Kohler 20RCAL Operation
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Kohler 20RCAL Operation

Kohler 20RCAL Operation

Residential/commercial generator sets
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Operation
Residential/Commercial Generator Sets
Models:
14RCA/14RCAL
20RCA/20RCAL
26RCA/26RCAL
Controller:
RDC2
TP-7092 8/24f

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Summary of Contents for Kohler 20RCAL

  • Page 1 Operation Residential/Commercial Generator Sets Models: 14RCA/14RCAL 20RCA/20RCAL 26RCA/26RCAL Controller: RDC2 TP-7092 8/24f...

  • Page 2: Product Identification Information

    State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factory- authorized 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 ............................7 Introduction ....................................13 Service Assistance................................... 16 Section 1. Descriptions and Service Views ......................17 Introduction ................................17 Engine ..................................17 Alternator ................................17 Generator Set Enclosure ............................17 Transfer Switch ..............................17 Controller ................................
  • Page 4 2.5.6 Faults Related to Paralleling ........................39 Section 3. RDC2 Controller Operation ........................41 RDC2 Generator Set/Transfer Switch Controller ....................41 Control and Indicators ............................41 3.2.1 Controller Keypad ............................ 42 3.2.2 LED Indicators ............................43 3.2.3 LCD Display ............................. 43 Controller Power ..............................
  • Page 5 4.7.2 Testing the Battery ........................... 79 Storage Procedure ..............................79 4.8.1 Lubricating System ..........................79 4.8.2 Fuel System ............................. 79 4.8.3 Cylinder Lubrication ..........................80 4.8.4 Exterior Preparation ..........................80 4.8.5 Battery ..............................80 Section 5. Troubleshooting ............................. 81 Introduction ................................81 Fault Messages ..............................
  • Page 6 TP-7092 8/24...

  • Page 7: 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 8 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 9: Exhaust System

    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 10: Fuel System

    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 11 Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. 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 12: Hot Parts

    Heavy Equipment WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Hot Parts WARNING Hot engine and exhaust system. Can cause severe injury or death.

  • Page 13: Introduction

    Do not install or operate the generator set indoors. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

  • Page 14: List Of Related Literature

    List of Related Literature Figure 2 identifies literature available for the generator sets and related accessories covered in this manual. Only trained and qualified personnel should install or service the generator set. Generator Set Literature Literature Part No. Specification Sheet, 14RCA/L G4-270 Specification Sheet, 20RCA/L G4-272...

  • Page 15: Emission Information

    Figure 3 Typical Nameplate Emission Information ® The Kohler Model CH740 engine used on the 14RCA/L generator set is certified to operate using natural gas or propane fuel. ® The Kohler Model CH1000 engine used on the 20RCA/L and 26RCA/L generator sets is certified to operate using natural gas or propane fuel for emergency standby use only.

  • Page 16: Service Assistance

    • Visit the Kohler Co. website at KOHLEREnergy.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 17: Section 1. Descriptions And Service Views

    1.5 Transfer Switch The RDC2 controller is designed to interface with and control the Kohler Model RXT Automatic Transfer Switch (ATS). If the power system uses a different model transfer switch, the RDC2 controller will not control the transfer switch. An ATS other than the Model RXT must be equipped with a transfer switch controller and engine start contacts that connect to the remote engine start terminals on the generator set.

  • Page 18: Controller

    1.6 Controller RCA and RCAL models are equipped with the RDC2 controller. See Figure 5. ® The controller provides integrated control for the generator set, Kohler Model RXT transfer switch, programmable interface module (PIM) and load management devices. The controller’s 2-line LCD screen displays status messages and system settings that are clear and easy to read, even in direct sunlight or low light.
  • Page 19 • Exercise modes Unloaded cycle exercise with complete system diagnostics Unloaded full-speed exercise Loaded full-speed exercise (Model RXT ATS required) • ® Front-access mini USB connector for Kohler SiteTech™ connection • ® ® Integral Ethernet connector for Kohler OnCue Plus Generator Management System •...

  • Page 20: Oncue Plus Generator Management System

    Plus Generator Management System ® ® ® The Kohler OnCue Plus Generator Management System is now included with the generator set. The OnCue Plus System allows monitoring and control of your generator set from your home or other location with Internet access using a computer or ®...

