Kohler 48RCLC Installation Manual
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Kohler 48RCLC Installation Manual

Residential/light commercial generator set
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Installation
Residential/Light Commercial Generator Set
Models:
48RCLC
60RCLB
Controller:
RDC2
TP-7203 4/23b

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Summary of Contents for Kohler 48RCLC

  • Page 1 Installation Residential/Light Commercial Generator Set Models: 48RCLC 60RCLB Controller: RDC2 TP-7203 4/23b...
  • Page 2 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 dealers install and service the generator. Product Identification Information Product identification numbers determine service parts.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............................5 Introduction ....................................11 Service Assistance................................... 13 Section 1. Lifting and Location ..........................15 Introduction ................................15 Lifting the Generator Set ............................17 Location and Mounting ............................19 1.3.1 Location Factors ............................19 1.3.2 Mounting Surface .............................
  • Page 4 Section 7. Generator Reconnection ........................55 Voltage Reconnection ............................55 Four-Lead (Single-Phase) Generator Sets ......................56 12-Lead (Three-Phase) Generator Sets ......................... 57 Changing System Settings ............................. 59 Voltage Calibration ..............................62 7.5.1 Calibration using the RDC2 Controller Keypad and Menus ..............62 7.5.2 Calibration Using SiteTech ........................

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
  • Page 6 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area.
  • Page 7 Engine Backfire/Flash Fire WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.
  • Page 8 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels.
  • Page 9 Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hazardous voltage.
  • Page 10 Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Engine block heater.

  • Page 11: Introduction

    This manual provides installation instructions for Model 48RCLC and 60RCLB reduced-setback generator sets equipped with the Kohler 6.2L engine and the RDC2 controller. Operation manuals are available separately. See Figure 1 for an illustration of a typical Kohler generator set equipped with the Kohler 6.2L engine.
  • Page 12 Operation Manual, Engine TP- 7095 Service Manual, Generator Set TP- 7103 Service Manual, Kohler KG6208 Engine TP- 7096 Service Manual, Kohler KG6208 Fuel System & Diagnostic TP- 7097 Service Manual, Alternator TP- 6783 Parts Catalog, Engine TP- 6731 Parts Catalog, Generator Set...

  • Page 13: Service Assistance

    • Visit the Kohler Co. website at KOHLERPower.com. • Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. • Call toll free in the US and Canada 1-800-544-2444.
  • Page 14 TP-7203 4/23...

  • Page 15: Lifting And Location

    The generator set and accessories must be installed by an authorized Kohler dealer or authorized representative. The installation must comply with the National Electrical Code (NEC) and local codes. For Canadian installations, refer to the Canadian Electrical Code (CEC).
  • Page 16 Tools Required: • Multimeter (for measuring voltage and current) • Frequency meter (may be part of multimeter) • Manometer (for measuring fuel pressure) • Torque wrench • Wrenches • Screwdrivers • Socket wrenches or nut drivers • Pliers • Safety glasses or goggles •...

  • Page 17: Lifting The Generator Set

    The approximate weight of the generator set with enclosure is shown in Figure 3. Use equipment that is rated for the generator set’s weight to lift the unit into place. Lift the enclosure and generator set together as one unit. Model Weight, kg (lb.) 48RCLC 767 (1690) 60RCLB 859 (1894)
  • Page 18 The installer or lifting contractor should choose one of the following methods to lift the generator set depending upon the location circumstances and the generator set’s weight and size. Single and Double Spreader Bar and Skid Lifting Bar Method. See Figure 5. Single Spreader Bar and Skid Lifting Bar Method Double Spreader Bar and Skid Lifting Bar Method Spreader bar...

  • Page 19: Location And Mounting

    1.3 Location and Mounting 1.3.1 Location Factors The generator set MUST be mounted on a non-combustible surface. The preferred method is to mount the generator set at ground level on a concrete pad. The concrete pad or other non-combustible mounting surface must cover the entire bottom of the generator base/skid to ensure proper air flow through the enclosure.

  • Page 20: Mounting Surface

    1.3.2 Mounting Surface Install the generator set on a single, level concrete mounting pad. This method provides maximum stability and ensures correct cooling air flow through the generator set. The recommended mounting pad dimensions are shown on the dimension drawing. Refer to the generator set dimension drawing for conduit and fuel-line placement.

  • Page 21: Electrical System

    Section 2. Electrical System DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hazardous voltage.

  • Page 22: Electrical Connections

    2.1 Electrical Connections Several electrical connections must be made between the generator set and other components of the system for proper operation. Most field-installed accessory kits include installation instructions. Comply with applicable national and local codes when installing a wiring system. For Canadian installations, refer to the Canadian Electrical Code (CEC).
  • Page 23 Tightening Torque, Nm (in. lb.) Wire Size for Unit Hexagonal Head—External Drive Connection Slot Head 4.7 mm (No. 10) or Larger* Socket Wrench Slot Width <1.2 mm (0.047 in.) Slot Width >1.2 mm (0.047 in.) Split-Bolt Other AWG, kcmil (mm Slot Length <6.4 mm (0.25 in.) Slot Length >6.4 mm (0.25 in.) Connectors...

