Residential/Light Commercial Generator Sets

Residential/Light Commercial Generator Sets

Models:

24RCL30RCL

38RCLBController:

RDC2

TP-6905 7/18c

Operation

WARNING: This product can expose youto chemicals, including carbon monoxideand benzene, which are known to the Stateof California to cause cancer and birthdefects or other reproductive harm.For more information go towww.P65warnings.ca.gov

Kohler strongly recommendsthat only factory-authorizeddistributors or dealers installand service the generator.

Product Identification Information

Generator Set Identification NumbersRecord the product identification numbers from thegenerator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine IdentificationRecord the product identification information from theengine nameplate.

Manufacturer

Model Designation

Serial Number

Controller IdentificationRecord the controller description from the generator setoperation manual, spec sheet, or sales invoice.

Controller Description

Table of Contents

TP-6905 7/18 Table of Contents 3

Product Identification Information 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions and Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Service Views 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Generator Set Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Operating Area 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Prestart Checklist 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Exercising the Generator Set 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Generator Set Operation 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Local Starting and Stopping 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.2 Automatic Starting and Stopping 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.3 Remote Starting and Stopping 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.4 Engine Start Crank Cycle 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.5 Engine Cooldown 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.6 Automatic Operation with Model RXT Transfer Switch 17. . . . . . . . . . . . . .2.4.7 Automatic Operation with Other Transfer Switches 18. . . . . . . . . . . . . . . . .

2.5 Exercise 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.1 Unloaded Cycle Exercise with Complete System Diagnostics 18. . . . . . . .2.5.2 Unloaded Full-Speed Exercise 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3 Loaded Full-Speed Exercise (with RXT only) 19. . . . . . . . . . . . . . . . . . . . . .2.5.4 Shutdown During Exercise 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.5 Power Failure During Exercise 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.6 Exerciser Reset 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.7 Setting the Exerciser at Power-up 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.8 Changing the Exercise Setting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Faults 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.1 Warnings 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.2 Shutdowns 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.3 ATS Communication Errors 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.4 Resetting the Controller after a Fault Shutdown 23. . . . . . . . . . . . . . . . . . . .2.6.5 Event Log 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Model RXT Transfer Switch Operation 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.1 Source Availability 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.2 ATS Control Sequence of Operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.3 Time Delays 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.4 ATS Load Control Relay Time Delay 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 RDC2 Controller Operation 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 RDC2 Generator Set /Transfer Switch Controller 31. . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Controls and Indicators 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Controller Keypad 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 LED Indicators 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.3 LCD Display 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Controller Power 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Battery Charging 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Changing Settings 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 Controller Menus 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7 Main Menu 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8 Overview Menu 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Engine Metering Menu 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10 Generator Metering Menu 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11 Generator Set Information Menu 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-6905 7/18Table of Contents4

3.12 Genset Run Time Menu 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13 Genset System Menu 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14 ATS Status Menu 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15 ATS Configuration Menu 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16 Date and Time Menu 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17 Networking Information Menus 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.17.1 Networking Status Submenu 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17.2 Networking Configuration Submenu (OnCue Plus Password) 46. . . . . . . .3.17.3 RBUS Information Submenu 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17.4 Remote Devices Submenu 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.18 Programmable Interface Module (PIM) Menus 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19 Load Control Menus 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Scheduled Maintenance 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 General Maintenance 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Service Schedule 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Lubrication System 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Oil Specifications 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.2 Oil Check 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.3 Oil Additions 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.4 Oil and Filter Change 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 Air Cleaner 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 Exhaust System 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6 Cooling System 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Checking and Filling Coolant 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.2 Cooling System Inspection 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.3 Draining Cooling System 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.4 Flushing and Cleaning 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.5 Filling Cooling System 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 Ignition System 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8 Battery 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.1 Checking Electrolyte Level 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.8.2 Checking Specific Gravity 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 Storage Procedure 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Troubleshooting 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Introduction 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 USB Port 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Fault Messages 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Circuit Protection 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Load Circuit Breaker 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4.2 Fuses 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4.3 Controller Internal Circuit Protection 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Generator Set Troubleshooting 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 Controller Troubleshooting 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6905 7/18 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

Battery

Sulfuric acid in batteries.Can cause severe injury or death.

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

Explosion.Can cause severe injury or death.Relays in the battery chargercause arcs or sparks.

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery electrolyte is a dilutedsulfuric acid. Battery acid cancausesevere injury or death. Battery acidcan cause blindness and burn skin.Always wear splashproof safetygoggles, rubber gloves, and bootswhen servicing the battery. Do notopen a sealed battery or mutilate thebattery case. If battery acid splashes inthe eyes or on the skin, immediatelyflush the affected area for 15 minuteswith large quantities of clean water.Seek immediatemedical aid in the caseof eye contact. Never add acid to abattery after placing the battery inservice, as this may result in hazardousspattering of battery acid.

Battery acid cleanup. Battery acidcan cause severe injury or death.Battery acid is electrically conductiveand corrosive. Add 500 g (1 lb.) ofbicarbonate of soda (baking soda) to acontainer with 4 L (1 gal.) of water andmix the neutralizing solution. Pour theneutralizing solution on the spilledbattery acid and continue to add theneutralizing solution to the spilledbattery acid until all evidence of achemical reaction (foaming) hasceased. Flush the resulting liquid withwater and dry the area.

Battery gases. Explosion can causesevere injury or death. Battery gasescan cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of abattery in a fire. To prevent burns andsparks that could cause an explosion,avoid touching the battery terminalswith tools or other metal objects.Remove all jewelry before servicing theequipment. Discharge static electricityfrom your body before touchingbatteries by first touching a grounded

TP-6905 7/186 Safety Precautions and Instructions

metal surface away from thebattery. Toavoid sparks, do not disturb the batterycharger connections while the batteryis charging. Always turn the batterycharger off before disconnecting thebattery connections. Ventilate thecompartments containing batteries toprevent accumulation of explosivegases.

Battery short circuits. Explosioncan cause severe injury or death.Short circuits can cause bodily injuryand/or equipment damage.Disconnect the battery beforegenerator set installation ormaintenance. Remove all jewelrybefore servicing the equipment. Usetools with insulated handles. Removethe negative (--) lead first whendisconnecting the battery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnect the negative (--) battery cableto the positive (+) connection terminalof the starter solenoid. Do not test thebattery condition by shorting theterminals together.

Engine Backfire/FlashFire

Risk of fire.Can cause severe injury or death.

Do not smoke or permit flames orsparks near fuels or the fuel system.

WARNING

Servicing the fuel system. A flashfire cancausesevere injuryor death.Do not smoke or permit flames orsparks near the carburetor, fuel line,fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors.Catch fuels in an approved containerwhen removing the fuel line orcarburetor.

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner removed.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully to

minimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.

Exhaust System

Carbon monoxide.Can cause severe nausea,fainting, or death.

The exhaust system must beleakproof and routinely inspected.

WARNING

Generator set operation. Carbonmonoxide can cause severe nausea,fainting, or death. Carbon monoxideis an odorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Avoidbreathing exhaust fumeswhenworkingon or near the generator set. Neveroperate the generator set inside abuilding. Never operate the generatorset where exhaust gas could seepinside or be drawn into a potentiallyoccupied building through windows, airintake vents, or other openings.

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to the

possibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

Carbon monoxide detectors.Carbon monoxide can cause severenausea, fainting, or death. Installcarbon monoxide detectors on eachlevel of any building adjacent to thegenerator set. Locate the detectors toadequately warn the building’soccupants of the presence of carbonmonoxide. Keep the detectorsoperational at all times. Periodicallytest and replace the carbon monoxidedetectors according to themanufacturer’s instructions.

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

Use extreme care when handling,storing, and using fuels.

WARNING

The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecausedby vibration. Donot operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.

Explosive fuel vapors can causesevere injury or death. Takeadditional precautions when using thefollowing fuels:

TP-6905 7/18 7Safety Precautions and Instructions

Propane (LPG)—Adequate ventilationis mandatory. Because propane isheavier than air, install propane gasdetectors low in a room. Inspect thedetectors per the manufacturer’sinstructions.

Natural Gas—Adequate ventilation ismandatory. Because natural gas rises,install natural gas detectors high in aroom. Inspect the detectors per themanufacturer’s instructions.

Gas fuel leaks. Explosive fuelvapors can cause severe injury ordeath. Fuel leakage can cause anexplosion. Check the LPG vapor ornatural gas fuel system for leakage byusing a soap and water solution withthe fuel system test pressurized to6--8 ounces per square inch(10--14 inches water column). Do notuse a soap solution containing eitherammonia or chlorine because bothprevent bubble formation. A successfultest depends on the ability of thesolution to bubble.

Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Engine noise. Hazardous noise cancause hearing loss. Generator setsnot equipped with sound enclosurescan produce noise levels greater than105 dBA. Prolonged exposure to noiselevels greater than 85 dBA can causepermanent hearing loss. Wear hearingprotection when near an operatinggenerator set.

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER

Hazardous voltage. Moving parts.Will cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

DANGER

Hazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.

If the generator set is used forstandby power, install an automatictransfer switch to prevent inadvertentinterconnection of standby andnormal sources of supply.

WARNING


This equipment must be installed andserviced by qualified electricalpersonnel.

DANGER

Welding the generator set.Can cause severe electricalequipment damage.

Never weld components of thegenerator set without firstdisconnecting the battery, controllerwiring harness, and engine electroniccontrol module (ECM).

CAUTION

Grounding electrical equipment.Hazardous voltagewill causesevereinjury or death. Electrocution ispossible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Disconnecting the electrical load.Hazardous voltagewill causesevereinjury or death. Disconnect thegenerator set from the load by turningoff the line circuit breaker or bydisconnecting the generator set outputleads from the transfer switch andheavily taping the ends of the leads.High voltage transferred to the loadduring testing may cause personalinjury and equipment damage. Do notuse the safeguard circuit breaker inplace of the line circuit breaker. Thesafeguard circuit breaker does notdisconnect the generator set from theload.

Welding on the generator set. Cancause severe electrical equipmentdamage. Before welding on thegenerator set perform the followingsteps: (1) Remove the battery cables,negative (--) lead first. (2) Disconnectall engine electronic control module(ECM) connectors. (3) Disconnect allgenerator set controller and voltageregulator circuit board connectors.(4) Disconnect the engine battery-charging alternator connections.(5) Attach the weld ground connectionclose to the weld location.

TP-6905 7/188 Safety Precautions and Instructions

Connecting the battery and thebattery charger. Hazardous voltagewill cause severe injury or death.Reconnect the battery correctly,positive to positive and negative tonegative, to avoid electrical shock anddamage to the battery charger andbattery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardousvoltage/current will cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Accessing the middle compartmenton the control panel. Hazardousvoltage will cause severe injury ordeath. On the controller base box andautomatic voltage regulator, do nottouch the terminals for voltage andcurrent measurement. Disconnect allpower sources and disable thegenerator set before servicing.

Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death. Installa transfer switch in standby powerinstallations to prevent the connectionof standby and other sources of power.Electrical backfeed into a utilityelectrical system can cause severeinjury or death to utility personnelworking on power lines.

Servicing the generator set when itis operating. Exposedmoving partswill cause severe injury or death.Keep hands, feet, hair, clothing, andtest leads away from the belts andpulleys when the generator set isrunning. Replace guards, screens, andcovers before operating the generatorset.

Hot Parts

Hot coolant and steam.Can cause severe injury or death.

Before removing the pressure cap,stop the generator set and allow it tocool. Then loosen the pressure capto relieve pressure.

WARNING

Hot engine and exhaust system.Can cause severe injury or death.

Do not work on the generator set untilit cools.

WARNING

Servicing the alternator. Hot partscan cause severe injury or death.Avoid touching the alternator field orexciter armature. When shorted, thealternator field and exciter armaturebecome hot enough to cause severeburns.

Servicing the exhaust system. Hotparts can cause severe injury ordeath. Do not touch hot engine parts.The engine and exhaust systemcomponents become extremely hotduring operation.

Servicing the engine heater. Hotparts can cause minor personalinjury or property damage. Install theheater before connecting it to power.Operating the heater before installationcan cause burns and componentdamage. Disconnect power to theheater and allow it to cool beforeservicing the heater or nearby parts.