  • Page 21: Battery Heater Kit

    0°C (32°F). Note: Battery heaters are compatible with all Kohler-supplied lead-acid batteries. For other battery types, check the battery manufacturer’s instructions for any restrictions regarding the use of battery heaters. The battery heater requires a source of AC power. Verify that AC power is connected to the generator set as described in the generator set Installation Manual.

  • Page 22: Breather Tube Heater And Oil Heater Kit

    1.8.3 Breather Tube Heater and Oil Heater Kit The breather tube heater and oil heater kit is recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32°F). Note: The heaters require a continuous source of AC power. See Figure 7 and Figure 8 for the power supply voltage required. Note: The breather tube heater and oil heater must be used together.

  • Page 23: Fuel Regulator Heater (20/26 Kw Models Only)

    1.8.4 Fuel Regulator Heater (20/26 kW models only) An optional fuel regulator heater is recommended for models 20/26 kW for improved cold starting in locations where the ambient temperature drops below -18°C (0°F). The heater requires a continuous source of AC power. Heater rating 120 VAC, 60 W 240 VAC, 100 W...

  • Page 24: Oil Pressure Sensor Boot Kit

    1.8.5 Oil Pressure Sensor Boot Kit The oil pressure sensor boot protects the oil pressure sensor and its connection from moisture and frost buildup that can cause false low oil level faults. Install the oil pressure sensor boot in locations where the ambient temperature drops below 0°C (32°F). See Figure 14 for illustrations of the installed kit.

  • Page 25: Emergency Stop Kit

    TT-1613 and TT-1795 instructions. ® RDC2 firmware to version 5.5 or higher is required for E-stop operation. Use a personal computer (laptop) and Kohler SiteTech™ software or the USB Utility to update the controller firmware, if necessary. See TP-6701, SiteTech Operation Manual, or TT-1636, Firmware Update Using the USB Utility, for instructions if necessary.

  • Page 26: Powersync Automatic Paralleling Module (Apm)

    Two single-phase generator sets. The generator sets must be the same size (kW) and model. APM RDC2.4 paralleling firmware for the blue-board controller on each generator set. Download the latest version of paralleling firmware from the Service Support section of the Kohler Power Resource Center (KPRC). One Model RXT automatic transfer switch (ATS).

  • Page 27: Service Views

    1.9 Service Views ENCLOSURE PANELS REMOVED TO SHOW DETAIL ADV9746 Hinged roof Oil fill Lock AC receptacle for accessories Air intake Oil drain valve Enclosure key, provided with generator set Exhaust outlet High voltage electrical in Silencer Optional emergency stop button location USB connector (for firmware updates) Lifting holes RDC2 controller...
  • Page 28 ADV9919 ENCLOSURE PANELS REMOVED TO SHOW DETAIL Hinged roof 17. AC receptacles for accessories (not shown) Lock 18. Oil fill Air intake 19. Three-pin connectors for accessories Enclosure key, provided with generator set 20. Oil level switch Optional emergency stop button location 21.

  • Page 29: Section 2. Generator Set Operation

    Section 2. Generator Set Operation 2.1 Prestart Checklist To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. Air Cleaner.

  • Page 30: Local Starting And Stopping

    Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following: •...
  • Page 31 Emergency Stop Switch Operation Press the red STOP button to shut down the generator set in an emergency. Using the emergency stop button bypasses the engine cooldown cycle, stopping the engine immediately. The controller emergency stop lamp lights (if equipped) and the unit shuts down. The generator set cannot be restarted until the emergency stop switch(es) is/are reset.

  • Page 32: Engine Start Crank Cycle

    Automatic Operation with Other Transfer Switches If a transfer switch other than the Model RXT (such as a Kohler Model RDT) is used, the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set.

  • Page 33: Exercise

    Automatic Stop The engine start contacts on the ATS open to signal the generator set to stop. 2.4 Exercise The RDC2 controller can be set to automatically run the generator set at the same time and day each week. Weekly, bi- weekly, or new monthly exercise is required to keep the engine and alternator in good operating condition.

  • Page 34: Ecoexercise (26 Kw Only)

    To set a loaded exercise, follow the procedure in the Changing the Exercise Settings section and select Exercise Type: Loaded. ® For a loaded exercise with a transfer switch other than a Kohler Model RXT, program the exercise at the transfer switch controller. Refer to the transfer switch operation manual for instructions.

