Kohler 20RCA Manual
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Kohler 20RCA Manual

Residential/commercial generator sets with controller rdc2
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Service
Residential/Commercial Generator Sets
Models:
14/20RCA/RCAL
Controller:
RDC2
TP-7093 11/20a

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Summary of Contents for Kohler 20RCA

  • Page 1 Service Residential/Commercial Generator Sets Models: 14/20RCA/RCAL Controller: RDC2 TP-7093 11/20a...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Table of Contents, continued Controller Firmware ........... 4.4.1 Firmware Version .
  • Page 5 ....... . . 6.12.2 Fuel Conversion, 20RCA/RCAL ....... . .
  • Page 6 Notes TP- 7093 11/20...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Battery IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, WARNING can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be aware of potential dangers and act safely.
  • Page 8 Engine Backfire/Flash Exhaust System Battery acid cleanup. Battery acid can cause severe injury or death. Fire Battery acid is electrically conductive WARNING and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a WARNING container with 4 L (1 gal.) of water and mix the neutralizing solution.
  • Page 9 Hazardous Voltage/ Carbon monoxide symptoms. The fuel system. Explosive fuel Carbon monoxide can cause severe vapors can cause severe injury or Moving Parts nausea, fainting, or death. Carbon death. Vaporized fuels are highly monoxide is a poisonous gas present in explosive.
  • Page 10 Heavy Equipment Connecting the battery and the DANGER battery charger. Hazardous voltage will cause severe injury or death. WARNING Reconnect battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and Hazardous voltage.
  • Page 11 Notice NOTICE Electrostatic discharge damage. NOTICE Electrostatic discharge (ESD) damages electronic circuit boards. Canadian installations only. Prevent electrostatic discharge standby service connect the output of damage by wearing an approved the generator set to a suitably rated grounding wrist strap when handling transfer switch in accordance with electronic circuit boards or integrated Canadian Electrical Code, Part 1.
  • Page 12 Notes Safety Precautions and Instructions TP-7093 11/20...

  • Page 13: Introduction

    24 690 06 (14 kW models) Information in this publication represents data available Engine Service Manual, CH1000 at the time of print. Kohler Co. reserves the right to 62 690 01 (20 kW models) change this publication and the products represented...

  • Page 14: Service Assistance

    Visit the Kohler Co. website at KOHLERPower.com. Fax: (65) 6264-6455 China Look at the labels and decals on your Kohler product North China Regional Office, Beijing or review the appropriate literature or documents Phone: (86) 10 6518 7950 included with the product.

  • Page 15: Section 1 Specifications

    Consult the generator set nameplate for specific generator set ratings. 1.2 Controller Specifications Model 14RCA, 14RCAL, 20RCA, and 20RCAL generator sets are equipped with the RDC2 controller. For a specific description of the controller, see the generator set operation manual.

  • Page 16: Engine Service

    1.4 Engine Service Generator sets covered in this manual are equipped with four-cycle, twin cylinder, air-cooled Kohler engines. For engine service information and specifications not covered in this manual, see the engine service manual. See the List of Related Materials in the Introduction section.

  • Page 17: Alternator Specifications

    1.6 Alternator Specifications Alternator Specification 14RCA/L 20RCA/L Alternator model Frequency Hz Phase Number of leads Excitation method Static excited Voltage regulator type Digital Coupling type Direct Insulation (rotor and stator) Epoxy varnish, vacuum impregnated; class 180 (H) Winding material Copper...

  • Page 18: Service Views

    30. Oil drain hose (shown in storage position) 15. Oil fill 31. Nameplate location (alternate) 16. AC receptacle for accessories (not shown) 17. Engine starting battery location (battery purchased separately) 32. Oil filter (14 kW models) Figure 1-2 Service Views, 14/20RCA/L Section 1 Specifications TP-7093 11/20...

  • Page 19: Section 2 Scheduled Maintenance

    Section 2 Scheduled Maintenance WARNING WARNING Hot engine and exhaust system. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Do not work on the generator set until Disconnect the battery cables before it cools. working generator set.

  • Page 20: Service Schedule, 14 Kw Models

    2.1.1 Service Schedule, 14 kW Models Procedure Visually Inspect Check Change Clean Test Section System Component or Procedure Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level Every 8 hours of engine operation Crankcase breather hose Yearly or 500 hours...

  • Page 21: Service Schedule, 20 Kw Models

    2.1.2 Service Schedule, 20 kW Models Procedure Visually Inspect Check Change Clean Test Section System Component or Procedure Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level Every 8 hours of engine operation Change oil Yearly or 100 hours...

  • Page 22: Air Cleaner Service

    2.2 Air Cleaner Service Air Cleaner Service Use the following procedure to replace the paper WARNING element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions. 1. Press the OFF button on the generator set controller.

  • Page 23: Air Cleaner, 20 Kw Models

    2. Cover 4. Base 10. When element replacement is necessary, order genuine Kohler parts. Figure 2-2 Air Cleaner Components Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around the air cleaner system.