NoticeNOTICE

Canadian installations only. Forstandby service connect the output ofthe generator set to a suitably ratedtransfer switch in accordance withCanadian Electrical Code, Part 1.

NOTICEElectrostatic discharge damage.Electrostatic discharge (ESD)damages electronic circuit boards.Prevent electrostatic dischargedamage by wearing an approvedgrounding wrist strap when handlingelectronic circuit boards or integratedcircuits. An approved grounding wriststrap provides a high resistance (about1 megohm), not a direct short, toground.

TP-6905 7/18 9Introduction

Introduction

This manual provides operation instructions for Model24RCL, 30RCL, and 38RCLB residential/lightcommercial generator sets equipped with the RDC2generator set/transfer switch controller.

Kohler strongly recommends that only factory-authorized distributors or dealers install andservice the generator.

This generator set is approved for use in stationaryapplications in locations served by a reliable utilitypower source. Refer to the Installation Manual forinstallation instructions.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Read and follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

The equipment maintenance requirements are veryimportant for safe and efficient operation. Inspect theparts often and perform required maintenance at theprescribed intervals. Obtain service from an authorizedKohler distributor/ dealer or service technician to keepequipment in top condition.

ADV-8641

Figure 1 Model 24RCL Generator Set

Nameplate

Figure 2 showsa typical generator set nameplate.Copythe model, serial, and specification numbers from thenameplate into the spaces provided in the productinformation section on the inside front cover of thismanual. See the service view in Section 1 for thenameplate location.

Service Duty

Voltage

Alt Model

Insulation

MFG Date

Amps

Phase

RPM

Battery

Fuel

kW

kVA

Hz

Genset Model

Spec Number

Serial Number

Material Number

PF

Figure 2 Nameplate, Typical

TP-6905 7/1810 Introduction

List of Related Literature

Figure 3 identifies related literature available for thegenerator sets covered in this manual. Only trained andqualified personnel should install or service thegenerator set.

Literature Type Part Number

Specification Sheet, 24RCL G4-228

Specification Sheet, 30RCL G4-261

Specification Sheet, 38RCLB G4--262

Installation Manual, Generator Set TP-6906

Operation Manual, KG2204/KG2204TEngine TP-6901

Service Manual, Generator Set TP-6907

Service Manual, KG2204/KG2204TEngine Mechanical TP-6902

Service Manual, Engine ECMDiagnostics TP-6903

Parts Catalog, KG2204/KG2204T Engine TP-6904

Parts Catalog, 24RCL, 30RCL, 38RCLBGenerator Set TP-6908

Operation Manual, OnCuer PlusSoftware TP-6928

Operation/Installation Manual, RXT ATS TP-6807

Operation/Installation Manual, RDT ATS TP-6345

Installation Instructions, ProgrammableInterface Module (PIM) TT-1584

Installation Instructions, Load Shed Kit TT-1609

Installation Instructions, 50 Amp PowerRelay Modules for Load Management TT-1646

Figure 3 Related Literature

TP-6905 7/18 11Service Assistance

Service Assistance

For professional advice on generator set powerrequirementsandconscientiousservice, pleasecontactyour nearest authorized Kohler distributor or dealer.

D Visit the Kohler Co. website at KohlerPower.com.

D Look at the labels and decals on your Kohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler EMEA HeadquartersNetherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

(86) 10 6518 7951(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

TP-6905 7/1812 Service Assistance

Notes

TP-6905 7/18 13Section 1 Service Views

Section 1 Service Views

6

1. Oil check (dipstick)2. Oil fill location (on valve cover)3. See cooling system detail4. Exhaust outlet5. Enclosure locking key (shipping location only)6. Spark plugs (qty. 4)7. Fuel pressure regulator8. Engine ECM9. Fuel inlet (1 in. NPT)10. Fuel solenoid valves (qty. 2 shown)11. Lube oil filter12. Customer load lead access (behind panel)13. Customer connection access panel14. Line circuit breaker15. Generator set master control buttons (on RDC2 controller)16. Nameplate location

17. RDC2 controller18. Fan fuses19. Cooling air inlet (remove this panel to access coolant drain)20. Access to coolant fill21. Air-fuel mixer22. Throttle body23. Air cleaner24. Battery25. Oil drain26. Coolant drain27. Fans (qty. 3)28. Radiator29. Pressure cap (engine coolant fill)30. Coolant overflow tube31. Temperature sensor32. Coolant overflow bottle

ADV-8641

14

17

23

15

28

10 9

19

16

111213

3

8

1

22

24Cooling System Detail

2727

3029

26

32

4

1820

5

SERVICE SIDE

NON-SERVICE SIDE

GM90230

18 2

21

7

25

31

Figure 1-1 24RCL Service Views for Maintenance

TP-6905 7/1814 Section 1 Service Views

5

1. Oil check (dipstick)2. Oil fill location (on valve cover)3. Exhaust outlet4. Enclosure locking key (shipping location only)5. Spark plugs (qty. 4)6. Fuel inlet (1 in. NPT)7. Oil cooler adapter8. Battery9. Lube oil filter10. Customer load lead access11. Customer connection access panel12. Line circuit breaker13. Generator set master control buttons (on RDC2 controller)14. Nameplate location15. RDC2 controller16. Fan fuses17. Cooling air inlet (remove this panel to access coolant drain)18. See cooling system detail

19. Access to coolant fill (on roof)20. Turbocharger21. Air-fuel mixer22. Air cleaner23. Fuel pressure regulator24. Fuel solenoid valves (located behind the fuel regulator)25. Oil drain26. Coolant drain27. Fans (qty. 3)28. Charge air cooler (CAC, located between fan and radiator)29. Radiator30. Pressure cap (engine coolant fill)31. Coolant overflow tube32. Temperature sensor33. Coolant overflow bottle34. MAP sensor35. Oil cooler hoses36. Oil cooler (at bottom of radiator)

ADV-8663

12

16

22

13

29

24

6

17

15

91011

18

1

8

Cooling System Detail

27

27

3130

26

33

3

19

4

SERVICE SIDE

NON-SERVICE SIDE

GM92075

2

21

23

25

2028

14

32

34

35

36

7

Figure 1-2 30RCL and 38RCLB Service Views for Maintenance

TP-6905 7/18 15Section 2 Generator Set Operation

Section 2 Generator Set Operation

2.1 Operating Area



WARNING

Carbon monoxide symptoms. Carbon monoxide cancause severe nausea, fainting, or death. Carbonmonoxideis a poisonous gas present in exhaust gases. Carbonmonoxide is an odorless, colorless, tasteless, nonirritating gasthat can cause death if inhaled for even a short time. Carbonmonoxide poisoning symptoms include but are not limited tothe following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles


D Stomachache, vomiting, nauseaIf experiencing any of these symptoms and carbon monoxidepoisoning is possible, seek fresh air immediately and remainactive. Do not sit, lie down, or fall asleep. Alert others to thepossibility of carbon monoxide poisoning. Seek medicalattention if the condition of affected persons does not improvewithin minutes of breathing fresh air.

Generator set operation. Carbon monoxide can causesevere nausea, fainting, or death. Carbon monoxide is anodorless, colorless, tasteless, nonirritating gas that can causedeath if inhaled for even a short time. Avoid breathing exhaustfumes when working on or near the generator set. Neveroperate the generator set inside a building. Never operate thegenerator set where exhaust gas could seep inside or bedrawn into a potentially occupied building throughwindows, airintake vents, or other openings.

Carbon monoxide detectors. Carbon monoxide cancause severe nausea, fainting, or death. Install carbonmonoxide detectors on each level of any building adjacent tothe generator set. Locate the detectors to adequately warn thebuilding’s occupants of the presence of carbon monoxide.Keep the detectors operational at all times. Periodically testand replace the carbon monoxide detectors according to themanufacturer’s instructions.

Keep the generator set area clear. Maintain at least0.9 m (3 ft.) of clearance on all sides of the generatorset. Verify that there are no windows, air vents, or otheropenings in the building within 1.5 m (5 ft.) of thegenerator set exhaust outlet in any direction.

NoticeDo not locate patios, decks, play areas, or animalshelters near the generator set. Keep items such aslawn furniture, toys, sports equipment, and allcombustible materials away from the generator setexhaust outlet. Remind family members, children,and visitors to use caution near the generator set.

Generator sets connected to automatic transferswitches start automatically during exercise periodsand power outages. Some generator set componentsbecome hot when the generator set is running andremain hot for a time after the generator set shutsdown.

2.2 Prestart Checklist



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.

TP-6905 7/1816 Section 2 Generator Set Operation



WARNING

Explosion.Can cause severe injury or death.Relays in the battery chargercause arcs or sparks.

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery gases. Explosion can cause severe injury ordeath. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur near a battery at any time,particularly when it is charging. Do not dispose of a battery in afire. To prevent burns and sparks that could cause anexplosion, avoid touching the battery terminals with tools orother metal objects. Remove all jewelry before servicing theequipment. Discharge static electricity from your body beforetouching batteries by first touching a grounded metal surfaceaway from the battery. To avoid sparks, do not disturb thebattery charger connections while the battery is charging.Always turn the battery charger off before disconnecting thebattery connections. Ventilate the compartments containingbatteries to prevent accumulation of explosive gases.

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid can causeblindness and burn skin. Always wear splashproof safetygoggles, rubber gloves, and boots when servicing the battery.Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediatelyflush the affected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case of eyecontact. Never add acid to a battery after placing the battery inservice, as this may result in hazardous spattering of batteryacid.



DANGER

Grounding electrical equipment. Hazardous voltage willcause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set, transfer switch, and related equipment andelectrical circuits. Turn off the main circuit breakers of allpower sources before servicing the equipment. Never contactelectrical leads or appliances when standing inwater or onwetground because these conditions increase the risk ofelectrocution.

Connecting the battery and the battery charger.Hazardous voltage will cause severe injury or death.Reconnect the battery correctly, positive to positive andnegative to negative, to avoid electrical shock and damage tothe battery charger and battery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardous voltage/current will causesevere injury or death. Short circuits can cause bodily injuryand/or equipment damage. Do not contact electricalconnections with tools or jewelry while making adjustments orrepairs. Remove all jewelry before servicing the equipment.

To ensure continued satisfactory operation perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In addition, some checks requireverification after the unit starts.

Air Cleaner. Check for a clean and installed air cleanerelement to prevent unfiltered air from entering theengine.

Air Inlets. Check for obstructions that could block theflow of cooling air. Keep the air intake area clean. Do notleave rags, tools, or debris on or near the generator set.

Battery. Check for tight battery connections. Consultthe battery manufacturer’s instructions regardingbattery care and maintenance.

Coolant Level.Check the coolant level according to thecooling system maintenance information.


Drive Belt. Check the belt condition of the water pumpand battery charging alternator belt.

Exhaust System. Check for exhaust leaks andblockages. Check the silencer and piping condition andcheck for tight exhaust system connections.

Inspect the exhaust system components for cracks andcorrosion (exhaust manifold, exhaust pipe, exhaustclamps, and silencer).

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check that there are no combustible materials nearthe exhaust outlet.

D Check that the exhaust outlet is unobstructed.

Carbon Monoxide Detectors. Check for theinstallation and operation of carbon monoxide (CO)detectors on each level of any building near thegenerator set.

Oil Level.Maintain the oil level at or near, not over, thefull mark on the dipstick.


2.3 Exercising the Generator SetOperate the generator set without load every week orevery other week for 20 minutes. Perform all of theprestart checks before starting the exercise procedure.See Section 2.5 for instructions to set the automaticexerciser.

2.4 Generator Set Operation

2.4.1 Local Starting and Stopping

Start: Press the RUN button to immediately start thegenerator set.

Stop: Press the OFF button. The engine stops.

Run the generator set with no load for at least 2 minutesto ensure adequate engine cooldown.

2.4.2 Automatic Starting and Stopping

An automatic transfer switch monitors the utility powerand signals the generator set to start when utility poweris lost. The ATS then transfers the load to the generatorset.

When utility power is restored, the transfer switchtransfers the load back to utility, runs the generator setwith no load to cool down the engine, and then stops thegenerator set engine. The electric fans continue to runfor twominutes after the engine shuts down to evacuatethe engine compartment.

2.4.3 Remote Starting and Stopping

A remote switch connected to terminals 3 and 4 can beused to start and stop the generator set. Close theswitch to start and run the generator set. Open theswitch to stop the generator set.