  • Page 35: Shutdown During Exercise (Advanced Diagnostic)

    2.4.6 Shutdown During Exercise (Advanced Diagnostic) The following advanced diagnostic operation applies to RDC2 controllers with firmware versions 5.04 and higher. If the generator set shuts down on a fault during an exercise, the controller will try to restart the engine. If the engine starts, the generator set will run at full speed for two minutes and then stop.

  • Page 36: Resetting The Controller After A Fault Shutdown

    2.5.5 Resetting the Controller After a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault message displayed on the controller and refer to Figure 25 to identify and correct the fault condition before proceeding. Contact an authorized dealer for service, if necessary.
  • Page 37 Warning (W) or Fault Message Condition Check Shutdown (SD) Check the battery rating and Engine starting battery voltage falls below 11 VDC for more condition. Battery CrLo than 10 seconds. Inhibited during the engine crank cycle. Check the battery charger Warning Clears when the battery voltage returns to an acceptable operation.
  • Page 38 Warning (W) or Fault Message Condition Check Shutdown (SD)  Engine cooldown runs before shutting down. Figure 25 Controller Fault Messages TP-7092 8/24...

  • Page 39: Faults Related To Paralleling

    2.5.6 Faults Related to Paralleling ® If the PowerSync Automatic Paralleling Module (APM) is used with two 14 kw or two 20 kW generator sets, additional faults and events related to the paralleling system may be displayed on the controller and/or in OnCue Plus. This section lists those faults and events.
  • Page 40 Fault Text Description Possible Causes * RBUS disconnected, secondary controller The primary controller has lost communication with the secondary battery disconnected, updating firmware in LossOfComm2 controller. (A secondary controller was detected, then secondary controller, or intermittent RBUS communication was lost.) connections.

  • Page 41: Section 3. Rdc2 Controller Operation

    Section 3. RDC2 Controller Operation 3.1 RDC2 Generator Set/Transfer Switch Controller Model RCA and RCAL generator sets are equipped with the RDC2 generator set/transfer switch controller. The RDC2 controls the following power system components: • Model RCA or RCAL generator set •...

  • Page 42: Controller Keypad

    2-line LCD display Up button AUTO button and LED Select button OFF button and LED Down button RUN button and LED Utility power available LED* Generator power available LED* Building on utility power LED* Building on generator power LED* GM77569 ...

  • Page 43: Led Indicators

    3.2.2 LED Indicators LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 32. Power System LEDs indicate the status of the utility power and the generator set, and indicate which source is supplying power to the building (based on the position of the RXT transfer switch).

  • Page 44: Controller Power

    Active Alert Active Alert Genset Status Genset Status Running Standby Voltage: 240V Battery Freq: 60.0 Hz 12.3V Engine: 72.0F Engine Runtime: Oil Pressure: OK 24.5 h Battery Date: 02DEC2011 12.3V Time: HR:MNpm Engine Runtime: Next Exercise: 24.5 h 09:00p 09Dec2011 Date: 02DEC2011 Next Maintenance: Time: HR:MNpm...

  • Page 45: Changing Settings

    3.5 Changing Settings Some settings can be changed from the controller keypad. The controller settings and generator set output are factory-set and should not require field adjustment under normal circumstances. Check and adjust the settings and/or output when: • The controller has been replaced. •...
  • Page 46 Changing Settings on the RDC2 Controller Press the Select button to enter the main menu. When the correct date is shown, press the Select button. The saved date is shown. Overview --> Press: Display: Date 1.2 h Press: Display: 03Jan2012 Press the down arrow button until the desired menu Press the down arrow button to step to the next menu.

  • Page 47: Setting The Exerciser

    After a scheduled exercise run, the next exercise time and date will be updated automatically based on the Exercise Frequency setting. ® Other transfer switches: For a loaded exercise with a transfer switch other than a Kohler Model RXT ATS, refer to the transfer switch operation manual for instructions.
  • Page 48 Genset - - > System Freq: System XX.X Hz System Phase System Volt System Battery Fuel Type HOLD: Next Exercise * Next Exercise HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY HOLD: Exercise Mode: Exercise Mode: Unloaded Cycle/Unloaded Loaded Full/ Loaded Full HOLD: Exercise Freq: Exercise Freq:...

  • Page 49: Rdc2 Controller Menus

    3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator, and optional RBUS accessories, exercise settings, and event history. Some menus allow changes to the controller settings. Status information, including the engine runtime, cannot be changed by the operator. Diagrams in the following sections show how to navigate through the menus.