  • Page 24: Battery

    BCI Group Size (0_F), Minimum blindness and burn skin. 14RCA(L) 20RCA(L) Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause Figure 2-3 Battery Size blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

  • Page 25: Checking Electrolyte Level

    2.3.2 Checking Electrolyte Level Tempera- Correction ture   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: Cooling System

    2.4 Cooling System 2.5 Exhaust System The engine fan draws cooling air through the openings WARNING in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet.

  • Page 27: Fuel System Maintenance

    2.6 Fuel System Maintenance 2.7 Lubrication System See the service schedules in Section 2.1 for oil change WARNING and oil filter replacement intervals. See the service views in Section 1.7 for the oil drain, oil check, oil fill, and oil filter locations. WARNING Explosive fuel vapors.

  • Page 28: Oil Check

    2.7.2 Oil Check 2.7.4 Oil Change Procedure The generator set is shipped with oil. Before operating Note: Dispose of all waste materials (engine oil, fuel, the generator set, check the engine oil in the crankcase. filter, etc.) in an environmentally safe manner. To check the oil level, shut down the generator set and Drain the oil while it is still warm.

  • Page 29: Resetting The Maintenance Timer

    3. Fill with oil. d. Reconnect the generator set engine starting battery, negative (- ) lead last. Note: When the oil is drained, some oil remains in the engine. The amount of oil needed to refill the e. Reconnect the utility power to the generator engine may be less than the capacity shown in set.

  • Page 30: Spark Plugs

    Figure 2-13. After cleaning, reinstall the oil cooler and secure with the mounting screws. 62 590 01 1. Oil cooler Figure 2-14 Oil Cooler, 20RCA/L 2.8 Spark Plugs 1. Oil filter 24 590 01- A 2. Oil cooler WARNING Figure 2-12 Oil Cooler Location, 14RCA/L Accidental starting.

  • Page 31: Stepper Motor Coupling

    2.9 Stepper Motor Coupling WARNING Replace the stepper motor coupling and bushings at the intervals shown in the service schedule. See the Parts Catalog for replacement part numbers. Figure 2-18 shows the location of the coupling Hot engine and exhaust system. assembly under the air cleaner.

  • Page 32: Storage Procedure

    2.10 Storage Procedure 2.10.3 Cylinder Lubrication 1. Remove the spark plugs. Perform the following storage procedure before removing the generator set from service for three 2. Pour one tablespoon of engine oil into each spark months or longer. Consult the engine service manual for plug hole.

  • Page 33: Section 3 Generator Reconnection

    Section 3 Generator Reconnection 3.1 Voltage Reconnection Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the The reconnection procedure explains reconnections to generator set as follows: (1) Move the generator set master change the voltage configuration only.

  • Page 34: 12-Lead (Three-Phase) Generator Sets

    3.2 12-Lead (Three-Phase) 8. Follow the instructions in Section 4.6 to check the system voltage, frequency, and phase settings, Generator Sets and change them if necessary. Three-phase, 12-lead generator sets are reconnectable 9. Connect a digital multimeter (DVM) to the to the voltages shown on the generator set specification generator set output.
  • Page 35 Figure 3-2 12-Lead Generator Reconnection TP-7093 11/20 Section 3 Generator Reconnection...
  • Page 36 Notes Section 3 Generator Reconnection TP-7093 11/20...

  • Page 37: Section 4 Controller

    SiteTech software available RDC2.4 firmware are not interchangeable. Kohler-authorized distributors and dealers. See the SiteTech Operation Manual, TP-6701, for general The RDC2.4 controller can be identified as follows: software operation instructions. The circuit board, visible on the back of the controller, Use a USB cable to connect the personal computer is blue.