  • Page 24: Ground And Neutral Connections

    2.3 Ground and Neutral Connections Ground the generator set. The grounding method must comply with NEC and local codes. Connect the ground to the generator set ground lug, terminal GRD inside the junction box (see Figure 10). Connect the grounds for utility and low voltage connections to the ground lugs provided in the customer connection box for those specific connections (see Figure 10).

  • Page 25: Power Supply

    60Hz, 120/208V, Wye, 3Ph, 4W 175 Amp, 3- Pole 9- 10.2 (80- 90) 60Hz, 120/240V, Delta, 3Ph, 4W 150 Amp, 3- Pole 48RCLC 60Hz, 127/220V, Wye, 3Ph, 4W 200 Amp, 3- Pole 25- 26 (220 - 230) 60Hz, 277/480V, Wye, 3Ph, 4W 80 Amp, 3- Pole 9-10.2 (80-90)
  • Page 26 Generator Set Connections Note: Read all safety precautions at the beginning of this publication before performing any work on the generator set. Use separate conduit for the power cables and the low voltage communication or engine start leads. Local codes and the length of run as well as the transfer switch wire size requirements will determine the wire size needed for the AC leads.

  • Page 27: Automatic Transfer Switch Connection

    Kohler Model RXT Automatic Transfer Switch The RDC2 controller is designed to control the Kohler Model RXT transfer switch as well as the generator set. Follow the installation instructions to connect the transfer switch interface board to the appropriate terminals on the generator set.
  • Page 28 ® RBUS communication connections for a Kohler Model RXT transfer switch One Model RXT transfer switch can be connected to the generator set. See Figure 13. Use shielded, twisted-pair cable to connect P10-1 through P10-4 on the transfer switch interface module to the generator set terminal block connections A, B, PWR, and COM.
  • Page 29 Model RRT transfer switch with Model RCL generator sets. ™ Other Kohler transfer switches, including Model RDT or Model K (MPAC ) transfer switches can be used with the Kohler generator sets covered in this document. These transfer switches contain separate ATS controls that do not communicate with the RDC2 controller.

  • Page 30: Communication Cable Specifications

    2.8 Communication Cable Specifications The following sections cover communication connections from the generator set to automatic transfer switches and RBUS accessories, including the programmable interface module (PIM) and the load shed kit. RBUS Connections A and B For the RBUS communication connections A and B to the optional RBUS modules, use 20 AWG shielded, twisted-pair communication cable.

  • Page 31: Accessory Module Rbus Communication Connections

    2.9 Accessory Module RBUS Communication Connections See Figure 16 through Figure 19 for RBUS communication connection options with up to three accessory modules. Accessory modules can include one Model RXT transfer switch, one programmable interface module (PIM), and/or one load shed kit. See the Communication Cable Specifications section for cable size and length specifications.
  • Page 32 Connect one end of each cable shield to GROUND at the generator set. Communication cable Belden #9402, #1075, or equivalent 20 AWG shielded, twisted-pair cable (one pair). 12 AWG or 14 AWG leads for PWR and COM. Generator set terminal block. Check the decal on the generator set for terminal block connections.

  • Page 33: Other Accessories

    Customer connection terminal block. Check the decal on the generator set for terminal block Connect all of the shield leads On this connections. end to GROUND at the generator set. Splice Note: See the Communication Cable Specifications section for cable specifications.

  • Page 34: Engine Starting Battery

    2.11 Engine Starting Battery WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well‐ventilated area. Isolate the battery charger from explosive fumes. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.

  • Page 35: Fuel System

    Section 3. Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels.

  • Page 36: Gas Regulators

    (20) (40) (60) (80) (100) (150) (200) 0.962 25.8 909.9 1 1/4 1 1/4 1 1/2 2 1/2 48RCLC 0.633 14.1 498.2 1 1/4 1 1/4 1 1/2 1 1/2 1 1/2 1 1/2 0.962 29.8 1053 1 1/4 1 1/2...

  • Page 37: Install And Connect Fuel Supply

    3.3 Install and Connect Fuel Supply Note: Read all safety precautions at the beginning of this publication before performing any work on the generator set. Note: Have the fuel piping and primary regulator installed by the fuel supplier. The fuel supply installation must comply with NEC and local codes.