  • Page 50: Overview Menu

    3.9 Overview Menu Overview ---> Active Alert (if any) 1.2 h Genset Status Standby Voltage: 240V Freq: 60.0 Hz Engine: 72F Oil Pressure: OK Battery: 12.0V Engine Runtime: 24.5 h Date: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09Dec2011 Next Maintenance: 150 h or Mar2012 SW Version: 4.07...

  • Page 51: Engine Metering Menu

    3.10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 38. This menu displays status information only. No settings can be changed from this menu. Eng Speed: Engine ---> 3600 RPM Metering Oil Pressure: Switch: OK Oil Temperature: 72.0 F...

  • Page 52: Generator Metering Menu

    Voltage Calibration The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized dealer for service. The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration, if necessary.

  • Page 53: Generator Set Information Menu

    Model and serial numbers are factory-set and should not require changes in the field, except in the event that the controller is ® being replaced. A personal computer running Kohler SiteTech™ software is required to enter the generator set model number and serial numbers on a replacement controller. Contact an authorized Kohler dealer for service. Genset M/N: Genset ----> Information...

  • Page 54: Genset System Menu

    A Kohler-authorized dealer can adjust these settings, if necessary. If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason, see the Changing Settings section for instructions to enable editing and change the system settings.
  • Page 55 System Voltage: Genset ---> 240 V System System Freq: 60 Hz VR Voltage Adj: 240.0 V System Phase: Single System Battery: 12 V Fuel Type: Next Exercise 06:30PM 15Dec2011 Exercise Mode: Unloaded Variable Exercise Freq: Weekly Language: English Meas System: English Contrast: 50 Note:...

  • Page 56: Ats Status Menu

    3.15 ATS Status Menu ATS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model ATS is connected to the engine start connections, Remote ATS is displayed on the ATS Status screen. The ATS Status menu displays Model RXT transfer switch and source information.

  • Page 57: Ats Configuration Menu

    3.16 ATS Configuration Menu Note: The ATS Configuration menu appears only if a Model RXT transfer switch is connected. Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings, if necessary. Changing ATS Configuration Settings To enable editing, press the select button.

  • Page 58: Date And Time Menu

    Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or ® ® load shed kit, and for systems that use the Kohler OnCue Plus Generator Management System. RBUS is a proprietary RS-485 communications protocol.

  • Page 59: Networking Status Submenu

    3.18.1 Networking Status Submenu ® The Networking Status submenu contains settings for OnCue Plus. Changes to these settings are not typically required. If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the IP parameters are displayed.

  • Page 60: Networking Configuration Submenu (Oncue® Password)

    3.18.2 Networking Configuration Submenu (OnCue® Password) ® ® The networking Configuration menu includes settings used for communication with the Kohler OnCue Plus Generator Management System. Password Note: ® Use the OnCue password shown on the controller display for OnCue or OnCue Plus applications.
  • Page 61 Networking---> Networking---> Status Information HOLD Networking Reset OnCue Reset OnCue Configuration Password Password? No UP arrow for YES, Down arrow for NO. RBUS - - > Reset OnCue Information Password? Yes Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds.

  • Page 62: Rbus Information

    3.18.3 RBUS Information The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol. This includes the following optional modules: • Model RXT transfer switch • Combined interface/ load management board on the RXT transfer switch •...

  • Page 63: Remote Devices Submenu

    3.18.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: • Model RXT ATS • Programmable Interface Module (PIM) • Load shed kit or combined interface/ load management board on a Model RXT transfer switch •...

  • Page 64: Programmable Interface Module (Pim) Status Menu

    PIM is connected. This is a status display menu only. Input and output settings cannot be changed from the RDC2 controller’s user interface. ® A personal computer running Kohler SiteTech™ software is required to change the input and output settings. Contact an authorized dealer for service.

  • Page 65: Load Control Menus

    3.20 Load Control Menus The Load Control menu displays the status of the load management device inputs and outputs, and allows a test of the load control output relays. This menu appears only if a load management device (load shed kit or Model RXT transfer switch with the combined interface/ load management board) is connected.

  • Page 66: Event Log

    3.21 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1-1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number of the event, a code to indicate whether the event was a warning (W), shutdown (S), or informational notice (I), the engine hours at the time of the event, and the event description.