Run the generator set with no load for at least 2 minutesto ensure adequate engine cooldown.

2.4.4 Engine Start Crank Cycle

The controller attempts to start the generator set threetimes (three crank cycles, 15 seconds crank and15 seconds off). If the generator set does not start inthree attempts, the system shuts down on an overcrankfault. See Section 2.6.

Pressing the OFF button during the crank cycle stopsthecranking.Noother buttonsareacknowledgedduringthe crank cycle.

2.4.5 Engine Cooldown

The engine cooldown time delay allows the engine torun after the loads have been removed.

The engine cooldown time delay is set to 5minutes. Theengine stops before the cooldown time delay expires ifthe temperature drops below the cooled-downtemperature level, or if the temperature rises above thehigh limit during the cooldown cycle.

Theelectric fanscontinue to run for twominutesafter theengine shuts down to evacuate the enginecompartment.

If a transfer switch other than theModel RXT is used, anadditional engine cooldown time delay may beprogrammed on the transfer switch. To allow the smartengine cooldown on the RDC2 controller to operatemost efficiently, set the cooldown time on the transferswitch controller to zero or the minimum time allowed.Refer to the instructions provided with the transferswitch for more information.

2.4.6 Automatic Operation with ModelRXT Transfer Switch

The Model RXT transfer switch connects to the RDC2controller through the ATS interface board on thetransfer switch. Also see Section 2.7, Model RXTTransfer Switch Operation.

The RDC2 controller must be in AUTO mode forautomatic transfer switch operation.

Automatic Start

The RDC2 controller receives utility source voltagesensing data from the Model RXT transfer switch.

1. If the utility source voltage falls below anacceptable level, the controller starts the enginestart time delay.

2. If the utility source is not restored before the timedelay expires, the generator set starts.

3. After the Normal-to-Emergency time delay, theATS is signaled to transfer the load to theemergency source.

Automatic Stop

1. When the utility source is restored, theEmergency-to-Normal time delay starts.

2. When the Emergency-to-Normal time delayexpires, the load is transferred to the utility.

3. The generator set stops.


2.4.7 Automatic Operation with OtherTransfer Switches

If a Kohler Model RDT transfer switch is used, theengine start contacts from the ATS must be connectedto engine start leads 3 and 4 on the generator set.

The RDC2 generator set controller must be in AUTOmode to respond to remote start/stop signals from anATS or remote switch. Press the AUTO button on theRDC2 controller to put the generator set into automaticmode.

Automatic Start

The engine start contacts on the ATS close to signal thegenerator set to start, and remain closed while thegenerator set is running.

Automatic Stop

The engine start contacts on the ATS open to signal thegenerator set to stop.

2.5 Exercise

The RDC2 controller can be set to automatically run thegenerator set at the same time and day every week orevery other week. Exercising the generator set everyweek or every twoweeks is required in order to keep theengine and alternator in good operating condition.

Three exercise modes are available: unloaded cycle,unloaded full speed, and loaded full speed. SeeSections 2.5.1 through 2.5.3 for information about theexercise modes. A loaded exercise can be set at theRDC2 controller only if a Model RXT transfer switch isconnected.

Note: With the RDT transfer switches, it is possible tohave two exercise settings (one unloadedexercise set at the generator set controller, andanother exercise set at the ATS controller). If theexercise times overlap, the ATS exercise settingtakes priority.

If a Model RDT transfer switch is used, refer to theinstructions provided with the transfer switch to set aloaded exercise at the ATS, if desired.

2.5.1 Unloaded Cycle Exercise withComplete System Diagnostics

An unloaded cycle exercise runs the generator setwithout signalling the transfer switch to transfer theelectrical load from theutility source to thegenerator set.The Unloaded Cycle exercise with diagnostics is the

recommended exercisemode and is the factory-defaultexercise setting.

The Unloaded Cycle exercise runs the engine for20 minutes in the cycle shown in Figure 2-1 anddescribed below.

D Runs at reduced speed for 10 minutes to warm upand exercise the engine.

D Ramps up and runs at full speed for 3 minutes.Engine diagnostics are performed during thisfull-speed portion of the cycle, which provides thebest test of engine and alternator power backupcapability. Diagnostic tests at full speed can identifypotential problemswith the power output and alert theoperator before an emergency event.

D Ramps down and runs at reduced speed for5 minutes to cool down the engine before shuttingdown automatically.

EngineSpeed,R

PM

EngineExercise

Full-SpeedDiagnostics

Cooldown

3 min.

1 min.1 min.

10 min. 5 min.

Figure 2-1 Unloaded Exercise Cycle

System Diagnostics

During the unloaded cycle exercise, the controllermonitors the following data. The controller displayindicates an unloaded exercise run during thediagnostics, unless a fault is detected as describedbelow.

D ATS connection. The controller verifies that theModel RXT ATS interface board is connected.

D Battery voltage. Battery voltage is checked beforeexercise to verify engine starting capability. Batteryvoltage provides a measurement of battery health. Ifthe controller detects low battery voltage, low batteryor low charging battery is displayed and the exercisedoes not start.

D Coolant level check. The coolant level is checked.


D Communication integrity tests. J1939, RBUS,Ethernet, and USB are monitored for messagesindicating that the controller and wiring are reliable.

D Engine speed. Engine speed is measured at lowspeed and full speed. An overspeed or underspeedcondition will result in a fault condition and shutdown.

D Generator output frequency and voltage.Operating the generator at full speed allows theRDC2 controller to check the output power for correctvoltage, frequency, and stability. When the engine isrunning at full speed, the controller verifies that thevoltage and frequency are within acceptable limits. Afault message is displayed if the voltage or frequencyis out of range.

D Oil pressure. Oil pressure is verified to ensureproper lubrication of critical engine components.Pressure is monitored at both low and full speeds. Ifthe oil pressure is low, low oil pressure is displayedand the generator set shuts down.

2.5.2 Unloaded Full-Speed Exercise

The unloaded full speed exercise runs the generator setat full speed for 20minuteswithout transferring the load.

To set an unloaded full speed exercise, follow theprocedure in Figure 2-3 and select Exercise Mode:Unloaded Full.

2.5.3 Loaded Full-Speed Exercise (withRXT only)

A loaded exercise starts the generator set, ramps up tofull speed, and then transfers the electrical load from theutility source to thegenerator set. The load is transferredback to the utility source before the generator set shutsdown.

Note: With a loaded exercise, power to the building islost for up to 10 seconds during load transfer.

For a loadedexercise controlled by theRDC2controller,a Model RXT transfer switch must be connected to thegenerator set. To set a loaded exercise, follow theprocedure in Section 2.5.8 and select Exercise Type:Loaded.

For a loaded exercise with a transfer switch other than aKohlerr Model RXT, program the exercise at thetransfer switch controller. Refer to the transfer switchoperation manual for instructions.

2.5.4 Shutdown During Exercise

The following advanced diagnostic operation applies toRDC2 controllers with firmware versions 5.04 andhigher.

If the generator set shuts down on a fault during anexercise, the controller will try to restart the engine. If theengine starts, the generator set will run at full speed fortwo minutes and then stop. The event history will showAdvanced Diagnostic Active. The exercise schedule ismaintained.

If the engine does not start, the shutdown message willbe displayed. Correct the fault condition and reset thefault as described in Section 2.6.

2.5.5 Power Failure During Exercise

If the utility power is lost during an unloaded exercise,theATS transfers to theemergencysource, theexerciseis ended and the control remains in the AUTO mode.

If the utility power is lost during a loaded exercise, theexercise is ended. The ATS remains in the emergencyposition and the control goes into the AUTO mode.

The generator set continues to run and supply power tothe load for the duration of the utility power outage.WhenUtility power is restored, theATSwill re-transfer tothe utility source through normal timing sequences.

2.5.6 Exerciser Reset

To reset the exerciser to run at a different day and/ortime or to change the exercise mode, follow theprocedure in Section 2.5.7 to change the exercisersettings.

2.5.7 Setting the Exerciser at Power-up

When power is connected to the controller, you will beprompted to set the date, time, and exercise schedule.

1. At power--up, the date is displayed with the yearflashing. Use the up or down arrow key to step tothe current year.

2. Press Select button to save the year and move tothe month.

3. Use the arrow and select buttons to set the monthand the day.


4. The time is displayed with the hour flashing. Usethe up or down arrowkey to step to the current hourand am or pm setting.

Note: Check the am/pm setting displayed. If pm isdisplayed and you need to change it to am,use the down arrow button to step down intime until the correct hour and am aredisplayed.

5. Press the Select button to save the hour andmoveto minutes.

6. Use the up or down arrow button to change theminutes.

7. Press Select to save the time andmove to the nextscreen.

8. Next Exercise is displayed. Use the up, down, andselect buttons to set the exercise time and date. Besure to set a time and date in the future.

9. Press Select. The controller exits the exercisemenu.

10. Press the Auto button and verify that the AUTOLED is lit. The generator set must be in automaticmode for the exercise to run as scheduled.

The exercise will run every 7 days at the same time,starting on the date set. To change the exerciser to runevery other week or on a different day and time, use thefollowing procedure.

2.5.8 Changing the Exercise Setting

Set the date and time on the controller before setting theexercise schedule. Set the exerciser to automaticallyrun thegenerator set for 20minutes everyweekor everytwo weeks. Follow the procedure below and see theflowchart in Figure 2-3 to set the exercise time and date,mode, and frequency.

Procedure to Change the Exercise Setting

1. Press the AUTO button on the controller.

2. Press the Select button to go to the main menu.See Figure 2-2.

3. Press the down arrow button to step to the GensetSystem menu.

4. Press theSelect button to enter theGenset systemmenu. See Figure 2-3.

5. Use the down arrow button to step to the nextExercise menu.

6. Press the Select button. The setting flashes toshow that it can be changed. For example, the hourflashes to show that the hour can be changed.

7. Press the UP or Down arrow buttons to change thesetting.

8. Press the Select button to save the setting andmove to the next. For example, save the hoursetting and move to minutes.

9. Repeat steps 5 through 8 to change the next itemon the line until the desired settings are displayed.

10. Press Select to save after all settings have beenselected. Settings will stop flashing.

11. If thegenerator set is connected toaKohlerrModelRXT transfer switch, the exercise can be changedto a loaded exercise. Set the Exercise Mode toloaded full speed, unloaded full speed, or unloadedcycle as shown in Figure 2-3.

12. Set the exercise frequency (weekly or every twoweeks). Weekly exercises are recommended.

13. Press the down arrow button to step to the Returnmenu. Press the Select button to return to themainmenu.

14. Check that the AUTO LED is lit. The generator setmust be in automatic mode for the exercise to runas scheduled.

After a scheduled exercise run, the next exercise timeand date will be updated automatically based on theExercise Frequency setting.

Other transfer switches: For a loaded exercise with atransfer switch other than a Kohlerr Model RXT,program the exercise at the transfer switch controller.Refer to the transfer switch operation manual forinstructions.


Overview ---->1.2 h

Engine ---->Metering

tp6810

Generator---->Metering

Genset ---->Information

Genset ---->Run Time

Date ---->and Time

ATS ---->Configuration

Genset ---->System

Event Log---->

Load ---->Control

PIM ---->Status

Network ---->Information

StatusDisplays

ATS ---->Status

Figure 2-2 RDC2 Main Menu


tp6809

Genset ---->

System

Next Exercise

HR:MN PM MM/DD/YY

Exercise Freq:

Weekly/Every Other Week

Meas. System:

English

<---- Return

Next Exercise *

HR:MN PM MM/DD/YY

Exercise Freq:

Weekly

Exercise Mode:

Unloaded Cycle

Exercise Mode:

None/Unloaded Full Sp/ Un-loaded Cycle/Loaded Full SP

Contrast:

50

System Freq:

60 Hz

System Voltage:240 V

VR Voltage Adj:

240.0V

System Phase:

Single

System Battery:12 V

See Section 2.5.8, Changingthe Exercise Setting

* If the exerciser has not been set, No Exercise Sch will be displayed.

Figure 2-3 Procedure to Set the Exerciser


2.6 Faults

Selected fault conditions are shown in Figure 2-5. Faultconditions are classified as warnings or shutdowns. If afault occurs that is not listed in the table, contact anauthorized distributor/dealer for service.