  • Page 38: Auto Dual Fuel Changeover Connections

    3.4 Auto Dual Fuel Changeover Connections Some applications use natural gas as the primary fuel and LP gas as the emergency fuel when natural gas is not available. The optional automatic changeover dual fuel system allows the system to switch to LP fuel automatically if the natural gas supply is not available.
  • Page 39 Dual Fuel Automatic Changeover System The optional dual fuel automatic changeover systems for RCL models are available as loose kits. Refer to the instruction sheet provided with the kit for installation instructions. Fuel Connection Check the decals near the fuel inlet connections on the generator set skid and be sure to connect the natural gas and LPG fuel supplies to the correct inlet pipes.

  • Page 40: Fuel Conversion Procedures

    Converting the fuel will change the generator set rating. See the generator set specification sheet for ratings with natural gas and LP. Order a new nameplate with the updated rating and fuel information from a Kohler authorized dealer. Provide the following information from the original nameplate: •...
  • Page 41 GM116372 Figure 25 Harness Connections TP-7203 4/23...
  • Page 42 Figure 26 Using SiteTech to Change the Fuel Type TP-7203 4/23...

  • Page 43: Cooling System

    Maintain the coolant level in the coolant overflow bottle between the High and Low markings. See Figure 28 for the coolant overflow bottle location. Model Coolant Capacity, L (gal.) Generator Set With Block Heater 48RCLC 60RCLB 20.8 (5.5) 22 (5.8) Figure 27 Coolant Capacity...
  • Page 44 Engine coolant fill Overflow tube (pressure cap not shown) Coolant overflow bottle Coolant fill access GM103966 ADV-8954 Figure 28 Cooling System Components TP-7203 4/23...

  • Page 45: Prestart Check And Test

    Section 5. Prestart Check and Test 5.1 Prestart Installation Check Review the entire installation sections. Inspect all wiring and connections to verify that the generator set is ready for operation. Check all items in the following Prestart Checklist. Prestart Checklist Air Cleaner.

  • Page 46: Set Exerciser

    Set Date, Time, and Exercise, RDC2 Controller ® In order to set a loaded exercise using the RDC2 controller, a Kohler Model RXT transfer switch must be connected. To set a loaded exercise on a generator set connected to a transfer switch other than a Model RXT, use the transfer switch controller to set the exercise.

  • Page 47: Oncue Plus Generator Management System

    5.4 OnCue Plus Generator Management System ® The OnCue Plus Generator Management System is included with the RCL generator sets and allows monitoring and control of your generator set from a personal computer, smart phone, or tablet. OnCue Plus can also be configured to send email or text message notifications in the event of a generator set fault.
  • Page 48 TP-7203 4/23...

  • Page 49: Accessories

    Accessories are available factory-installed and/or shipped loose. Obtain the most current list of accessories from the generator set specification sheet or by contacting an authorized Kohler dealer. Have accessories installed by your local authorized Kohler dealer or authorized representative. Follow the installation instructions provided with each kit.

  • Page 50: Block Heaters

    6.3 Block Heaters Block heaters are available as loose accessories. Use block heaters on standby applications where the generator set is frequently subjected to temperatures below 0º C (32º F). The generator set engine is equipped with valves that eliminate the need to drain the cooling system before installing the block heater.

  • Page 51: Load Management

    6.5 Load Management Two optional load management devices are available for use with single-phase generator sets and a model RXT or RDT transfer switch. • The optional Load Shed Kit mounts inside a model RDT or RXT transfer switch. Figure 33 shows the load shed assembly.

  • Page 52: Power Relay Module

    Use this kit to connect the generator ® ® set to the Internet for the Kohler OnCue Plus Generator Management System. The kit uses two wireless bridges that communicate with each other. One wireless bridge is installed inside the generator enclosure and powered by the generator’s engine starting battery.

  • Page 53: Programmable Interface Module (Pim)

    The common fault output is activated on a fault. ® ® Use a personal computer running Kohler OnCue Plus or SiteTech™ software to assign functions to the other inputs and outputs, and/or change the settings for factory-set inputs and outputs. Verify that the input and output assignments match the connections to the PIM terminal strip.
  • Page 54 TP-7203 4/23...

  • Page 55: Generator Reconnection

    Section 7. Generator Reconnection WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery. Reconnect the negative (–) lead last when reconnecting the battery. Disabling the generator set.

  • Page 56: Four-Lead (Single-Phase) Generator Sets

    7.2 Four-Lead (Single-Phase) Generator Sets Figure 38 shows the factory connection for the single- phase 120/240 V 60 Hz generator set. Four-lead, single-phase models are not reconnectable. ADV-5875U-1 Figure 38 Single-Phase Factory Connection, 120/240 V 60 Hz TP-7203 4/23...

  • Page 57: 12-Lead (Three-Phase) Generator Sets

    7.3 12-Lead (Three-Phase) Generator Sets Three-phase, 12-lead generator sets are reconnectable to the voltages and phases shown on the generator set specification sheet. See Figure 39 and Figure 40 for the applicable three-phase configurations and single-phase dogleg configuration. Use the following procedure to reconnect the generator to the desired voltage configuration, change the system voltage setting, and adjust the output voltage.
  • Page 58 Figure 39 12-Lead Generator Reconnection, 1 of 2 TP-7203 4/23...