  • Page 38: Controller Parameters

    1. USB cable connection to PC 2. USB cable connection to controller TP-7093 Figure 4-3 USB Connection 4.3 Controller Parameters 4.3.2 Notes on Selected Parameters Adjustable parameter settings can be changed using a Temperature Settings personal computer (or laptop) with Kohlerr SiteTecht In SiteTech, all temperature settings are shown in software.
  • Page 39 Replacement, for information about other setup These outputs will display the load management relay required on a replacement controller. status. Changing the genset model number will update the Refer to Installation Instruction Sheet TT-1584, engine model number automatically. Select the genset provided with the PIM, for information about the input model number and then click Apply Changes in and output events.
  • Page 40 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Identity Vendor Read Only Kohler Company Product Read Only RDC 2 Firmware Version Read Only Engine Metering Engine Speed R/min Read Only Engine Target Speed R/min Read Only Engine Oil Pressure...
  • Page 41 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Generator Metering Generator Voltage L1-L2 Read Only Generator Voltage L2-L3 Read Only 3-phase Generator Voltage L3-L1 Read Only 3-phase Generator Voltage Average Line Read Only To Line Generator Current L1 Read Only Generator Current L2 Read Only...
  • Page 42 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset Personality Profile ECM Model DO NOT CHANGE No ECM Maximum Alternator Current Read Only Engine Number Of Flywheel Locked Teeth Engine Warmed Up Temperature 77 - 140 _C 90_C _C/F Engine Cooled Down Locked...
  • Page 43 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset Personality Profile Personality Power Rating Single No effect. Phase 50 Hz 10 PF Personality Power Rating Single No effect. Phase 50 Hz 8 PF Personality Power Rating Fixed No effect. Volt 50 Hz Personality Power Rating 50 Hz No effect.
  • Page 44 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Genset System Genset System Voltage 110 - 600 240.0 Configuration Genset System Frequency 50 / 60 60.0 Genset Voltage Phase Dropdown menu Single Connection Phase Genset Power Rating DO NOT CHANGE Auto select based on...
  • Page 45 Factory set per unit. Proportional Gain 1.00000 DO NOT CHANGE Transient Integral Gain 1.00000 unless instructed by Derivative Gain 1.00000 the Kohler Slow Correction Integral Gain 1.00000 Generator Service Department. Diagnostic Derivative Gain 1.00000 Diagnostic Transient Integral 1.00000 14 kW Gain 0.30000...
  • Page 46 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Generator Protection Loss Of AC Sensing Shutdown Read Only Delay Genset Low Voltage Shutdown Read Only Delay Genset High Voltage Shutdown Read Only Delay Genset Low Voltage Shutdown Read Only Limit Genset High Voltage Shutdown Read Only...
  • Page 47 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Digital Output B2 Digital Output B2 Value Read Only False Digital Output B2 Event See dropdown list in Common SiteTech. Fault Digital Output B3 Digital Output B3 Value Read Only False Digital Output B3 Event See dropdown list in...
  • Page 48 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes ATS Connection ATS Source Read Only Configuration Source 1 System Source 1 System Voltage 110.0 - 600.0 Genset Configuration (Auto select with System system voltage) Voltage Source 1 System Frequency 48.0 - 62.0 Genset (Auto select with...
  • Page 49 0.0.0.0 - 0.0.0.0 255.255.255.255 Static DNS Server 1 0.0.0.0 - 0.0.0.0 255.255.255.255 Static DNS Server 2 0.0.0.0 - 0.0.0.0 255.255.255.255 Server Host Name devices.kohler.com devices. kohler. Network Status OnCue IP Address Read Only 0.0.0.0 Plus Subnet Mask Read Only 0.0.0.0...
  • Page 50 Adjustment Default Range * Setting SiteTech Group Parameter Units Notes Rbus Devices B2 RXT, Rbus Devices B2 Serial Number Read Only PIM, or Rbus Devices B2 Type Read Only Load Rbus Devices B2 Communication Read Only Mgmt Errors Rbus Devices B2 Communication Read Only Timeouts Rbus Devices B2 Modbus Id...

  • Page 51: Controller Firmware

    Kohler Power Resource Center website or from the Genset Status Standby Downloads section of the Dealer Portal. Controller firmware is also available for download on the Kohler dealer portal and at www.KohlerGenerators.com/usb. Voltage: 240V The RCA generator sets use the RDC2.4 controller.

  • Page 52: Firmware Update

    1. Download the latest RDC2.4 firmware file from the the Kohler Power Resource Center website or the Kohler dealer portal. Save the new firmware file on your PC. Be sure to note the file location. Firmware files are typically downloaded as .zip files and will need to be extracted.

  • Page 53: Controller Replacement

    4.5 Controller Replacement Always check the controller settings, wiring, and connections before replacing the controller. Use the procedure in this section for controller replacement, WARNING when necessary. Some setup is required after the new controller is installed. See Section 4.6 after replacing the controller. The RDC2 controller can be set up using the buttons on the controller or using a personal (laptop) computer and Accidental starting.
  • Page 54 4. Disconnect the generator set engine starting battery, negative (- ) lead first. 5. Remove the two (2) screws securing the controller to the junction box and carefully lift the bottom edge of the controller. See Figure 4-10. Note: Be careful of the leads and harness connected to the controller panel.
  • Page 55 Manual or the USB Utility instruction sheet for instructions. Note: When downloading new firmware from the Kohler Power Resource Center, be sure to choose firmware for the RDC2.4 controller. 14. Set up the controller as instructed in Section 4.6, 1. P6 Ethernet connection 3.

  • Page 56: Controller Setup

    SiteTech The Fuel Type parameter setting affects the software can be used to load the saved settings onto the generator set power rating, which is used to new controller. In some cases, the Kohler Generator determine setpoints optional...
  • Page 57 Genset - - > System Voltage: 240 V System System Freq: 60 Hz VR Voltage Adj: 240.0V System Phase: Single System Battery: 12 V Fuel Type Next Exercise 06:30p 15Mar2019 Exercise Mode: Unloaded Variable Exercise Freq: Weekly Language: English Meas System: English Contrast: <- -...

  • Page 58: Voltage Calibration

    4.7 Voltage Calibration 4.7.1 Calibration using the RDC2 Controller Keypad and Menus DANGER The controller’s voltage calibration can be adjusted using the controller keypad. See Figure 4-15 and follow the procedure below. Note: A digital voltmeter is required for these adjustments.
  • Page 59 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 60: Calibration Using Sitetech

    4.7.2 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: To simplify the calculation, set the calibration Connect a personal computer (laptop) to the controller factor to 1.0000 and then repeat the calibration using a USB cable and follow this procedure to use procedure from step 3.
  • Page 61 1. Voltage calibration factor Figure 4-17 Voltage Calibration Factor in SiteTecht TP-7093 11/20 Section 4 Controller...

