhaust manifold, Generator set operation.

  • Page 23: Spark Plug

    Reconnect the negative (--) lead last when reconnecting the battery. Model Spark Plug Gap 24RCL 0.9–1.0 mm (0.036–0.040 in.) Disabling the generator set. Accidental starting can 30RCL and 38RCLB 0.7-0.8 mm (0.028–0.031 in.) cause severe injury or death.
  • Page 24 Figure 2-8. Otherwise, hand-tighten the spark plug until you feel resistance. Model Spark Plug Torque 24RCL 18 Nm (13.3 ft. lbs.) 30RCL and 38RCLB 25 Nm (18.4 ft. lbs.) Figure 2-8 Spark Plug Torque 16. Use a ratchet wrench to tighten an additional 1/4 turn.

  • Page 25: 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 26: Checking Specific Gravity

    2.7.2 Checking Specific Gravity Temperature Correction C F Use a battery hydrometer to check the specific gravity of 71.1 + .032 the electrolyte in each battery cell. While holding the + .030 hydrometer vertically, read the number on the glass bulb 65.6 + .028 EXAMPLE NO.

  • Page 27: 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 28 Notes Section 2 Scheduled Maintenance TP-6907 5/16...

  • Page 29: Section 3 Controller

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

  • Page 30: Controller Parameters

    3.3 Controller Parameters 3.3.1 Controller Parameters Table The table on the following pages lists controller Adjustable parameter settings can be changed using a parameters that are visible in SiteTech. Settings marked personal computer (or laptop) with Kohlerr SiteTecht Read Only are not user-adjustable. software.
  • Page 31 ECM Model A1--A2 and Digital Outputs A1--A2 do not apply to the PIM. Digital outputs B7--B12 are reserved for the load Do not change the ECM Model setting (located in the management device and cannot be changed by the Genset Personality Profile group). Changing the ECM user.
  • Page 32 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Identity Vendor Read Only Kohler Company Identity Product Read Only RDC2 Identity Firmware Version Read Only Engine Metering Engine Speed R/min Read Only Engine Metering Engine Target Speed R/min Read Only...
  • Page 33 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Generator Metering Generator Voltage L3-L1 Read Only Generator Metering Generator Voltage Average Read Only Line To Line Generator Metering Generator Current L1 Read Only Generator Metering Generator Current L2 Read Only Generator Metering Generator Current L3 Read Only...
  • Page 34 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset Personality Profile Engine Warmed Up 25 -- 60 _C 32_C (90_F) _C/F note in Temperature Section Genset Personality Profile Engine Cooled Down Locked 79_C _C/F 3.3.2. Temperature (174_F) Genset Personality Profile Engine Crank Disconnect 300 --1000 Speed...
  • Page 35 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset Personality Profile Personality Power Rating 50 Hz No effect. 200 400 Genset Personality Profile Personality Power Rating 50 Hz No effect. 190 380 Genset Personality Profile Personality Power Rating 50 Hz No effect.
  • Page 36 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset System ECM Power On or Off Configuration Genset System Display Contrast 0 -- 100 Configuration Genset System Genset System Language 0 -- 4 English Configuration Genset System Genset Maximum Percent 0 -- 120 70.0 Configuration...
  • Page 37 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Advanced Speed Control Derivative Gain No effect. Advanced Speed Control Slow Correction Integral Gain No effect. Advanced Speed Control Diagnostic Derivative Gain No effect. Advanced Speed Control Diagnostic Transient Integral No effect.
  • Page 38 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Generator Protection Genset High Voltage Shutdown Read Only Limit Generator Protection Genset Short Term Low Read Only Frequency Shutdown Delay Generator Protection Genset Long Term Low Read Only Frequency Shutdown Delay Generator Protection Genset High Frequency Read Only...
  • Page 39 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Digital Output B4 Digital Output B4 Event See dropdown list in Not In Auto SiteTech. Warning Digital Output B5 Digital Output B5 Value Read Only False Digital Output B5 Digital Output B5 Event See dropdown list in Engine Cool SiteTech.
  • Page 40 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Source 2 Metering Source 2 Frequency Read Only ATS Connection ATS Source Read Only Configuration Source 1 System Source 1 System Voltage 110.0 -- 600.0 Genset Configuration System Voltage Source 1 System Source 1 System Frequency 48.0 -- 62.0 Genset...
  • Page 41 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. OnCue kohler.com Plus Network Status IP Address Read Only 0.0.0.0 OnCue Plus Network Status Subnet Mask Read Only 0.0.0.0...
  • Page 42 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes RXT, RBUS Devices B1 RBUS Devices B1 Serial Read Only PIM, or Number Load RBUS Devices B1 RBUS Devices B1 Type Read Only (RXT, Mgmnt§ PIM, or Load Mgmnt§) RBUS Devices B1 RBUS Devices B1 Read Only Communication Errors...
  • Page 43 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes RBUS Devices B4 RBUS Devices B4 Last Read Only Connection Date RBUS Devices B4 RBUS Devices B4 Firmware Read Only Version RBUS Devices B4 RBUS Devices B4 Connected Read Only RBUS Devices B5 RBUS Devices B5 Serial Read Only...