Note: All ECM faults are grouped under one listing inFigure 2-5.

If a programmable interface module (PIM) is connectedto the generator set controller, additional faults can beactivated by customer-supplied equipment. SeeTT-1584, Installation Instructions for the ProgrammableInterface Module, for available inputs and outputs.

2.6.1 Warnings

The controller displays a fault message but thegenerator set does not shut down on a warning. Thecontroller resets automatically after a warning conditionis corrected.

2.6.2 Shutdowns

Under a fault shutdown condition, the generator setshuts down automatically and the controller displays afault message. The OFF LED flashes. See Figure 2-5.

Shutdownswitches (suchas the lowcoolant level switchor high engine temperature switch) on the generator setwill automatically reset when the problem is corrected.However, the fault condition at the controller does notclear until the controller is reset.

The generator set cannot be restarted until the faultcondition is corrected and the controller is reset. SeeSection 2.6.4 to reset the controller after a faultshutdown.

2.6.3 ATS Communication Errors

When aModel RXT transfer switch is used, an ATS faultindicates that the connection to the interface board onthe transfer switch has been lost. Check the connectionto the ATS interface board.

2.6.4 Resetting the Controller after aFault Shutdown

Always identify and correct the cause of a faultshutdownbefore resetting the controller. Check the faultmessage displayed on the controller and refer toFigure 2-5 to identify and correct the fault conditionbefore proceeding. Contact an authorizeddistributor/dealer for service, if necessary.

Press theOFFbutton to reset the controller, or follow theprocedure below. See Figure 2-4.

Procedure to Reset the Controller after a FaultShutdown

1. Press the Select button to go to the Overviewmenu.

2. Press Select again. The active fault is displayed.

3. PressSelect.ConfirmClearFault:NO isdisplayed.

4. Press the Up arrow button. Confirm Clear Fault:YES is displayed.

5. Press the Select button to enter YES and clear thefault.

6. Press the Select Button to return to the overviewmenu.

7. PressAUTO to put the generator set into automaticmode.

Overview ---->1.2 h

Fault Message Confirm ClearFault: NO

Confirm ClearFault: YES

Fault Message

Press Uparrow button.

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Figure 2-4 Clearing a Fault


Fault (RDC2) Fault (OnCuerPlus)

Condition Check

AC Sens Loss

Warning(1 sec.)

Shutdwn(3 sec.)

AC SensingLost

AC Sensing Lost. In Auto mode, generatoroutput AC sensing is lost. Detection begins 10seconds after crank disconnect.

Warning: after 1 second if no output detectedafter crank disconnect.

Shutdown: after 3 seconds if voltage waspresent and then lost.

Contact an authorizeddistributor/dealer for service.

Accy PwrOverWarning

AccessoryPower Overload

Accessory Power Overload. An over currentfault (short circuit) on the accessory controllerpower output.


ATS ComErrorWarning

ATSCommunicationError

ATS Communication Error. Warning isdisplayed if RXT interface connection is lost.See Section 2.6.3.

Check communication wiring betweentransfer switch interface board andgenerator set.

ATS PhaseRotWarning

ATS PhaseRotationMismatch

ATS Phase Rotation Mismatch. Transferswitch phase rotation does not match. ATSwill not transfer.

Correct the ATS connection. Refer tothe ATS Installation manual, wiringdiagrams, and labels on the transferswitch.

Aux InputShutdwn

Auxiliary Input Auxiliary Input. An optionalcustomer-connected input is closed. (Digitalinput from optional PIM.)

Check customer-supplied equipment.

Battery CrLoWarning

Critically LowBattery Voltage

Engine starting battery voltage falls below 11V for more than 10 seconds. Inhibited duringthe engine crank cycle.

Clears when the battery voltage returns to anacceptable level.

Check the battery rating andcondition.

Check the battery charger operation.

Charge or replace the battery.

Battery HighWarning

High BatteryVoltage

Engine starting battery voltage rises above133% (16 V) of the battery voltage setting formore than 10 seconds. Inhibited during theengine crank cycle.




Battery LowWarning

Low BatteryVoltage

Engine starting battery voltage falls below thebattery voltage setting (typically 12.5 volts) formore than 90 seconds when the engine is notrunning. Inhibited during the engine crankcycle.





Chk DateTimeWarning

Verify DateTime Setting

The time and date have not been set on thegenerator controller.

Enter the date and time using theRDC2 controller. See Figure 3-8 andFigure 3-16.

Coolant Lvl LowShutdwn

Low CoolantLevel Shutdown

The coolant level switch input has beenactivated.

Check coolant level.

Check radiator hoses for leaks.


CoolTempHighWarning

Ect HigherThanExpected 1

Coolant temperature is too high. Check coolant level.

Check radiator and fans forobstruction.

Contact an authorizeddistributor/dealer for service andprovide the fault code.



Condition Check

CoolTemp VhiShutdwn

Ect HigherThanExpected 2

Coolant temperature is extremely high. Check coolant level.



CoolntTemp 0Shutdwn

Coolant Temp 0Shutdown

The ECM reported a problem with the coolanttemperature sensor reading: 0 = hightemperature.

Check coolant level.



CoolntTemp 3Shutdwn


The ECM reported a problem with the coolanttemperature sensor reading: 3 = high voltage.


CoolntTemp 4Shutdwn


The ECM reported a problem with the coolanttemperature sensor reading: 4 = low voltage.


CoolntTemp 5Shutdwn


The ECM reported a problem with the coolanttemperature sensor reading: 5 = open circuit.


Crank LostWarning

Crank SignalLost

Crankshaft Position Sensor (CPS) timeouterror occurred.


ECM warnings(any warningswith ECM in thefault name)

ECM warnings(any warningswith ECM inthe fault name)

This group of faults includes a wide variety offaults that originate from the engine ECMand also contain ECM in the fault name.


Emerg StopShutdwn

EmergencyStop Shutdown

The emergency stop switch has beenactivated, or there has been an open circuit inthe wiring.


Eng Speed HighShutdwn

High EngineSpeed

Engine speed exceeds 115% of the normalrunning speed for more than 0.3 seconds.


Eng Speed LowShutdwn

Low EngineSpeed

Engine speed drops below 85% of the normalrunning speed for more than 3 seconds.

Reduce the load by turning offappliances.


Exer Not SchWarning

ATS ExerciseNot Scheduled

Exercise Not Scheduled. No exercise hasbeen scheduled on the RDC2 controller.

See Section 2.5 for instructions to setthe exerciser.

Frequency HighShutdwn

High Frequency Governed frequency exceeds 110% of thesystem’s frequency setpoint for more than 10seconds. Function becomes active 10seconds after engine start (10 second inhibit).


Frequency LowShutdwn

Low Frequency Governed frequency falls below 90% of thesystem frequency setting for more than10 seconds, or 1 Hz below the systemfrequency setting for more than 60 seconds.

Function becomes active 10 seconds afterengine start (10 second inhibit).

Reduce the load by turning offappliances and restart the generatorset.




Condition Check

Genset S/NUnaval Warning

UnavailableGenset SerialNumber

Generator set serial number is unavailable. Contact an authorizeddistributor/dealer for service. Seesection 3.11.

Ground FaultWarning

Ground FaultWarning

The digital input for Ground Fault Warning isactive (low). (PIM required.)

Check customer equipmentconnected to the PIM.

IAT High 1Warning

Iat HigherThanExpected 1

Engine manifold air temperature is too high. Contact an authorizeddistributor/dealer for service andprovide the fault code.

IAT Volt LoWarning

Iat LowVoltage

The ECM reported an Engine AirTemperature/Manifold Absolute PressureSensor (TMAP) error.


Lo Crank VltWarning

Low CrankingVoltage

Low cranking voltage. Battery voltage fallsbelow 60% of system battery voltage for morethan 6 seconds while the starter is engaged.


Locked RotorShutdwn

Locked Rotor No engine rotation is sensed during cranking.Shuts down 3 seconds after the fault isdetected.

Check the battery.

Check for loose connections.

Check for obstruction of alternator orengine.


MainPwrOverLShutdwn

Main PowerOverload

Main power overload. An over current fault onthe 70 controller power output (short circuit).

Check for shorted run relay. Checkwiring for short circuits.


Maint Req’dWarning

MaintenanceRequiredWarning

Engine maintenance is due. Check the maintenance schedule inthe operation manual for tasks suchas changing the oil, spark plugs or theair filter.

Not in AutoWarning

Not In Auto The generator set is not in Automatic(standby) mode. Remote start and stopcommands from a transfer switch or remoteswitch will be ignored.

Press AUTO to place the generatorset in Automatic mode, whenappropriate.

Oil Pres LowShutdwn

Low OilPressure

The engine ECM indicates low oil pressure.

Note: The low oil pressure shutdown does notprotect against low oil level. Check the engineoil level regularly as recommended inSection 4.

Check for leaks in the lubricationsystem.

Check the oil level and add oil if thelevel is low.

Check the oil pressure switch andwiring.

Over CrankShutdwn

Over Crank Three unsuccessful starting attempts. Check the fuel supply, spark plug,and battery.

Check for loose connections.




Condition Check

PrimLoopOpnWarning

Primary LoopOpen

Ignition coil 1 voltage is below normal orthere is an open circuit.

Check the battery voltage.


PrimLoopShtWarning

Primary LoopShorted

Ignition coil 1 voltage is abnormal. Check the battery voltage.


Spd Sens FltShutdwn

Speed SensorFault

Engine speed sensor has failed or enginestalled. ECM is no longer reporting validspeed.


Volts L1-L2 HighShutdwn

High GeneratorVoltage L1-L2

Generator Voltage High. Output voltageexceeds 120% of the system nominal voltagefor more than 2 seconds.


Volts L1-L2 LowShutdwn

Low GeneratorVoltage L1-L2

Generator Voltage Low. Output voltage fallsbelow 80% of the nominal system voltage formore than 10 seconds.





















Figure 2-5 Controller Fault Messages


2.6.5 Event Log

The event log displays up to 1000 controller faults andnotices, starting with the most recent event. Events arenumbered 1--1000, with 1 being the most recent. Eachevent is displayed with the date and time of the event,the number of the event, a code to indicate whether theevent was a warning (W), shutdown (S), orinformational notice ( I), the engine hours at the time ofthe event, and the event description.

Procedure to View Event History

1. Press Select to enter the main menu.

2. Press thedownarrow to stepdown to theevent log.

3. Press Select to display the most recent event.

4. Press the down arrow to step to the next event.

5. Use the up and down arrow buttons to viewevents.

6. Press the Select button to exit the event log.

To stop viewing the event history before the last event,press the select button to return to the main menu.

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Event Log ---->

Date MO/DA/YEAR

time HR:MN

event number, W/S/I, engine hours

event name

Press UP and Down arrow but-tons to scroll through events

Date MO/DA/YEAR

time HR:MN

event number, W/S/I, engine hours

event name

Press Select button at any time toreturn to the main menu.

Event codes:W = WarningS = ShutdownI = Informational Notice

Figure 2-6 Event Log

2.7 Model RXT Transfer SwitchOperation

The RDC2 generator set/transfer switch controllermanages automatic transfer switch (ATS) functionswhenconnected toaKohlerrModelRXT transfer switchthrough the ATS interface board. Refer to the ModelRXT Operation/Installation Manual for informationabout the transfer switch operation.

2.7.1 Source Availability

The Model RXT transfer switch supplies voltagesensing data to the RDC2 controller through the ATSinterface board. If the source voltage falls below theundervoltage dropout setting, the source is consideredto have failed. See Figure 2-7.

Item Setting

Accuracy ±5%Undervoltage Dropout 90% of Pickup

Undervoltage Pickup 90% of Nominal

Figure 2-7 Voltage Sensing Parameters

The RDC2 controller also has a set of power systemLEDs below the pushbuttons. The power system LEDsindicate which power sources are available and whichsource is supplying power to the building. SeeFigure 3-1.

Note: The power system LEDs operate only if a ModelRXT transfer switch is connected. They will notoperate if a Model RDT transfer switch is used.


2.7.2 ATS Control Sequence ofOperation

See Figure 2-8 for time delay settings.