  • Page 62: Setting The Oncue Password

    4.8 Setting the OnCue Password 5. Press and HOLD the Select button until Reset OnCue Password? No appears. The word No will If the Kohlerr OnCue Plusr Generator Management flash. System is used to monitor the generator set, reset the 6.

  • Page 63: Section 5 Troubleshooting

    Section 5 Troubleshooting 5.1 Introduction f. The engine rotation and field excitation produces alternator voltage. Corrective action and testing in many cases requires 2. Fuel and Ignition knowledge of electrical systems and electronic circuits. Testing and service must be performed by an authorized a.

  • Page 64: Initial Checks

    5.3 Initial Checks 5.4 USB Port and Auxiliary Winding Mini-Breaker When troubleshooting, always check for simple problems first. Check for the following common The USB port is located under a small rubber cover on problems before replacing parts: the front of the controller . The alternator winding circuit is located on the left side of the controller compartment Loose connections or damaged wiring.

  • Page 65: Circuit Protection

    5.5 Circuit Protection A lock is not required in order to keep the switch activated. The switch button will stay depressed until it is pulled out by the operator. Line Circuit Breaker Resetting the Emergency Stop Switch The line circuit breaker interrupts the generator output in the event of an overload condition or a fault in the wiring To reset the E-stop switch, remove the locking device between the generator and the load.

  • Page 66: Shutdown Prime Mover Switch (Engine Stop Switch)

    5.7 Shutdown Prime Mover Switch (Engine Stop Switch) ESS or 1 ESN or 1A The generator set may be equipped with a Shutdown (Prime Mover) switch. See Figure 5-5. This switch, also referred to as the Engine Shutdown switch, commands an immediate shutdown and prevents an engine start if asmGM103743 the switch is turned to the off (open, O) position.

  • Page 67: Thermostat

    5.8 Thermostat WARNING The generator set is equipped with a resettable thermostat located in the air intake area. The thermostat detects excess heat inside the enclosure. If the thermostat trips, the generator will shut down and the Hot engine and exhaust system. controller will display...
  • Page 68 img1079 ADV-8928 1. Roof 2. Air intake end panel 3. Service-side panel 4. Panel hanging bushings, qty. 4 Figure 5-7 Removing the Air Intake Panel 1. Thermostat location 2. Thermostat reset button Figure 5-8 Thermostat Location Section 5 Troubleshooting TP-7093 11/20...

  • Page 69: Oncue Plus Troubleshooting

    The Kohler Generator Service Department will provide the most current version if it is not yet available on the Kohler Power Resource Center website. Note: Be sure to use RDC2.4 firmware. RDC2 firmware cannot be used on RDC2.4...
  • Page 70 Note: If the generator set still hunts after performing gasket. Apply Loctiter to the bolt threads and these procedures, please contact the Kohler tighten as needed. Generator Service Department for assistance. Loctiter is a registered trademark of the Henkel-Loctite Corporation.

  • Page 71: Fault Messages

    5.12 Fault Messages 5.12.2 Battery Low Warnings The RDC2 controller provides charging voltage to the The RDC2 controller displays fault messages to aid in battery. If Battery Low Warning or Battery CRLow troubleshooting. Fault messages, descriptions, and Warning appears, check the battery charging DC output recommended checks are listed in Figure 5-9, which from the controller.
  • Page 72 Fault Message Action Description/ Comments Check AC Sens Loss Shutdwn Shutdown The controller shut down the generator Check for loose wiring and because there was less than 5% of connections. (Loss of AC sensing shutdown) rated voltage measured on Phase A for Check all AC leads.
  • Page 73 Fault Message Action Description/ Comments Check Default Pars Warning Warning The controller has been loaded with Configure settings as required default parameters. for desired operation. (Default Parameters) Emerg Stop Shutdwn Shutdown The optional emergency stop button Reset the emergency stop has been pressed or emergency stop button and clear the fault as leads ESS and/or ESN are not...
  • Page 74 Fault Message Action Description/ Comments Check GenBrkerOpen Warning Warning There is voltage at the generator set but Check line circuit breaker. no voltage measured on the emergency (Generator Circuit Breaker Check for and correct short side of the ATS (Model RXT transfer Open) circuits or overloading on the switch required).
  • Page 75 Fault Message Action Description/ Comments Check Oil Pressure Low Shutdwn Shutdown The low oil pressure switch was closed Check for oil leaks. for 5 seconds or more, indicating low oil Check the oil level and add oil pressure. Function is inhibited until 30 if low.

  • Page 76: Faults Related To Paralleling

    5.12.3 Faults Related to Paralleling system may be displayed on the controller and/or in OnCuer Plus. This section lists those faults and events If the PowerSyncr Automatic Paralleling Module (APM) in Figure 5-10 and Figure 5-11. See the installation is used with two 14 kW or two 20 kW generator sets, instructions provided with the APM for additional additional faults and events related to the paralleling paralleling information.
  • Page 77 Fault Text Description Possible Causes * ErraticSig The power metering on this controller gives a signal Bad wiring to the CT. that is not consistent with the system configuration. Too much tension on wires from the CT to Reversing the power direction does not resolve the the controller.