  • Page 44: Controller Firmware

    Overview ----> 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 or at www.kohlergenerators.com/usb. Genset Status...

  • Page 45: Controller Replacement

    3.5 Controller Replacement (laptop) with Kohler SiteTech software can be used to load the settings onto the new controller. DANGER Note: Load the old controller settings onto the new controller only if you are certain that the settings are correct. Many controller operation problems can be caused by incorrect settings.
  • Page 46 5. Remove the customer connection access panel and use a voltmeter to confirm that utility power has been disconnected. See Figure 3-6. 6. Remove the two (2) screws securing the controller to the junction box and carefully lift the bottom edge of the controller.

  • Page 47: Controller Setup

    Three-Phase Wye Figure 3-8 Voltage and Phase Connections Parameter Controller Menu SiteTech Group Settings Genset Model Number 24RCL, 30RCL, or 38RCLB Genset Information Genset Info Genset Serial Number From nameplate; see Figure 3-6. Natural Gas or Fuel Type [ Liquid Propane (LP)
  • Page 48 Genset M/N: Genset ----> 24RCL 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:...
  • Page 49 tt6907 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 TP-6907 5/16 Section 3 Controller...

  • Page 50: 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 51 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 displayed. The voltage flashes. Volts L3--L1: Calibrate 240 V 2.

  • Page 52: Calibration Using Sitetech

    3.7.2 Calibration Using SiteTech ÷ V ) x F meter control Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 controller. Connect a personal computer (laptop) to the controller = Voltmeter reading meter using a USB cable and follow this procedure to use Kohlerr SiteTecht software to calibrate the controller.

  • Page 53: Setting The Oncue Plus Password

    3.8 Setting the OnCue Plus 4. Press Select. Reset OnCue Password is displayed. Password 5. Press and HOLD the Select button until Reset If the Kohlerr OnCuer Plus Generator Management OnCue Password? No appears. The word No will System is used to monitor the generator set, reset the flash.
  • Page 54 Notes Section 3 Controller TP-6907 5/16...

  • Page 55: Section 4 Cooling System

    Section 4 Cooling System 4.1 General The generator set engine is water cooled. The cooling system includes the radiator and cooling fans. Components of the cooling system are shown in WARNING Figure 4-1 and Figure 4-2. Cooling fans are described in Section 4.10.

  • Page 56: Cleaning The Radiator Fins And Inspecting The Hoses

    1. Radiator 2. Radiator fill/pressure cap 3. Upper radiator hose 4. Engine compartment temperature sensor 5. Engine compartment fan 6. Lower radiator hose 7. Coolant overflow bottle 8. Coolant overflow tube 9. Low coolant level sensor 10. Radiator fans GM83070 Note: See Figure 4-2 for additional components for the 30RCL and 38RCLB.