Normal Source Fails:

1. The load control contact opens.

2. The engine start time delay times out.

3. The generator set is signaled to start.

4. The generator starts and the emergency sourcebecomes available.

5. The normal-to-emergency time delay times out.

6. The transfer switch transfers to the emergencysource.

7. The load control contact time delay times out.

8. The load control contact closes.

Normal Source Returns:

1. The emergency-to-normal time delay times out.

2. The contactor transfers to the normal source.

3. The engine cooldown time delay times out.

4. The generator is signaled to stop.

2.7.3 Time Delays

Time delays are factory-set to the values shown inFigure 2-8. An authorized distributor/dealer can adjusttime delays using a personal computer and KohlerrSiteTecht software.

Time delays described in this section operate onlywhenthe controller is connected to a Kohlerr Model RXTtransfer switch.

The engine start and load transfer time delays preventengine start and load transfer caused by brief variationsin the utility power source.

2.7.4 ATS Load Control Relay TimeDelay

The load control time delay allows delayed starting oflarge motor loads (such as air conditioners), preventingsimultaneous starting of large motors after transfer tothe generator set. The load control time delay is fixed at5 minutes. It is not adjustable.

The load must be connected to the load control outputon the interface board of theModel RXT transfer switch.See the transfer switch operation and installationmanual for connection instructions.

Time Delay Setting Description

Engine Start 3 seconds Time delay after utility source is lost until the engine start cycle begins.Guards against starting the generator set because of a brief change inthe utility source.

Transfer, Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer toemergency source.

Transfer, Emergency to Normal 2 minutes Time delay after the utility source returns until transfer back to normal.Ensures that the the utility source is stable before transferring from theemergency source.

Load Control 5 minutes See Section 2.7.4. Allows delayed connection of selected loads to thegenerator set to prevent simultaneous starting of large motors aftertransfer to the emergency source. Recommended for delayed startingof air conditioners.

Figure 2-8 Time Delays

TP-6905 7/18 31Section 3 RDC2 Controller Operation

Section 3 RDC2 Controller Operation

3.1 RDC2 Generator Set/TransferSwitch Controller

Model 24RCL, 30RCL, and 38RCLB generator sets areequipped with the RDC2 generator set/transfer switchcontroller. The RDC2 controls the following powersystem components:

D Model 24RCL, 30RCL, or 38RCLB generator set

D Model RXT automatic transfer switch (ATS)

D Load management device

D Programmable interface module (PIM)

RDC2 Controller features include:

D Two-line x 16 character backlit LCD display withadjustable contrast

D OFF, AUTO, and RUN generator set master controlbuttons

D Generator set status indicating LEDs (OFF, AUTO,RUN)

D Up, Down, and Select buttons for navigation throughmenus and adjustments

D Power system indicator LEDs to show utility andgenerator source status, and to show which source(utility or generator) is supplying power to the building

3.2 Controls and Indicators

Figure 3-1 illustrates the keypad, display, and indicatorson the controller’s user interface.

1. 2-line LCD display2. Up button3. Select button4. Down button5. RUN button and LED6. Generator power available LED *7. Generator supplying power to the building LED *8. Utility supplying power to the building LED *9. Utility power available LED *10. OFF button and LED11. AUTO button and LED

* These LEDs operate only if a Model RXT transfer switch isconnected.

1

10

3

2

5

11

4

GM77569

6789

Figure 3-1 RDC2 User Interface

TP-6905 7/1832 Section 3 RDC2 Controller Operation

3.2.1 Controller Keypad

TheRun,Off, andAuto buttons control the generator setas described in Figure 3-2. Use the Select, Up arrow,and Down arrow buttons to navigate through themenusand change settings, if necessary. See Section 2.4 foroperation instructions.

3.2.2 LED Indicators

LEDs above the RUN, OFF, and AUTO buttons indicatethe mode of operation as shown in Figure 3-2.

The RDC2 controller also has a set of power systemLEDs below the pushbuttons. The power system LEDsindicate which power sources are available and whichsource is supplying power to the building (based on theposition of the Model RXT transfer switch). SeeFigure 3-1.

Note: The power system LEDs operate only if a ModelRXT transfer switch is connected. They will notoperate if a Model RDT transfer switch is used.

Button Button Function

RUN Starts the generator set. The engine start time delay is ignored.

OFF Stops the generator set. The cooldown time delay is ignored.

During the engine crank cycle, pressing OFF will stop the crank cycle.

Press OFF to clear faults and reset the controller.

AUTO Places the generator set in Automatic (standby) mode.

Down arrowUse to navigate through menus and change settings. This manual contains instructions to navigate thecontroller menus and adjust settings on the RDC2 controller.

Select

Up arrow

Figure 3-2 Pushbutton Operation

LED LED Operation

RUN Lights when the generator set has been started locally by pressing the RUN button.Remote start and stop commands are ignored.

OFF Lights for 2 seconds, then flashes every 2 seconds when the generator set andcontroller are off. Remote start/stop commands have no effect. The exercise cycle willnot run.

In Auto mode, OFF LED flashes quickly to indicate a fault shutdown. Attention required.Identify and correct the fault condition before resetting the controller.

AUTO Lights when the generator is in automatic (standby) mode. Generator set will respond toengine start and stop commands from the controller (for example, exercise start andstop commands), an ATS, or OnCuerPlus, Time delays operate as described in Section2.4.

Utility Power Available * Lights when utility power is available.

Building on Utility Power * Lights when the building load is connected to utility power through the RXT transferswitch.

Generator Power Available * Lights when generator power is available.

Building on Generator Power * Lights when the building load is connected to generator power through the RXT transferswitch.

* These LEDs operate only if a Model RXT transfer switch is connected.

Figure 3-3 RDC2 Controller LED Operation


3.2.3 LCD Display

The controller is equipped with a two-line x 16 characterbacklit liquid crystal diode (LCD) display with adjustablecontrast. When the generator is running, the controllerautomatically scrolls through the displays shown inFigure 3-4. When the system is in AUTO, the LCDdisplay scrolls through the status messages shown inFigure 3-5.

When a fault or warning condition exists, the controllerwill show the corresponding message. See Section 2.6for more information on fault and warning messages.

Controller menus display power system information,including status information for the engine, generator,and optional RBUS accessories, exercise settings, andevent history. Some menus allow changes to thecontroller settings. See Sections 3.6 through 3.19 formenu diagrams.

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Genset StatusRunning

Voltage: 240VFreq: 60.0Hz

Engine: 123FOil Pressure: 40 psi

Battery12.3V

Engine Runtime:27.4 h

Date: 02DEC2014Time: HR:MN pm

Active Alert

Sample data shown.

Figure 3-4 Autopaging Displays, Generator Running

The display contrast is adjustable. Navigate to theGenset System menu and step down to the Contrastscreen.Press theSelect button, and thenuse theupanddown arrow buttons to adjust the contrast. See Section3.5, Changing Settings, and Section 3.11, GeneratorSet System Menu.

The display backlight turns off after about aminute of noactivity. The backlight turns onwhen a button is pressedor when the generator set starts.

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Genset StatusStandby

Battery12.3V



Next Exercise:09:00p 09Dec2014

Next Maintenance:150 h or Mar2015

Sample data shown.

Figure 3-5 Autopaging Displays, Automatic Mode


3.3 Controller Power

The RDC2 controller is powered by the generator setengine starting battery and the built-in battery charger.

Note: To disconnect controller power, disconnect thebattery and the utility power to the generator set.

If controller power is disconnected and reconnected,youwill be prompted to set the time, date, and exerciser.The first setting will flash. Press the Up and Down arrowbuttons to change the setting. Press Select to save thesetting andmove on to the next. Repeat until all settingsare saved and the controller returns to the main menu.SeeSection 3.5 formore detailed instructions to changesettings on theRDC2. SeeSection 2.5 formore detailedinstructions to set the exerciser or change the exercisesettings.

3.4 Battery Charging

The controller includes a built-in battery charger tomaintain the engine starting battery. The RDC2controller monitors the battery voltage and provides aconstant 13.5 ±0.2% VDC voltage and maximum 2.4amps to charge the battery.

The installer must connect utility power provided fromthe building (90--265 VAC, 50/60 Hz) on abreaker-protected circuit for the built-in battery charger.See the Installation Manual for instructions to connectthe utility power for the battery charger.

3.5 Changing Settings

Some settings can be changed from the controllerkeypad.Thecontroller settingsandgenerator set outputare factory-set and should not require field adjustmentunder normal circumstances. Check and adjust thesettings and/or output when:

D The controller has been replaced.

D The voltage requires adjustment for a particularapplication.

D Troubleshooting generator set problems.

Havecontroller setupandadjustmentperformedonlybyan authorized Kohler distributor/dealer or authorizedrepresentative.

The following procedure explains how to changesettings. See Figure 3-6 for an example using the Dateand Time settings.

Note: Use caution when navigating the controllermenus and changing the settings. In somemenus, pressing the Select button can enableediting of the controller settings. Changing somesettings to incorrect values can adversely affectgenerator set operation or render the unitinoperable.

Procedure to Change Settings

1. Press the Select button to enter the main menu.

2. Press thedownarrowbuttonuntil thedesiredmenuis displayed. The Date and Time menu is used forthe example in Figure 3-6.

3. Press theSelect button to enter the selectedmenu.See Figure 3-6.

4. Press the down arrow button to step through theparameters in the selected menu.

5. To change a setting, press the Select button. Theselected setting flashes.

6. Press the up or down arrow buttons to increase ordecrease the setting.

7. When the desired setting is shown, press Select.The value stops flashing. If there are additionaladjustable settings on the screen, the next settingflashes. For example, in the date menu, the year,month, and day can be adjusted.

8. Repeat steps 5 through 7 for each setting on thescreen.

9. Press the down arrow to step to the next screen.

10. To exit, press the down arrow button until Return isdisplayed.Press theSelect button toexit themenu.

11. Press the AUTO or OFF button to exit the mainmenu.

Note: If no buttons are pushed, the controller exits themenus and returns to the generator set statusdisplay after 5 minutes.


1. Press the Select button to enter the main menu.

2. Press the down arrow button until the desiredmenu is displayed. SeeFigure 3-7.Date andTimeare used for this example.

3. Press theSelect button to enter theDate andTimemenu.

4. To change the date and time settings, press theSelect button again. The year will flash.

5. Press the up or down arrow buttons to change theyear.

6. When the correct year is shown, press the Selectbutton. The year is saved and the next setting(month) flashes.

7. Repeat steps 5 and 6, using the arrow and selectbuttons to set the month and the date.

Press:

Changing Settings on the RDC2 Controller

Press: Display:Overview ---->

1.2 h

Display:

Press: Display:

Press: Display:

Date ---->

and Time

Date:

05Dec2013

8. When the correct date is shown, press the Selectbutton. The saved date is shown.

9. Press the down arrow button to step to the nextmenu.

10. Repeat steps 5 and 6, using the arrow and selectbuttons to set and save the time.

Note: To change from am to pm, press the up arrowkey to increase the hour until the correct hourand pm is displayed.

11. Repeat to set the time format to 12 hr. or 24 hr.

12. Press the down arrow button. Return isdisplayed.

13. Press Select to return to the Date and Timemenu.

14. Press the Up or Down arrow buttons to step to adifferent menu.

15. Press Auto to signal the controller to exit themenus and return to the generator set statusdisplay.

Note: If no buttons are pressed, the controller returnsto the status display after 5 minutes.

Press: Display:OR

Press: Display:

Press: Display:<---- Return

Press: Display:

Time:

01:49pm

Date ---->

and Time

AUTO

Press: Display:Genset State

Standby

Date:

05Dec2013

Date:

05Dec2014

Press: Display:Date:

05Dec2014

Press: Display:Date:

03Jan2014

Figure 3-6 Changing Settings


3.6 Controller Menus

The following sections show theRDC2controllermenusand submenus. Use the Select button and the up anddown arrow buttons to navigate the menus as shown inthe diagrams.

Note: Use caution when navigating the controllermenus. In some menus, pressing the Selectbutton can enable editing of the controllersettings. Changing the settings to incorrectvalues can adversely affect generator setoperation or render the unit inoperable.

If a setting on the controller display is flashing, editmodehasbeenenabled.Press theOFForAUTObutton toexitthe edit mode.

3.7 Main Menu

Press theSelect button once to bring up themainmenu.Overview is displayed. See Figure 3-7. Press the downarrow button to step to the next menu, EngineMetering.Use the UP and DOWN arrow buttons to step up anddown through the menus shown in Figure 3-7.