  • Page 78: Status Messages

    5.13 Status Messages The messages shown in Figure 5-12 and Figure 5-13 (PIM) is required for display of those messages as noted are displayed to show system status. Notices are in the table. displayed in the Event History in SiteTech when active Most status messages indicate normal system but do not appear on the controller display.
  • Page 79 Status Message Action Description/ Comments Check Gen Running Notice The digital output for Generator Running Check controller front panel (PIM) is active (contacts closed), buttons for potential RUN indicating the generator is running. command. If in AUTO, check remote start lines. Consult ATS operation manual for events that may cause the generator to start.
  • Page 80 Status Message Action Description/ Comments Check Load Shed 1 Status Info Notice The digital output for LoadPriority1Shed — is active (contacts closed), indicating the 1st priority load shed has been activated. Load Shed 2 Status Info Notice The digital output for LoadPriority2Shed —...

  • Page 81: Troubleshooting Chart

    5.14 Troubleshooting Chart simplest and most likely causes of the problem are listed first; follow the recommendations in the order shown. Use the following table as a reference in troubleshooting The reference column provides additional sources of individual problems. Generator set faults are listed in information in this and related manuals regarding the groups and include likely causes and remedies.
  • Page 82 Problem Possible Cause Test Corrective Action Reference No fuel Verify that manual fuel valve is Open (turn on) manual fuel valve. — Cranks but open. does not start Check fuel supply tank (LP). Contact fuel supplier to add fuel to fuel supply tank (LP).
  • Page 83 Problem Possible Cause Test Corrective Action Reference Starts hard Low battery voltage Check battery voltage during Charge battery. Replace battery if cranking. necessary. Check battery charger Tighten loose connections. W/D Section 8 connections and utility power connection to the generator set. Air cleaner clogged Check for a dirty air cleaner Replace element.
  • Page 84 Problem Possible Cause Test Corrective Action Reference Fault shutdown Check for a fault shutdown Correct the fault and then press Section 5.12 Stops message on the controller display. the controller’s OFF button to suddenly Identify the cause of the fault. reset the controller.
  • Page 85 Problem Possible Cause Test Corrective Action Reference Air cleaner clogged Check air filter element. Replace element. Erratic operation Spark plug(s) Check spark plug condition and Replace or regap plugs. gap. Spark plug wire(s) Check spark plug connections Tighten connections. Replace Engine S/M and wires.
  • Page 86 Problem Possible Cause Test Corrective Action Reference Air intake Inspect air intakes and exhaust Clear air intakes and exhaust Lacks restriction, for obstructions. area. Maintain clearances shown power inadequate cooling on the genset dimension drawing. Check air cleaner. Replace air cleaner element. Generator Reduce electrical load and check Unplug some lights or appliances...
  • Page 87 Problem Possible Cause Test Corrective Action Reference Brush connection Check for loose brush Tighten loose brush connections. Section 6.6 Low output connections. Tighten mounting screws. excessive Check for loose brush mounting. Replace brushes if they show drop in Check the resistance through the uneven wear or are worn to voltage, brushes.

  • Page 88: Controller Troubleshooting

    5.15 Controller Troubleshooting adjusted through the controller’s user interface or using a personal computer and Kohlerr SiteTecht software. Refer to the controller troubleshooting table in The generator set operation manual contains the Figure 5-14 when troubleshooting procedures in instructions for checking and changing the controller Section 5.14 indicate a possible controller problem.

  • Page 89: Troubleshooting Load Management Problems

    5.16 Troubleshooting Load 5.16.2 Verify that the Controller Recognizes the Load Shed Kit Management Problems There are three ways to verify that the RDC2 controller The load control module (LCM), load shed kit, and the recognizes the load management device. combined interface/load management board on the RXT transfer switch are all load management devices 1.
  • Page 90 Networking- - > Networking- - > Information Status Networking- - > Configuration RBUS - - > Modules Connected: Information <- - Return Remote - - > Devices See Figure 3. Net Cycle Time: 123ms Module Timeouts: 1234 Module Errors: 1234 <...
  • Page 91 From Figure 2. <- - Return S/N: XXXXXXXXX S/N: XXXXXXXXX <<*DeviceType*>> <<*DeviceType*>> Device Status: Connected Comm. Errors: 12345 Comm. Timeouts: 12345 ModBus ID: Firmware Ver.: Connected: Displays date/time device was connected. Connected: MM/DD/YY 12:12 Disconnected: Displays date/time of the last successful com- munication.
  • Page 92 Troubleshooting Tables The following tables list potential load management device operation problems and recommendations for troubleshooting. Load management functional issues. Problem Check Load shed AC relays do not activate. Verify 120 VAC supply voltage to relays. Verify correct wiring to the load management device board and AC relays. Metering always reads 0% under load.
  • Page 93 Loads do not add when they should. Problem Check Loads do not add when load is below 56%. Verify that the generator set maximum load capacity is adequately sized for the application. Verify that the load is not jumping above the maximum capacity. Loads never add.
  • Page 94 Notes Section 5 Troubleshooting TP-7093 11/20...