  • Page 57: Engine Thermostat

    Do not use alcohol or methanol antifreeze or mix them with the specified coolant. 1. Thermostat Figure 4-3 Thermostat Location on the Engine (24RCL engine shown) Item Setting Thermostat Valve open at 76_C (169_F) Valve lift fully open at 88_C (190_F)

  • Page 58: Draining Cooling System

    The radiator contains a coolant drain valve to drain the Model Coolant Capacity, L (gal) cooling system. When draining the coolant, remove the 24RCL, 30RCL, radiator’s pressure cap, which will allow the entire 13.2 (3.5) and 38RCLB system to drain and will prevent air pockets from forming Figure 4-5 Coolant Capacity and restricting coolant passage to the block.

  • Page 59: Cooling Fans

    4.10 Cooling Fans is selected when engine compartment temperature exceeds 43_C (110_F). If the engine compartment temperature returns to an operating temperature below 4.10.1 Fan Operation 32_C (90_F), the fan returns to low-speed operation. The generator cooling system includes three electric Note: The engine compartment fan continues to run for fans to provide cooling air flow.

  • Page 60: 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 61: Section 5 Troubleshooting

    Section 5 Troubleshooting 5.1 Introduction c. Lead 70 also sends 12 VDC to the ECM on inputs P26-3 (SW IGN) and P26--65 (ACTPWR Corrective action and testing in many cases requires Diagnostic Feedback), ignition coil, fuel control knowledge of electrical systems and electronic circuits. valve, battery charging alternator, and the O2 Have an authorized distributor/dealer or trained service (HEGO) sensor.

  • Page 62: Initial Checks

    a. This low voltage signal initiates the activator 11. While monitoring engine compartment circuit, which allows 12 VDC input voltage on temperature, the RDC2 controller turns the engine leads 55A to flow through the activator board compartment fan on low speed (6 VDC) by and to F1--F2 field winding.

  • Page 63: Line Circuit Breaker

    5.3.1 Line Circuit Breaker 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 The line circuit breaker interrupts the generator output in a soap and water solution with the fuel system test pressurized the event of an overload condition or a fault in the wiring to 6--8 ounces per square inch (10--14 inches water column).

  • Page 64: Fault Messages

    5.6 Fault Messages Some fault conditions are reported to the RDC2 controller by the engine ECM. Refer to the Engine The RDC2 controller displays fault messages to aid in Service Manuals for more information. troubleshooting. Fault messages, descriptions, and Identify and correct the cause of the fault condition. recommended checks are listed in Figure 5-2.
  • Page 65 Fault Message Action Description/ Comments Check 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 (Check date and time warning) not be correct. Event history may not operation of scheduled have accurate time/date stamps.
  • Page 66 Fault Message Action Description/ Comments Check ECM Batt Lo Warning Warning The ECM reported low voltage for the Check the engine cranking engine battery. circuit. Check the battery and the battery charger. ECM Comm Err Shutdwn Shutdown The controller shut down the generator Check CAN communication because communication with the ECM wiring between controller and...
  • Page 67 Fault Message Action Description/ Comments Check ECM O2SenseInpLo Warning Warning The ECM reported a low voltage error Check the wiring to the HEGO for the Heated Exhaust Gas Oxygen sensor. Sensor (HEGO). Check that the ignition wires are fully seated. Check the ignition system, HEGO sensor, and fuel control valve for shorted...
  • Page 68 Fault Message Action Description/ Comments Check Fuel Level Low Warning * Warning The digital input for Low Fuel Level Check customer equipment Warning (PIM) is active (low). connected to the PIM module. GenBrkerOpen Warning Warning There is voltage at the generator set but Check line circuit breaker.
  • Page 69 Fault Message Action Description/ Comments Check OB1 CommLoss Warning Communications with option board #1 Check RBUS wiring to (PIM, load management device, has been lost. inoperative option board. or RXT) OB2 CommLoss Warning Communications with option board #2 Check RBUS wiring to (PIM, load management device, has been lost.
  • Page 70 Fault Message Action Description/ Comments Check Volts L2-L3 High Shutdwn Shutdown The controller shut down the generator Troubleshoot alternator; see because the voltage measured from alternator service manual. Phase B to Phase C exceeded the high limit for a time greater than the delay setting 2 seconds.