The controller will exit the main menu after 5 minutes ifno buttons are pressed. To exit the main menuimmediately, press the controller’s OFF or AUTObutton.

Overview ---->1.2 h


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Generator---->Metering



Date ---->and Time

ATS ---->Configuration *

Genset ---->System

Event Log---->

Load ---->Control ]

PIM ---->Status [

Network ---->Information

StatusDisplays

ATS ---->Status

* ATS Configuration appears only if a Model RXT transfer switch is connected.[ PIM Status appears only if a programmable interface module is connected.] Load Control appears only if a load management device is connected.

Press the Up and Down arrow buttonsto move between menus.Press OFF or AUTO to exit the menus.

Figure 3-7 RDC2 Main Menu


3.8 Overview Menu

Overview ---->1.2 h

Active Alert(if any)

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Genset StatusStandby

Voltage: 240VFreq: 60.0Hz

Engine: 95FOil: 40 PSI

Battery12.3V



Next Exercise:09:00p 09Dec2014

Next Maintenance:150 h or Mar2015

SW Version:4.03

<---- Return

Figure 3-8 Overview Menu

3.9 Engine Metering Menu

The engine metering menu displays engine statusinformation as shown in Figure 3-9. This menu displaysstatus information only. No settings can be changedfrom this menu.

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Eng Speed:1800 RPM

Coolant Temp:73 F

Battery:12.3 V

<---- Return


Oil Pressure:40 PSI

Oil Temp:73 F

Figure 3-9 Engine Metering Menu


3.10 Generator Metering Menu

The generator metering menu displays the generatorvoltage and frequency. See Figure 3-10.

The voltage calibration mode can be entered from thegenerator metering menu.

Voltage Calibration



DANGER

The voltage calibration mode can be entered from theGeneratorMeteringmenu.Contact a Kohler-authorizeddistributor/dealer for service.

The Reset Calibration menu allows you to set thevoltage reading back to the original value aftercalibration, if necessary. See Figure 3-10.

Volts L1--L2:240 V

Volts L2--L3:240 V

Volts L3--L1:240 V

Generator ---->Metering

ResetCalibration

<---- Return

ResetCalib? No

Volts:240 V

Three-phase Single-phase

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ResetCalib? Yes

Frequency:60.0 Hz

Frequency:60.0 Hz

Figure 3-10 Generator Metering Menu


3.11 Generator Set InformationMenu

The generator set model number and serial numbersare displayed. No changes are allowed from this menu.

Model and serial numbers are factory set and should notrequire changes in the field, except in the event that thecontroller is being replaced. A personal computerrunningKohlerrSiteTecht software is required to enterthe generator set model number and serial numbers ona replacement controller. Contact an authorized Kohlerdistributor/dealer for service.

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Genset M/N:24RCL

Genset S/N:

Controller S/N:

<---- Return


########

########

or

Figure 3-11 Generator Set Information Menu

3.12 Genset Run Time Menu

The data shown in Figure 3-12 are displayed. Nochanges are allowed from this menu.

The Next Maintenance menu shows the number ofhours of generator set operation until maintenance isrequired. The estimated date for the next scheduledmaintenance is also displayed. The maintenancereminder intervals are based on the enginemanufacturer’s recommendation for changing the oil.Refer to Section 4, Scheduled Maintenance, formaintenance instructions.

After changing the oil and performing otherrecommended maintenance, go to the Overview menuto reset the maintenance timer. See Section 4.3.4 forinstructions to reset the maintenance timer.

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Eng Runtime:27.4 h

Eng Starts:40

<---- Return


Next Maintenance:

150 h or Mar2014

Figure 3-12 Generator Set Run Time Menu


3.13 Genset System Menu

The genset system menu displays the systeminformation shown in Figure 3-13. Generator sets arefactorysetandshouldnot require changes to thesystemsettings in the field.

A Kohler authorized distributor or dealer can adjustthese settings, if necessary. If the generator set isreconnected to a different voltage or the systemsettingsrequire adjustment for some other reason, see Section3.5 for instructions to enable editing and change thesystem settings.

Note: Use caution when navigating the controllermenus. In some menus, pressing the Selectbutton can enable editing of the controllersettings. Changing the settings to incorrectvalues can adversely affect generator setoperation or render the unit inoperable.

Voltage Regulator (VR) Voltage Adjust

The generator set voltage is factory set and typicallydoes not require adjustment in the field. If voltageadjustment is required, contact a Kohler authorizeddistributor or dealer for service. Refer to the generatorset Installation Manual for instructions to adjust thevoltage.

Fuel Type

The fuel type, LP or natural gas, is shown. Do notchange the fuel type in thismenu unless the generator’sfuel system has been converted by an authorizeddistributor or dealer.

Setting the Exerciser

Use the Genset System menus to set the generator setexerciser. Refer to Section 2.5 for instructions to set theexerciser and for more information about exercising thegenerator set.

After a scheduled exercise run, the Next Exercise timeand date will be updated automatically based on theExercise Frequency setting.

Language

Controllers with firmware versions 6.1 or higher can beset for the following languages: English, French,Spanish, Dutch, or German.

Adjusting the Display Contrast

To adjust the display contrast, use the down arrowbutton to step to the Contrast menu. Press the Selectbutton, and then use the up and down arrow buttons to

adjust the contrast. Press the Select button to save thecontrast setting.

tp6804

Genset ---->

SystemSystem Voltage:

240 V

System Battery:12 V

System Phase:

Single

<---- Return

Next Exercise

06:30p 15Dec2015

Exercise Freq:

Weekly

Exercise Mode:

Unloaded Variable

System Freq:

60 Hz

Meas System:

English

Contrast:

50

VR Voltage Adj:

240.0V

Note: Actual settings may vary.

Fuel Type

LP

Language:

English

Figure 3-13 Genset System Menu


3.14 ATS Status Menu

ATS menus appear if a Model RXT transfer switch isconnected to the generator set. If no transfer switch isconnected, or another model ATS is connected to theengine start connections, Remote ATS is displayed onthe ATS Status screen.

The ATS Status menu displays Model RXT transferswitch and source information.

The voltage shown in these menus can be calibrated.Contact an authorized distributor or dealer for service ifcalibration is required.

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Frequency:60.0 Hz

Voltage L1--L2:240 V



ATS ---->Status

Voltage:240V

Frequency:60.0 Hz

ATS Position:Normal

Normal Status:Not/Acceptable

Emerg. Status:Standby

Three-phaseSingle-phase

ResetCalibration

<---- Return

ResetCalib? No

ResetCalib? Yes

Note: If there is no Model RXT transferswitch connected to the generator set,RemoteATS isdisplayedand theotherscreens on this page do not appear.

Figure 3-14 ATS Status Menu, with Calibration


3.15 ATS Configuration Menu

Note: The ATS Configuration menu appears only if aModel RXT transfer switch is connected.

Use theATSConfiguration submenu to check theModelRXT transfer switch system settings and time delays,and change the settings, if necessary.

Changing ATS Configuration Settings

To enable editing, press the select button. The valueflashes to indicate that it can be changed. Press the upand down arrow buttons to change the value. Press theSelect button to save the value shown.

Use the up and down arrow buttons to move to the nextvalue to be changed. Repeat the adjustment processuntil all values are correct.

Press the down arrow until Return is displayed. Pressthe select button to return to the main menu.

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Normal Freq:60.0 Hz

<---- Return

Normal Voltage:240.0 V

ATS ---->Configuration

Emerg. Freq:60.0 Hz

Emerg. Voltage:240.0 V

Emerg. EngineStart: 3 sec

Transfer FromNormal: 3 sec

Transfer FromEmerg.: 120 sec

Figure 3-15 ATS Configuration Menu


3.16 Date and Time Menu

The date and time will typically be set at controllerpower-up. To change the date, time, or time format(12 hour or 24 hour), use the Date and Time menu.See Figure 3-16.

tp6810

Date:

02Dec2014

Time:

12:34pm

Time Format:

12hr|24hr

Date andTime

<---- Return

To change the date and time, press the Select buttonSee Figure 3-6 for instructions.

Figure 3-16 Date and Time Menu


3.17 Networking Information Menus

Use the networking menus to view and adjustcommunication settings for systems with remote RBUSdevices such as aPIMor loadmanagement device, andfor systems that use the Kohlerr OnCuer Plus Home

Generator Management System. RBUS is a proprietaryRS-485 communication protocol.

The Networking Information menu leads to submenusfor network and RBUS communication settings.

tp6810

Networking---->Information

Networking---->Status

NS

RBUS ---->Information RB

<---- Return

Networking---->Configuration

NC

See Figure 3-18.

See Figure 3-19.

See Figure 3-20.

Figure 3-17 Networking Information Menu


3.17.1 Networking Status Submenu

The Networking Status submenu contains settings forOnCuer Plus. See the OnCue Plus SoftwareOperation Manual for information about the appropriatenetwork settings for OnCue Plus.

If DHCP is enabled, IP parameters are not displayed. IfDHCP is disabled (i.e., if a static IP address is used), theIP parameters are displayed.

To enable or disable DHCP and change the IP settings,go to the Networking Configuration menu. SeeSection 3.17.2.

tp6804

IP Address:

###.###.###.###

Gateway:

###.###.###.###

<---- Return

Subnet Mask:

###.###.###.###

DHCP:

Enabled

Ethernet Status:

Disconnected

DNS 1:###.###.###.###

DNS 2:

###.###.###.###

OnCue Server:

###.###.###.###

OnCue Status:Connected

Networking---->

Status


Figure 3-18 Network Status Submenu


3.17.2 Networking ConfigurationSubmenu (OnCue Plus Password)

The networking Configuration menu includes settingsused for communication with the KohlerrOnCuer PlusGenerator Management System.

For most applications, DHCP is enabled and the IPsettings cannot be changed from the controller keypad.If DHCP is enabled, IP parameters are not displayed.

If DHCP is disabled (i.e., if a static IP address isrequired), then the IP parameters can be modified. Forapplications that require static IP addresses, press andhold the select button to enable editing, disable DHCP,and then step to the next parameters and enter theinformation.

If an error occurs while setting a parameter, an errormessage is displayed and then the controller exits theedit mode. Previous settings are preserved.

Note: Use the OnCue password shown on thecontroller display for OnCue Plus applications.

For the initial OnCue Plus setup, you will berequired to reset the OnCue password on theRDC2 controller, and then enter it into theOnCuePlus software. To reset the password, follow theinstructions in Figure 3-19.

Note: The password is displayed for only 10 seconds.Be sure to write down the password and serialnumber.

A newpassword is generated each time the resetpassword procedure is performed. If thepassword is reset after the OnCue Plus systemhas been set up, the connection will be lost.Disconnect the battery power to the controller,wait a minute, then reconnect power.

tp6804

<---- Return

DHCP:Enabled

Reset OnCuePassword

Reset OnCuePassword? No

S/N: #######New PW: #####

Press Select to enter YESor NO as displayed. Newpassword is displayed forapproximately 10 seconds.

NetworkingConfiguration

HOLD

Reset OnCuePassword? Yes

UP arrow for YES,Down arrow for NO.



Figure 3-19 Network Configuration Submenu


3.17.3 RBUS Information Submenu

The RBUS Information menu contains settings forremote modules that communicate with the RDC2controller using RBUS protocol. This includes thefollowing optional modules:

D Model RXT transfer switch

D Programmable Interface Module (PIM)

D Load Shed Kit or RXT combined interface/loadmanagement board

tp6804

Modules Connected:3

Module Timeouts:####

Net Cycle Time:123ms

Module Errors:####

< ---- Return

RDRemote ---->Devices

See Figure 3-21.



RBUS ---->Information

<---- Return

Networking---->Configuration

Figure 3-20 RBUS Information Submenu


3.17.4 Remote Devices Submenu

Check the status of remote devices communicatingthrough RBUS. Device types can include:

D Model RXT ATS

D Programmable interface module (PIM)

D Load Shed Kit or RXT combined interface/loadmanagement board

The serial numbers for the PIM and load shed kit areprinted on the circuit boards inside the enclosures.

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Device Status:Connected

RD

Firmware Ver.:###

ModBus ID:##

S/N: #########<<*DeviceType*>>

Return ---->

S/N: #########<<*DeviceType*>>

Comm. Errors:#####

Comm. Timeouts:#####

...