  • Page 95: Section 6 Component Testing And Adjustment

    Section 6 Component Testing and Adjustment 6.1 Theory of Operation RDC2 The generator set utilizes a rotating-field alternator to Controller produce AC voltage. See Figure 6-1 and Figure 6-2. Refer to Section 8 for the complete generator set schematics. When the controller receives a start signal, it energizes leads FP and 71.

  • Page 96: Alternator Excitation

    6.2 Alternator Excitation generator, disconnect P2 and verify no continuity between ground and each of 55, 66, FP, FN. DANGER 2. Verify the connections for 55, 55F and 66 per Figure 6-1. 3. Reconnect P2, start the generator and check for voltage between 55 and 66.
  • Page 97 Increasing temperatures can cause the insulation to Note: The approximate ammeter reading should break down, resulting in a running fault. If this test be the battery voltage divided by the shows that the rotor and stator are in good condition, test specified rotor resistance.

  • Page 98: Stator

    6.3 Stator Stator Continuity and Resistance Tests 1. Press the OFF button on the controller to turn off The stator contains a series of coils of wire laid in a the generator set. laminated steel frame. The stator leads supply AC voltage to the load and voltage regulator.
  • Page 99 Note: For three-phase models, leads 1- 12 are the Leads Continuity generator output leads. Leads V7, V8, V9, 55, 1 and 4 and 66 are the controller sensing and supply 2 and 5 leads. Refer to the schematic in Figure 6-6 when 3 and 6 performing the following steps.

  • Page 100: Main Field (Rotor)

    6.4 Main Field (Rotor) 4. Check the rotor for continuity and resistance. a. Raise and secure the brushes away from the The two-pole rotor creates the magnetic field needed to slip rings by removing the two brush holder produce alternating current in the stator windings. mounting screws and moving the brush Before testing, inspect the rotor for visible damage to assembly out of the way.

  • Page 101: Slip Rings

    6.6 Brushes d. Following the test, reinstall the brush assembly and check the brush positions on the slip rings. See Section 6.6, Brushes. The brushes transfer current to the slip rings. The brushes should last the life of the generator. However, The generator set may be equipped with an optional abrasive dust on the slip ring can shorten the life of the brush cover.

  • Page 102: Voltage Adjustments

    6.7 Voltage Adjustments 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. Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live GM80980 circuits.

  • Page 103: Voltage Regulator Average Voltage Adjustment

    Excitation current control is performed by the patented Kohler Hybrid Voltage Regulator. This regulator particular location or to compensate for voltage drop on wiring between the generator and the ATS.

  • Page 104: 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 105: Governor System

    6.8 Governor System 6.8.2 Initial Checks The factory sets the electronic governor. Under normal The governor system consists of an electromechanical circumstances the electronic governor requires no stepper motor (actuator) and an engine speed further adjustment. Verify that the governor stepper detection/feedback circuit.

  • Page 106: Hunting/Surging

    6.8.3 Hunting/Surging DANGER Hunting/surging problems thought to be caused by the governor system are more likely to be caused by fuel supply, engine, or carburetor problems. Check engine speed stability using the following procedure before testing the governor. Hazardous voltage. Moving parts. Will cause severe injury or death.