  • Page 59: Changing System Settings

    ADV-5875C-AC Figure 40 12-Lead Generator Reconnection, 2 of 2 7.4 Changing System Settings The RDC2 controller’s keypad and display allow the installer to check and change the generator system settings, if necessary. The system settings for each generator model are set at the factory and should not normally require changes. Check the genset system settings and change them, if necessary, after generator reconnection or controller replacement.
  • Page 60 Status Overview - - > Displays 1.2 h Engine - - > ATS - - > Metering Configuration * Generator- - > Date - - > Metering and Time Genset - - > Network - - > Information Information Genset - - > PIM - - >...
  • Page 61 Changing System Settings on the RDC2 Controller Press the Select button to enter the main 7. When the desired setting is shown, press Select. The menu. value stops flashing. Overview - - > Press: Display: 1.2 h System Voltage: Press: Display: 220 V Press the down arrow button to navigate to the...

  • Page 62: Voltage Calibration

    Correct voltage calibration is necessary for proper generator set operation. Check the voltage calibration after controller replacement or generator set reconnection, and adjust if necessary. ® The RDC2 controller can be calibrated using the controller keypad and menus, or using a personal computer with Kohler ™ SiteTech software.
  • Page 63 Reset Calibration Pressing the select button when “Reset Calibration? Yes” is displayed will discard the changes and reset the calibration to the original settings. See Figure 44. Generator - - > Metering Three-phase Single-phase Volts L1- L2: Volts: Calibrate Calibrate 240 V 240V To Calibrate Voltage:...

  • Page 64: Calibration Using Sitetech

    Voltage calibration factors can be adjusted using SiteTech software to calibrate the RDC2 controller. Connect a personal ™ ® computer (laptop) to the controller using a USB cable and follow this procedure to use Kohler SiteTech software to calibrate the controller.
  • Page 65 Voltage calibration factor ™ Figure 46 Voltage Calibration Factor in SiteTech TP-7203 4/23...
  • Page 66 TP-7203 4/23...

  • Page 67: Diagrams And Drawings

    Section 8. Diagrams and Drawings This section contains dimension drawings, wiring diagrams, and schematics for the enclosed generator set. Figure 47 lists the drawing numbers and page numbers. See the generator set Operation Manual for service views, if necessary. Drawing Description Drawing Number Page Dimension Drawing:...
  • Page 68 TP-7203 4/23...
  • Page 69 Figure 48 Dimension Drawing, ADV-9760, Sheet 1 of 2 TP-7203 4/23...
  • Page 70 Figure 49 Dimension Drawing, ADV-9760, Sheet 2 of 2 TP-7203 4/23...
  • Page 71 Figure 50 Schematic Diagram, ADV-9762, Sheet 1 of 4...
  • Page 72 Figure 51 Schematic Diagram, ADV-9762, Sheet 2 of 4 TP-7203 4/23...
  • Page 73 Figure 52 Schematic Diagram, ADV-9762, Sheet 3 of 4 TP-7203 4/23...
  • Page 74 Figure 53 Schematic Diagram, ADV-9762, Sheet 4 of 4 TP-7203 4/23...
  • Page 75 Figure 54 Wiring Diagram, GM116372, Sheet 1 of 4 TP-7203 4/23...
  • Page 76 Figure 55 Wiring Diagram, GM116372, Sheet 2 of 4 TP-7203 4/23...
  • Page 77 Figure 56 Wiring Diagram, GM116372, Sheet 3 of 4 TP-7203 4/23...
  • Page 78 Figure 57 Wiring Diagram, GM116372, Sheet 4 of 4 TP-7203 4/23...

  • Page 79: Abbreviations

    Abbreviations A, amp ampere blk. htr. block heater digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure decibel alternating current bits per second dB(A) decibel (A weighted) analog to digital Brass direct current advanced digital control; BTDC before top dead center direct current resistance...
  • Page 80 (2 bytes) megabyte (2 bytes) gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker gallons per minute kilogram one thousand circular mils grade, gross kg/cm kilograms per square meggar megohmmeter centimeter...
  • Page 81 N, norm. normal (power source) permanent magnet generator silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) not available, not applicable potentiometer, potential s, sec. second Systeme international d’unites, nat. gas natural gas parts per million International System of Units National Bureau of Standards PROM programmable read-only...
  • Page 82 ultrahigh frequency user interface Underwriter’s Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) univ. universal uniform resource locator (web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt...
  • Page 84 TP-7203 4/23b KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLERPower.com © 2021 Kohler Co. All rights reserved.

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