Connected:MM/DD/YY 12:12

<---- Return

Connected: Displays date/time device was connected.

Disconnected: Displays date/time of the last successful com-munication.

Figure 3-21 Remote Devices Submenu


3.18 Programmable InterfaceModule (PIM) Menus

The PIM status menu displays the status of inputs andoutputs connected to the programmable interfacemodule (PIM). This is a status display menu only. Inputand output settings cannot be changed from the RDC2controller’s user interface.

A personal computer running Kohlerr SiteTechtsoftware is required to change the input and outputsettings. Contact an authorized distributor or dealer forservice.

TheKohlerrOnCuerPlusManagement Systemcan beused to turn outputs on and off. See the OnCue PlusSoftware Operation Manual for instructions.

tp6810

PIMStatus:

PIM 1 ---->

<---- Return

Input 1In/Active

Output 1:In/Active

Input 2In/Active

Output 2:In/Active

Output 3:In/Active

Output 4:In/Active

Output 5:In/Active

Output 6:In/Active

<---- Return

Figure 3-22 Programmable Interface Module (PIM) Status Menu


3.19 Load Control Menus

The Load Control menu displays the status of the loadmanagement inputs andoutputs, andallowsa test of theload management output relays. This menu appearsonly if a load management device is connected.

Generator current is displayed as a percent of themaximum generator capacity. The load management

device adds and sheds loads based on the generatorcurrent.

The test function cycles the relays in the order of theirpriority. For detailed information about loadmanagementoperation, refer toTT--1609, providedwiththe load shed kit, or TP--6807, RXT Transfer SwitchOperation and Installation Manual.

Input 1:In/Active

Output 1:Add/Shed

Input 2:In/Active

Output 2:Add/Shed

Output 3:Add/Shed

Output 4:Add/Shed

Output 5:Add/Shed

Output 6:Add/Shed

Test OutputsPush Select (blinking)

<---- Return

tp6810

Load ---->Control

Load ---->Control 1

<---- Return

GeneratorCurrent: 123 %

Figure 3-23 Load Control Status Menu

TP-6905 7/18 51Section 4 Scheduled Maintenance

Section 4 Scheduled Maintenance

4.1 General Maintenance



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Move the generator set masterswitch to the OFF position. (2) Disconnect the power to thebattery charger. (3) Remove the battery cables, negative (--)lead first. Reconnect the negative (--) lead last whenreconnecting the battery. Follow these precautions to preventstarting of the generator set by an automatic transfer switch,remote start/stop switch, or engine start command from aremote computer.



WARNING

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.

Servicing the alternator. Hot parts can cause severeinjury or death. Avoid touching the alternator field or exciterarmature. When shorted, the alternator field and exciterarmature become hot enough to cause severe burns.

Servicing the engine heater. Hot parts can cause minorpersonal injury or property damage. Install the heaterbefore connecting it to power. Operating the heater beforeinstallation can cause burns and component damage.Disconnect power to the heater and allow it to cool beforeservicing the heater or nearby parts.



DANGER

Hazardous voltage. Moving parts.Will cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

DANGER

Servicing the generator setwhen it is operating. Exposedmoving parts will cause severe injury or death. Keephands, feet, hair, clothing, and test leads away from the beltsand pulleys when the generator set is running. Replaceguards, screens, and covers before operating the generatorset.



WARNING

Servicing the air cleaner. A sudden backfire can causesevere injury or death. Do not operate the generator set withthe air cleaner removed.

TP-6905 7/1852 Section 4 Scheduled Maintenance

Servicing the fuel system. A flash fire can cause severeinjuryor death. Donot smokeor permit flames or sparks nearthe carburetor, fuel line, fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors. Catch fuels in anapproved container when removing the fuel line or carburetor.

The fuel system. Explosive fuel vapors can cause severeinjury or death. Vaporized fuels are highly explosive. Useextreme care when handling and storing fuels. Store fuels in awell-ventilated area away from spark-producing equipmentand out of the reach of children. Never add fuel to the tankwhile the engine is running because spilled fuel may ignite oncontact with hot parts or from sparks. Do not smoke or permitflames or sparks to occur near sources of spilled fuel or fuelvapors. Keep the fuel lines and connections tight and in goodcondition. Donot replace flexible fuel lineswith rigid lines. Useflexible sections to avoid fuel line breakage caused byvibration. Do not operate the generator set in the presence offuel leaks, fuel accumulation, or sparks. Repair fuel systemsbefore resuming generator set operation.

Gas fuel leaks. Explosive fuel vapors can cause severeinjury or death. Fuel leakage can cause anexplosion. Checkthe LPG vapor or natural gas fuel system for leakage by usinga soap andwater solutionwith the fuel system test pressurizedto 6--8 ounces per square inch (10--14 inches water column).Do not use a soap solution containing either ammonia orchlorine because both prevent bubble formation. A successfultest depends on the ability of the solution to bubble.

The engine and generator set may use both AmericanStandard and metric hardware. Use the correct sizetools to prevent rounding of the bolt heads and nuts.

See the Safety Precautions and Instructions at thebeginning of this manual before attempting to service,repair, or operate the generator set. Have an authorizedKohler distributor/dealer perform generator set service.

Engine Service. Perform generator set engine serviceat the intervals specified by the engine operationmanual.

Generator Set Service. Perform generator set serviceat the intervals specified by the generator set operationmanual.

RoutineMaintenance.Refer to the following generatorset service schedule, the engine service schedule, andthe runtime hours shown on the RDC2 controller todetermine when to schedule routine maintenance.Service generator sets that are subject to extremeweather or dusty or dirty conditions more frequently.

Maintenance and Service Parts.Obtain maintenanceand service parts from an authorized Kohlerdistributor/dealer.


4.2 Service Schedule

System Component or ProcedureSee

Section

Procedure

FrequencyVisuallyInspect Check Change Clean Test

General MaintenanceFluid leaks X Daily

Engine oil level X Daily

Coolant level 4.6.1 X Daily

Obstructions or combustible materials nearexhaust outlet

XWeekly

Leaks, hissing, and gas odor X Weekly

Bolts and nuts for tightness X Quarterly or 20 hours

Engine oil and filter [ 4.3 X Yearly or 120 hours

Inspect wiring for cuts, abrasions, orcorrosion

X5 Years

Belts and belt tension EngineO/M

XYearly or 120 hours

Inspect vacuum lines and fittings X 5 Years

Air Intake SystemAir cleaner element [ 4.4 Quarterly

or 20 hr.3 years or400 hr. Hours shown

Air induction for leaks X 3 Years or 500 hours

Intake manifold for vacuum leaks X 3 Years or 500 hours

Cooling SystemClamps and hoses, tightness and leaks 4.6.2 X X R Daily

Radiator exterior X X Yearly or 120 hours

Engine coolant w 4.6.2 X 3 Years or 500 hours

Hoses, condition 4.6.2 X X R 3 Years or 500 hours

Electrical SystemBattery charge 4.8 X Yearly or 120 hours

Battery fluid level X Yearly or 120 hours

Battery for cracks and corrosion X Yearly or 120 hours

Clean battery cables [ X Yearly or 120 hours

Exhaust System 4.5

Exhaust manifold for leaks X R 5 Years or 2000 hours

Exhaust piping for leaks X 5 Years or 2000 hours

Check HEGO (oxygen) sensor connectionsand wires

EngineO/M

X5 Years or 2000 hours

Fuel SystemFuel lines and connections X Quarterly

Fuel regulator pressure X Yearly or 120 hours

Fuel shutoff valve operation X 5 Years or 2000 hours

Ignition SystemSpark plug wires for cuts, abrasions, orhardening

4.7 X R3 Years or 500 hours

Secondary ignition coil wires X R 3 Years or 500 hours

Spark plugs 4.7 X 3 Years or 500 hours

GeneratorBrushes and collector ring D D Yearly or 300 hours

* Not necessary for maintenance-free batteries.[ Service more frequently under extremely dusty/dirty conditions.w Long-life coolant is recommended. When long-life coolant is used, thechange interval is 5000 hours or 5 years. Do not mix coolant types.

X ActionD Authorized distributor/dealer onlyR Replace as necessary


4.3 Lubrication System

4.3.1 Oil Specifications

Use oil that displays the American Petroleum Institute(API) Starburst certification mark FOR GASOLINEENGINES on the container. Do not use straight-weightoils recommended for industrial or stationary engines.CC or CD classification oils, even when labeled HeavyDuty or For Natural Gas Engines are not acceptable.

Multi--viscosity synthetic oils are recommended. Forbest performance in colder environments (such as theUnited States and Canada), use Society of AutomotiveEngineers (SAE) 5W-30,API service class SJ or higher.In extremely hot environments where temperatures arenever or rarely below 0_C (32_F), use a synthetic oil witha viscosity designation of 10W-30, API service class SJor higher.

4.3.2 Oil Check

Check the oil level in the crankcase every 24 hours ofoperation or before the engine is started each day. Donot check the oil level while operating the unit. Stop thegenerator set and keep the generator set level to get anaccurate reading.

To check the oil level, remove the dipstick and wipe theend clean. Reinsert the dipstick and wait at least 30seconds. Remove the dipstick and check the level.Maintain the oil level between theFull andAddmarks onthe dipstick, as shown in Figure 4-1. See Section 1,Service Views for the dipstick location.

Note: Do not operate the set if the oil level is below theAdd mark or above the Full mark on the dipstick.

1

TP-5586-32

1. Full mark2. Add mark

Figure 4-1 Oil Level Check

4.3.3 Oil Additions

Adding some oil between oil changes is normal. Theamount varies with generator set usage. Open the oil fillcap and pour in a small amount of oil using a funnel orother suitable pouring device. See Section 1, ServiceViews, for the oil check and oil fill locations.

4.3.4 Oil and Filter Change



WARNING




WARNING

Servicing the fuel system. A flash fire can cause severeinjuryor death. Donot smokeor permit flames or sparks nearthe carburetor, fuel line, fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors. Catch fuels in anapproved container when removing the fuel line or carburetor.

Change the oil yearly, after every 120 hours of use, orbefore generator set storage. Change the oil morefrequently if the generator set operates under dirty,dusty conditions. Change the oil while the engine is stillwarm.SeeSection 1,ServiceViews, for oil fill, oil check,and oil filter locations.

Dispose of all waste materials (engine oil, fuel, filter,etc.) in an environmentally safe manner.

Note: Reset the maintenance timer on the RDC2controller after changing the oil.


Oil Change Procedure

Whenever possible, drain the oil while it is still warm.

1. Drain the oil.

a. Press the OFF button on the RDC2 generatorset controller.

b. Disconnect the power for the battery charger.

c. Disconnect the generator set engine startingbattery, negative (--) lead first.

d. Remove the housing side panel.

e. Remove the plug from the oil drain fitting andinstall a drain hose.

f. Open the oil drain valve on the engine.

g. Allow time for the engine oil to drain completely.

h. Close the oil drain valve.

i. Replace the oil drain plug.

2. Replace the oil filter.

a. Remove the oil filter by rotating itcounterclockwise with an oil filter wrench.

b. Clean any surfaces that the oil filter contacts.

c. Apply a light coat of clean oil to the gasket of thenew oil filter.

d. Lightly thread the new oil filter by hand until youfeel resistance. Then, tighten the filter anadditional 3/4 turn with an oil filter wrench[Torque = 25 Nm (18.4 ft. lbs.)].

3. Fill with oil. Use 5W-30 for oil selection andFigure 4-2 for oil capacity.

Model Oil Capacity, L (qt.)

24RCL, 30RCL, and 38RCLB 4.2 (4.4)

Figure 4-2 Oil Capacity

4. Check for leaks.

a. Press the OFF button on the RDC2 generatorset controller.

b. Reconnect the generator set engine startingbattery, negative (--) lead last.

c. Reconnect the power for the battery charger.

d. Start the generator set and check for leaksaround the oil filter.

e. Stop thegenerator set and tighten theoil filter tostop any leaks.

f. Reinstall the housing side panel.

5. Stop the generator set. Check the oil level. Addoil, as necessary, to bring the level up to the Fullmark.

Note: Too high an oil level causes high oilconsumption and engine carbonizing. Toolow a level damages the engine.

6. Reset the maintenance timer on the RDC2.

a. In theOverviewmenu, step down to theGensetRun Time menu.

b. Press the Select button and then step down tothe Next Maintenance screen.

c. Press the Select button.

d. Press the Up arrow button so that Reset MaintTimer? Yes is displayed.