  • Page 107: Governor System Operation Test

    6.8.4 Governor System Operation Test 6. If the engine speed hunts or surges while the throttle is held steady, check the carburetor and If the engine continues to operate erratically after the engine operation. Refer to the engine service previous checks, test the governor system operation manual for engine diagnostic and service using the following procedure.
  • Page 108 Governor System Operation Test Procedure and operation. See stepper motor troubleshooting starting with step 8 of this procedure. Also check DANGER that the engine speed control parameters are set to the default settings (Engine Speed Governor and Advanced Speed Control parameters in SiteTech). Check the stepper motor, carburetor, and linkage.
  • Page 109 SiteTech to verify that the engine speed control parameters are set to Using Kohler SiteTech, adjust the Engine Speed Gain the default settings (Engine Speed Governor Adjustment setting in the Engine Speed Governor settings in SiteTech).
  • Page 110 Advanced Speed Control Governor Note: Do not adjust the Advanced Speed Control settings unless instructed to do so by the Kohler The Engine Speed Adjustment parameter in the Engine Generator Service Department. Speed Governor group in SiteTech can be adjusted while the generator set is running.
  • Page 111 TP-6805 1. Engine Speed Governor settings 2. Engine Run Speed setting (changes automatically with Genset System Frequency) 3. Genset System Frequency setting (50 or 60 Hz) Figure 6-20 Engine Speed and Frequency Parameters in SiteTech TP-7093 11/20 Section 6 Component Testing and Adjustment...
  • Page 112 6.10 Fault Shutdown Tests Parameter Setting 14 kW Genset Model Number* Verify the operation of the generator set overspeed, 20 kW overcrank, and low oil pressure shutdowns by Genset Serial Number* From nameplate; see Figure 4-8. performing the tests in Section 6.10.1. If these tests are Natural Gas or inconclusive, test...
  • Page 113 Underspeed and Underfrequency Shutdowns Close the throttle while the generator is running. The engine speed should decrease until the generator set shuts down and the controller indicates an Engine Speed Low Shutdown. To check the underfrequency shutdown, use very small movements over a longer period of time to close the throttle.
  • Page 114 Servicing the generator set when it is operating. Exposed moving parts will cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.
  • Page 115 6.11 Fuel Systems The controller energizes the fuel solenoid valve to open at startup and deenergizes the valve to close at shutdown. The secondary fuel regulator is a demand WARNING regulator that meters fuel flow to the mixing assembly in a gaseous state.
  • Page 116 14kW Model with Ignition Timing Leads 1. Ignition timing leads 5. Thermostat 2. LPG fuel orifice is tied here for shipping 6. Fuel orifice location inside fuel hose and fitting 3. Fuel solenoid valve 7. Fuel inlet, 1/2 in. NPT female 4.
  • Page 117 6.11.3 Checking the Fuel Pressure 6.11.4 Ignition Timing Leads (14 kW only) Use a gauge or manometer to check the fuel pressure at the fuel solenoid valve. See Figure 6-28. Measure the The digital spark advance ignition (DSAI) optimizes the fuel pressure with the generator set running at rated 14 kW generator engine timing for the selected fuel, load.
  • Page 118 6.12 Fuel Conversion WARNING The multi-fuel system allows conversion from natural gas to LPG (or vice-versa) in the field while maintaining emissions-standard compliance. A trained technician or an authorized distributor/dealer can convert the fuel system. Explosive fuel vapors. Can cause severe injury or death. After converting the fuel system, change the Fuel Type Use extreme care when handling, setting on the controller.
  • Page 119 Procedure to Convert from NG to LPG, 14RCA/L 1. Press the OFF button on the generator set controller. 2. Disconnect the utility power to the generator. 3. Disconnect the generator set engine starting battery, negative (- ) lead first. 4. Turn off and disconnect the fuel supply. 5.
  • Page 120 Connecting or disconnecting these leads has no effect on the 20RCA/RCAL operation. Procedure to Convert from NG to LPG, 20RCA/L 1. Press the OFF button on the generator set controller. 2. Disconnect utility power to the generator set (open the corresponding circuit breaker in the distribution panel).
  • Page 121 6.13 Start (Crank) and Run Relays The start (crank) and run relays are located under the controller. See Figure 6-37. Identify the relays by the connected leads shown in Figure 6-35. The start relay is connected to lead 71 from the controller (P1- 14). The run relay is connected to lead 70 from the controller (P1- 13).
  • Page 122 6.14 Continuity Checks controller circuit board. Use an ohmmeter to check the continuity of the components listed in Figure 6-38. Also see Section 8, Wiring Diagrams. DANGER Figure 6-38 gives resistance readings for functional components. A zero reading on the ohmmeter indicates continuity.
  • Page 123 Section 7 Disassembly/Reassembly This section provides instructions for the removal and DANGER replacement of the generator set alternator. Before beginning the generator disassembly or reassembly procedure, carefully read all safety precautions at the beginning of this manual. The engine and generator set may use both American Hazardous voltage.
  • Page 124 7.1 Stator Hardware Change WARNING In May of 2019, the mounting hardware on the stator was changed. See Figure 7-1. If you are replacing an original style stator with the updated stator, new mounting bolts and washers are required. Obtain the following hardware: Explosive fuel vapors.
  • Page 125 Figure 7-2. Model Weight, kg (lb) 14RCA 191 (420) 20RCA 243 (535) Figure 7-2 Approximate Weights Right Side Front (air intake end) 1. Roof 2. Left side panel adv-8928 3.
  • Page 126 3. The roof hinges are connected to the front and rear Figure 7-5. Remove the 4 screws and remove the bulkheads using 2 M6 screws for each hinge. See roof. ROOF dwgGM102548 1. Hinge assembly (qty.2) 2. Remove 2 M6 screws on rear bulkhead 3.
  • Page 127 4. The front (air intake) panel hangs on four 20 mm (0.8 in.) diameter bushings. Pull the air intake panel up and off. See Figure 7-6. 5. Unplug any accessories (if equipped) from the 120 VAC receptacle. 6. Verify that utility power to the generator set terminal block has been disconnected (the upstream circuit breaker has been opened).