  • Page 71: Status Messages

    5.7 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 72 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 73: Generator Set Troubleshooting

    5.8 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 74 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 to the battery. W/D Section 8 Check for 120 VAC on the black and white leads to controller P5-1 and P5-3 for battery...
  • Page 75 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 76 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 a load Load management in voltage.

  • Page 77: Controller Troubleshooting

    5.9 Controller Troubleshooting Figure 5-5 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 78 Notes Section 5 Troubleshooting TP-6907 5/16...

  • Page 79: Section 6 Component Testing And Adjustment

    5. Stator windings Running 6. P17 plug 7. P4 plug Unloaded full speed exercise Figure 6-1 24RCL Single-Phase or Three-Phase Unloaded cycle diagnostic mode (only during the 3 Generator Schematic minute full speed portion of the test) TP-6907 5/16 Section 6 Component Testing and Adjustment...

  • Page 80: Erratic Voltage Regulation

    4. Determine if the controller is damaged. With the producing flicker. If flicker is observed, it can be caused generator set running, disconnect P4 from the by any of the following: RDC2 controller and measure the voltage between Load Fluctuation pins P4--2 (+) and P4--1 (--).

  • Page 81: Voltage Connections

    6.2 Voltage Connections 6.4.1 Voltage Adjustments Using SiteTech Generator sets equipped with a 12-lead alternator are reconnectable to the following configurations: Delta, The SiteTech parameters used to adjust the voltage in Low Wye, and High Wye. See the generator set the following procedures are shown in Figure 6-2 and Installation Manual or the alternator service manual for Figure 6-3.

  • Page 82: Voltage Regulator Average Voltage Adjustment

    6.4.2 Voltage Regulator Average The Hybrid Voltage Regulator regulates to the average RMS voltage of all three phases on a three-phase Voltage Adjustment generator set. Voltage regulation is performed by the controller. The The Hybrid Regulator should require no voltage controller monitors generator output voltage and adjusts adjustment, as it regulates the RMS output voltage to the excitation current to the rotor.

  • Page 83: 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 84: Frequency Adjustment

    6.5 Frequency Adjustment 6.5.2 Hunting/Surging The engine speed regulation gains reside in the engine The engine speed determines the generator output ECM 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 85 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 6-6 Engine Speed and Frequency Adjustments in SiteTech TP-6907 5/16 Section 6 Component Testing and Adjustment...

  • Page 86: Generator Set Switches

    6.6 Generator Set Switches 6.6.1 Engine Compartment Air Temperature Sensor WARNING The temperature sensor is used to monitor engine compartment air temperature for the cooling fan operation. See the service views in Section 1.7 for the air temperature sensor location. The cooling fan operation is temperature-dependent.

  • Page 87: Fuel Systems

    1. Fuel pressure regulator idGM90228 supply, incorrect adjustments, or damaged fuel system 2. Dual-solenoid fuel valve components. 3. Fuel inlet connection Figure 6-9 Fuel System, 24RCL TP-6907 5/16 Section 6 Component Testing and Adjustment...

  • Page 88: Checking The Fuel Pressure

    Note: On the model 24RCL, two fuel solenoid valves were replaced with one dual-solenoid valve in February, 2016. If valve replacement is required, replace both valves with one dual-solenoid valve.

  • Page 89: Fuel Conversion Procedures

    Use the RDC2 controller menus or a personal computer To reset the regulator for NG: (laptop) with Kohler SiteTech software to change the fuel type. On controllers with firmware version 4.5 or higher, Reverse the above procedure to reset for NG operation.
  • Page 90 Notes Section 6 Component Testing and Adjustment TP-6907 5/16...