  • Page 67: Section 4. Scheduled Maintenance

    Section 4. Scheduled Maintenance 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 68: Service Schedule, 14 Kw Models

    4.1.1 Service Schedule, 14 kW Models Procedure Visually System Component or Procedure Inspect Check Change Clean Test 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 Change oil...

  • Page 69: Service Schedule, 20 And 26 Kw Models

    4.1.2 Service Schedule, 20 and 26 kW Models Procedure Visually System Component or Procedure Inspect Check Change Clean Test Frequency Fuel Flexible lines and connections Quarterly Main tank supply level Weekly Fuel piping Yearly Lubrication Oil level, 20 kW models 8 hours of operation Oil Level, 26 kW models 24 hours of operation...

  • Page 70: Lubrication System

    4.2 Lubrication System See the service schedules section for oil change and oil filter replacement intervals. See the service views section for the oil drain, oil dipstick, oil fill, and oil filter locations. WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set.

  • Page 71: Engine Oil Recommendation

    26 kW 14 kW 20 kW Dipstick 7092 Oil Fill Figure 54 Dipstick and Oil Fill Locations 4.2.4 Engine Oil Recommendation Use 5W-30 or 10W-30 API (American Petroleum Institute) Service Class SG, SH, or SJ synthetic oil. Synthetic oil oxidizes and thickens less than other oils and leaves the engine intake valves and pistons cleaner.

  • Page 72: Resetting The Maintenance Timer

    Fill with oil. Note: When the oil is drained, some oil remains in the engine. The amount of oil needed to refill the engine may be less than the capacity shown in Figure 55. Use the dipstick to check the oil level during the fill. Do not fill past the full mark on the dipstick.

  • Page 73: Oil Cooler (20 And 26 Kw Models)

    4.2.7 Oil Cooler (20 and 26 kW Models) Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris. See Figure 56 for the oil cooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud.
  • Page 74 1-514 Figure 58 Checking the Spark Plug Gap 1-511 Figure 59 Adjusting the Spark Plug Gap TP-7092 8/24...

  • Page 75: Air Cleaner Service

    4.4 Air Cleaner Service 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 air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.

  • Page 76: Air Cleaner, 20/26 Kw Models

    Reinstall the paper element onto the air cleaner base. Make sure the element is flat and properly seated. Install the air cleaner cover and secure with the two retaining knobs. When element replacement is necessary, order genuine Kohler parts. TP-7092...

  • Page 77: Cooling System

    4.5 Cooling System The engine fan draws cooling air through the openings 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 78: Battery

    4.7 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. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.

  • Page 79: Cleaning The Battery

    4.7.1 Cleaning the Battery Clean the battery and cables and tighten battery terminals using the service schedule recommendations. To prevent corrosion, maintain tight, dry electrical connections at the battery terminals. To remove corrosion from battery terminals, disconnect the cables from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water.

  • Page 80: Cylinder Lubrication

    4.8.3 Cylinder Lubrication Remove the spark plugs. Pour one tablespoon of engine oil into each spark plug hole. Install the spark plugs and ground the spark plug leads. Do not connect the leads to the plugs. Crank the engine two or three revolutions to lubricate the cylinders. 4.8.4 Exterior Preparation Clean the exterior surface of the generator set.

  • Page 81: Section 5. Troubleshooting

    If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to equipment.

  • Page 82: Usb Port And Auxiliary Winding Mini-Breaker

    The USB port is located under a small rubber cover as shown in Figure 63. The alternator winding circuit breaker is located on the engine side of the bulkhead as shown in Figure 63. ® A personal computer (laptop) with Kohler SiteTech software can be used to view the event history and adjust controller settings.
  • Page 83 WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.

  • Page 84: Troubleshooting

    No AC output. Line circuit breaker tripping because of short circuit. Contact an authorized Kohler dealer for service. Reset the circuit breaker (located in controller’s service Auxiliary winding circuit breaker tripped. access area). Contact an authorized dealer for service if breaker trips repeatedly.

  • Page 85: Appendix A. Abbreviations

    Appendix A. 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;...
  • Page 86 (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 87 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 88 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 89 TP-7092 8/24...
  • Page 90 TP-7092 8/24...
  • Page 91 TP-7092 8/24...
  • Page 92 TP-7092 8/24f Discovery Energy, LLC 200 Twin Oaks Road, Kohler, WI 53044 USA For the nearest sales and service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLEREnergy.com © 2018 - Discovery Energy, LLC - All rights reserved.

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