  • Page 128 11. Remove the right-side panel: b. Pull up on the top of each latch to release the panel. a. Locate two latches at the top of the panel. See Figure 7-8. c. Pull the right-side panel toward you until it is free from the hooks at the bottom.
  • Page 129 Remove the Left Side Panel 18. Remove four screws to remove the rear bulkhead. See Figure 7-10. 12. Make sure that fuel line been disconnected. 13. Label and disconnect any electrical leads that enter the enclosure through the panel. Disconnect conduit as needed to remove the enclosure panel.
  • Page 130 WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Note: Allow the muffler to cool before removing it. 19. Disconnect the muffler from the engine at the two flange connections.
  • Page 131 7.3.2 Generator Disassembly 23. Raise the alternator end of the generator set enough to place a wood support beneath the rear 21. Disconnect the following alternator wiring inside of the engine. The wood support must be long the controller junction box. See the wiring enough to span the opening in the base.
  • Page 132 Brushes 25. To gain access to the brush assembly, remove the alternator duct cover with reinforcing plate. See Figure 7-15 and Figure 7-16. 26. Remove the optional brush cover, if equipped. See Figure 7-17. 27. Remove the cable tie that attaches the brush leads to the end bracket.
  • Page 133 Alternator 29. Remove the end bracket assembly by removing four screws shown in Figure 7-19. Note: The alternator duct and bellows assembly is attached to the end bracket. GM80980 GM62996 TP-7093 1. End bracket mounting screws (qty. 4) GM80982 2. Alternator duct and bellows, attached to end bracket Figure 7-19 End Bracket Mounting Screws 30.
  • Page 134 31. The stator leads are routed through the bulkhead 34. 14RCA only: Remove the four generator adapter and into the controller junction box. Carefully pull mounting bolts to remove the generator adapter, if the leads out of the junction box. Pull the leads and necessary.
  • Page 135 Figure 7-24. 1. Engine crankshaft taper shaft Note: Do not use anti-seize compound when Figure 7-23 Shaft (20RCA shown) reassembling the rotor. a. Clean the crankshaft taper and mating rotor shaft. See Figure 7-23. b. Install the rotor assembly onto the engine crankshaft.
  • Page 136 4. Install the stator and end bracket. a. Re-attach the alternator support bracket to the alternator shell. Assemble with the part number of the mounting foot toward the engine end of alternator. See Figure 7-25. 1. Alignment marks TP- 7093 Figure 7-26 Alternator Alignment Marks GM102806 Assemble with part number of...
  • Page 137 5. Secure the generator set to the skid. a. Raise the alternator end of the generator set and remove the wood support block(s). b. Lower the end of the generator set and reinstall the screws and washers that secure the vibromounts to the skid.
  • Page 138 7. Install the end bracket. Note: See Section 7.1 for information about the stator hardware. a. Clean the bearing and the end bracket bore before assembly. b. Place the end bracket onto the stator assembly, using your hands to make the initial fitting of the end bracket over the bearing.
  • Page 139 9. Reinstall the end bracket components. a. Inspect the brushes. If brushes show uneven wear or are worn to less than half their original length, replace them. See Section 6.6. b. Install the brush holder with shim onto the end bracket.
  • Page 140 7.4.2 Reassemble Exhaust System 7.4.3 Reinstall Enclosure 10. Install the exhaust system. See Figure 7-36. 11. Reinstall the rear bulkhead assembly shown in Figure 7-37. Note: Use new exhaust gaskets when re-installing the muffler. a. Install the heat shields onto the alternator exhaust support.
  • Page 141 DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced qualified electrical personnel. Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. Reconnect the battery correctly, positive to positive and ADV-8928 negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).
  • Page 142 25. Re-apply the 120VAC power supply to the generator set by closing the upstream circuit breaker. 26. Turn on the fuel supply. Press RUN to start the generator set and check for leaks with the engine running. 27. Press OFF to turn off the generator set. Then press AUTO if an automatic transfer switch or remote start/stop switch is used.
  • Page 143 Section 8 Wiring Diagrams Figure 8-1 lists the drawing numbers and page numbers. Wiring Diagrams Drawing Number Page 14/20RCA/RCAL Schematic Diagram ADV-8956 Harnesses and cables Sheet 1 1 phase, 2 pole circuit breaker Sheet 2 1 phase, 1 pole circuit breaker...
  • Page 144 Figure 8-2 Schematic Diagram, ADV-8956, Sheet 1 Section 3 Diagrams and Drawings TP-7093 11/20...
  • Page 145 Figure 8-3 Schematic Diagram, ADV-8956, Sheet 2 TP-7093 11/20 Section 3 Diagrams and Drawings...
  • Page 146 Figure 8-4 Schematic Diagram, ADV-8956, Sheet 3 Section 3 Diagrams and Drawings TP-7093 11/20...
  • Page 147 Figure 8-5 Schematic Diagram, ADV-8956, Sheet 4 TP-7093 11/20 Section 3 Diagrams and Drawings...
  • Page 148 Figure 8-6 Wiring Diagram GM102647 Sheet 1, Single Phase, 2-Pole Circuit Breaker Section 3 Diagrams and Drawings TP-7093 11/20...
  • Page 149 Figure 8-7 Wiring Diagram GM102647 Sheet 2, Single Phase, 1-Pole Circuit Breaker TP-7093 11/20 Section 3 Diagrams and Drawings...
  • Page 150 Figure 8-8 Wiring Diagram GM102647 Sheet 3, Three Phase, 3-Pole Circuit Breaker Section 3 Diagrams and Drawings TP-7093 11/20...
  • Page 151 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.
  • Page 152 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 153 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 154 Appendix C General Torque Specifications American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Aluminum Size Grade 2 Grade 5 Grade 8 8-32 2.0 Nm (18 in. lb.) 3.1 Nm (27 in. lb.) 10-24 3.2 Nm (28 in.
  • Page 155 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 156 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 157 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 158 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.
  • Page 160 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-7093 11/20a For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2019 by Kohler Co. All rights reserved.

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