  • Page 91: Section 7 Disassembly/Reassembly

    Section 7 Disassembly/Reassembly 7.1 Introduction WARNING WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until Accidental starting. it cools. Can cause severe injury or death. Disconnect the battery cables before Servicing the alternator.

  • Page 92: Initial Steps

    7.2 Initial Steps 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 93: Enclosure Disassembly

    7.3 Enclosure Disassembly b. Remove the screw that secures the side panel to the skid. See Figure 7-1 for an illustration of enclosure parts. c. Lift and remove the side panel. Remove enclosure panels as necessary to access the alternator. 4.

  • Page 94: Connection Box Disassembly

    7.4 Connection Box Disassembly Quick connection leads on the fuel solenoid valves Remove the connection box before removing the Generator wire harness leads connected to the alternator. Refer to Figure 7-2 and the schematic starter motor diagrams, Section 8. 8. Remove the connection box ground strap that Note: To simplify the disassembly, the generator wire connects to the skid.

  • Page 95: Alternator Disassembly

    Alternator Disassembly WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature.

  • Page 96: Engine Disassembly

    7.6 Engine Disassembly 8. Remove the nuts on the exhaust flange and disconnect the exhaust. Remove the old exhaust See Figure 7-6 for 24 RCL engine component gasket and obtain a gasket for the reassembly identification. See Figure 7-7 for 30RCL and 38RCLB procedure.
  • Page 97 10. Exhaust flange 7. Exhaust flange 11. HEGO sensor 8. Coolant hose 12. Coolant hoses 9. Air intake elbow 13. Coolant hoses, charge air cooler Figure 7-6 Engine Components, 24RCL Figure 7-7 Engine Components, 30RCL/38RCLB TP-6907 5/16 Section 7 Disassembly/Reassembly...

  • Page 98: Engine Reassembly

    7.7 Engine Reassembly 2. Connect the engine wire harness to the following: Ground leads and battery ground on the See Figure 7-6 for 24 RCL engine component engine. identification. See Figure 7-7 for 30RCL and 38RCLB turbocharged engine components. The following instructions cover the general steps for securing the engine to the skid.

  • Page 99: Alternator Reassembly

    Alternator Reassembly WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature.

  • Page 100: Connection Box Reassembly

    7.9 Connection Box Reassembly 8. To attach the controller: a. Connect the wire harness and ethernet plugs 1. Attach the ground from the connection box to the on the back of the controller. stator housing. b. Position the controller. 2. Carefully position the connection box on the skid and secure with four mounting bolts.

  • Page 101: Enclosure Reassembly

    7.10 Enclosure Reassembly 3. To attach the side panels: a. Position the side panel. See Figure 7-12 for an illustration of enclosure parts. b. Use two screws to secure the side panel to the Note: When reassembling the enclosure, do not bulkhead.

  • Page 102: Final Steps

    7.11 Final Steps 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 103: Section 8 Diagrams And Drawings

    See the generator set Operation Manual for service diagrams, and schematics for the enclosed generator views, if necessary. set. Figure 8-1 lists the drawing numbers and page numbers. Drawings are arranged in numerical order on the following pages. 24RCL 30RCL, 38RCLB Drawing Number Page Drawing Number Page...
  • Page 104 Notes TP-6907 5/16...

  • Page 117: 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 118 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 119: 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 120: Appendix C General Torque Specifications

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

  • Page 121: 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 122: 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 123 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 124 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 125 Notes TP-6907 5/16...
  • Page 126 Notes TP-6907 5/16...
  • Page 128 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-6907 5/16c Call 1-800-544-2444 or visit KOHLERPower.com E 2014, 2015, 2016 by Kohler Co. All rights reserved.

This manual is also suitable for:

30rcl38rclb

Table of Contents