4.4 Air Cleaner



WARNING




WARNING

Servicing the air cleaner. A sudden backfire can causesevere injury or death. Do not operate the generator set withthe air cleaner removed.

At the interval specified in the service schedule (Section4.2), inspect and clean or replace the air cleanerelement. Clean the element more frequently in dirty,dusty conditions.Check the element for accumulated oilor dirt that could cause poor performance. Replace adamaged air cleaner element. Follow the proceduredescribed below.

Air Cleaner Service Procedure

A dry-type air cleaner silences and filters the intake air.The air intake silencer assembly connects to the intakemanifold via a rubber hose. Refer to Figure 4-3 duringthis procedure.

GM902801. Air Cleaner Cover

1

Figure 4-3 Air Cleaners

1. Release the retaining clips to open the cover andthen remove the air cleaner element.

2. Tap the element lightly against a flat surface todislodge loose surface dirt. Do not clean theelement in any liquid or use compressed air asthese will damage the filter element. Replace theelement and precleaner at the intervals shown inthe service schedule.

3. Examine the element and housing for damage.Replace the element and housing if damaged.

4. Wipe the cover and housing with a clean rag toremove dirt. Make sure the sealing surfaces fitcorrectly.

5. Replace the air cleaner cover.

4.5 Exhaust System



WARNING

Generator set operation. Carbon monoxide can causesevere nausea, fainting, or death. Carbon monoxide is anodorless, colorless, tasteless, nonirritating gas that can causedeath if inhaled for even a short time. Avoid breathing exhaustfumes when working on or near the generator set. Neveroperate the generator set inside a building. Never operate thegenerator set where exhaust gas could seep inside or bedrawn into a potentially occupied building throughwindows, airintake vents, or other openings.


Carbon monoxide symptoms. Carbon monoxide cancause severe nausea, fainting, or death. Carbonmonoxideis a poisonous gas present in exhaust gases. Carbonmonoxide is an odorless, colorless, tasteless, nonirritating gasthat can cause death if inhaled for even a short time. Carbonmonoxide poisoning symptoms include but are not limited tothe following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles


D Stomachache, vomiting, nauseaIf experiencing any of these symptoms and carbon monoxidepoisoning is possible, seek fresh air immediately and remainactive. Do not sit, lie down, or fall asleep. Alert others to thepossibility of carbon monoxide poisoning. Seek medicalattention if the condition of affected persons does not improvewithin minutes of breathing fresh air.

Carbon monoxide detectors. Carbon monoxide cancause severe nausea, fainting, or death. Install carbonmonoxide detectors on each level of the building. Locate thedetectors to adequately warn the building’s occupants of thepresence of carbonmonoxide. Keep the detectors operationalat all times. Periodically test and replace the carbonmonoxidedetectors according to the manufacturer’s instructions.

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION



WARNING

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.

At the interval specified in the service schedule, inspectthe exhaust system components (exhaust manifold,exhaust outlet, exhaust line, exhaust clamps, andmuffler) for cracks, leaks, and corrosion.

Exhaust System Inspection Points

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check that the exhaust outlet is unobstructed.

D Check the exhaust gas color. If the exhaust is blue orblack, contact your local authorized Kohler distributor/dealer.

D Visually inspect for exhaust leaks (blowby). Check forcarbon or soot residue on exhaust components.Carbon and soot residue indicates an exhaust leak.Seal leaks as needed.

D Check that all covers and doors are undamaged, inplace, and locked.

D Check for the installation and operation of carbonmonoxide (CO) detectors on each level of anybuilding near the generator set.

4.6 Cooling System

Hot coolant and steam.Can cause severe injury or death.

Before removing the pressure cap,stop the generator set and allow it tocool. Then loosen the pressure capto relieve pressure.

WARNING

Allow the engine to cool. Release pressure from thecooling system before removing the pressure cap. Torelease pressure, cover the pressure cap with a thickcloth and then slowly turn the cap counterclockwise tothe first stop. Remove the cap after pressure has beencompletely released and the engine has cooled. Checkthe coolant level at the tank if the generator set has acoolant recovery tank.


4.6.1 Checking and Filling Coolant

Maintain the coolant level in the coolant overflow bottlebetween the Hot and Cold markings. See Section 1,Service Views, for the coolant overflow bottle location.

Note: Periodically check the coolant level by removingthe radiator’s pressure cap. Do not rely solely onthe level in the coolant overflow bottle.

Ethylene glycol-based long-life coolant isrecommended. Use a coolant mixture of 50% long-lifecoolant and 50% clean, softened water to inhibitrust/corrosion and prevent freezing. Add fresh coolantuntil the level is just below the overflow tube opening.

A coolant solution of 50%ethylene glycol-based coolantprovides freezing protection to --37C (--34F) andoverheating protection to 149C (300F). A coolantsolution with less than 50% ethylene glycol may notprovide adequate freezing and overheating protection.A coolant solution with more than 50% ethylene glycolcan cause engine or component damage. Do not mixlong-life coolant and conventional coolants. Donotmixdifferent types and/or colors of long life coolants.

4.6.2 Cooling System Inspection

To prevent generator shutdown or damage because ofoverheating:

D Keep the cooling air inlets clean and unobstructed

D Inspect the radiator’s exterior for obstructions andremove dirt and foreign material with a soft brush orcloth to avoid damaging the radiator fins.

D Check the hoses and connections for leaks andreplace any cracked, frayed, or spongy hoses.

D Check the condition and tension of the drive belt.

D Check the rubber seal of the radiator’s pressure capand replace a cracked or deteriorated cap. Removedirt and other debris from the pressure cap and fillerneck. The pressure cap raises the boiling point of thecoolant, enabling higher operating temperatures. Ifthe cap leaks, replace it with the same rating type ofcap. Find the pressure cap rating in Figure 4-4.

Item Rating

Pressure cap 97 kPa (14 psi)

Figure 4-4 Pressure Cap Rating

4.6.3 Draining Cooling System

The radiator contains a coolant drain valve to drain thecooling system. When draining the coolant, remove theradiator’s pressure cap, which will allow the entiresystem todrain andwill prevent air pockets from formingand restricting coolant passage to the block.

1. Remove the pressure cap to allow the entiresystem to drain and prevent air pockets fromrestricting coolant flow through the engine block.

2. Open the coolant drain valve and allow the systemto drain.

3. If the inside of the radiator has mineral deposits orthe used coolant contains dirt or grease, go toSection 4.6.4, Flushing andCleaning. If the coolingsystem does not have mineral deposits, refill thecooling system as instructed in Section 4.6.5,Filling Cooling System.

4.6.4 Flushing and Cleaning

For optimum protection, drain, flush, and refill thecooling system at the interval listed in the serviceschedule.

Flushing and Cleaning Procedure

1. Flush the system with clean water.

2. Drain, clean, and flush the coolant overflow bottle.

3. Refill the cooling system as instructed inSection 4.6.5.

4.6.5 Filling Cooling System

Model

Coolant Capacity, L (gal.)

EngineEngine withBlock Heater

24RCL, 30RCL, 38RCLB 13.2 (3.5) 13.7 (3.6)

Figure 4-5 Coolant Capacity (approximate)

Note: Do not add coolant to a hot engine. Addingcoolant to a hot engine can cause the cylinderblock or cylinder head to crack. Wait until enginehas cooled.

Note: It is very important to purge air from the coolingsystem by following this entire procedure.

1. Close the radiator’s coolant drain valve and tightenthe hose clamps.

2. Fill the radiator with the recommended coolantmixture of 50% ethylene glycol and 50% clean,


softenedwater to inhibit rust/corrosion andpreventfreezing. The coolant capacity is shown inFigure 4-5.

3. Operate the engine with the radiator cap removeduntil the thermostat opens and the upper radiatorhose becomes hot.

4. Stop the engine and allow it to cool.

5. Add coolant to the radiator to just below theoverflow tube on the filler neck. See Section 1,Service Views, for the overflow tube location.

6. Replace the radiator’s pressure cap.

7. Maintain the coolant level in the coolant overflowbottle between the Hot and Cold markings. SeeSection 1, Service Views, for the coolant overflowbottle location.

4.7 Ignition System

Airborne particles.Can cause severe injury orblindness.

Wear protective goggles and clothingwhen using power tools, hand tools,or compressed air.

WARNING



WARNING


Service the spark plugs at the interval specified in theservice schedule using the following procedure.

1. Press the OFF button on the RDC2 controller.

2. Disconnect the power to the battery charger.

3. Disconnect the generator set engine startingbattery, negative (--) lead first.

4. Use a cloth to wipe dirt and oil away from the areaaround each of the four spark plug wires.

5. Remove spark plug wires by grasping the sparkplug boot and turning slightly while pulling. Do notpull thewire.Pullingon thewire rather than thebootmay damage the wire or terminal.

6. Wipe the interior of the spark plug tubes.

7. Loosen the spark plug with a ratchet and 13/16-in.spark plug socket with a rubber insert to preventspark plug damage.

8. Use compressed air to remove dirt from aroundeach spark plug to prevent dirt particles from fallinginto the combustion chamber.

9. Remove spark plugs, one at a time, and examine.Identify a normal spark plug in good operatingcondition by observing a light tan or gray deposit onfiring tip. See Figure 4-10 to evaluate engineconditionby color/condition of a problemsparkplug.

10. Check that the spark plug washer is in goodcondition.

11. Clean spark plugs by wiping them with a rag.

Note: Do not sandblast, wire brush, scrape, orotherwise service spark plugs in poorcondition.Obtain a newplug for best results.


12. Check the spark plug gap before installing anyspark plug. See Figure 4-6 and Figure 4-7. Attain acorrect gap when the feeler (or wire) passesbetween the spark plug electrodes. It should passeasily but with some resistance or drag; otherwiseadjust as necessary.

Model Spark Plug Gap

24RCL 0.9–1.0 mm (0.036–0.040 in.)

30RCL and 38RCLB 0.7--0.8 mm (0.028--0.030 in.)

Figure 4-6 Spark Plug Gap

1-514

1

2

1. Gap, see Figure 4-62. Spark plug electrodes

Figure 4-7 Spark Plug Gap Inspection

13. Use a gapping tool to gently bend the sideelectrode closer to or farther from the centerelectrode to set the correct gap. See Figure 4-8.Position the side electrode directly over the centerelectrode.

1-511

Figure 4-8 Spark Plug Gap Adjustment

Note: Ensure that the spark plug tubes are seatedbefore installing the sparkplugs. If the tubeswereremoved, reinstall them before installing thespark plugs.

14. Reinstall the spark plug.Donot bump theelectrodeagainst the cylinder head. Rotate the spark plugclockwise until you feel resistance.

15. Use a torque wrench to tighten each spark plug tothe torque shown in Figure 4-9.

Model Spark Plug Torque

24RCL 18 Nm (13.3 ft. lbs.)

30RCL and 38RCLB 25 Nm (18.4 ft. lbs.)

Figure 4-9 Spark Plug Torque

16. Use a ratchet wrench to tighten an additional 1/4turn. Do not overtighten, as doing so may strip thethreads or alter the electrode gap setting.

17. Check the spark plug wire connector in the boot foraccumulated dirt, grease, and other debris, andclean as necessary.

18. Firmly push the spark plug boot onto the sparkplug.

19. Reconnect the generator set engine startingbattery, negative (--) lead last.

20. Reconnect the power for the battery charger.


Problem/Condition Means of Identification Possible Cause/Solution

Gap-bridged sparkplug

Built-up deposits and gap betweenelectrodes closing.

Oil or carbon fouling. Clean and regap the sparkplug.

Oil-fouled spark plug Wet, black deposits on the insulator shell,bore, and electrodes.

Excessive oil entering combustion chamber throughworn rings and pistons, excessive clearancebetween valve guides and stems, or worn or loosebearings. Replace the spark plug.

Carbon-fouled sparkplug

Black, dry, fluffy carbon deposits on insulatortips, exposed shell surfaces and electrodes.

Incorrect spark plug, weak ignition, clogged airintake, overrich fuel mixture, or excessive no-loadoperation. Clean and regap the spark plug.

Lead-fouled spark plug Dark gray, black, yellow, or tan deposits; or aglazed coating on the insulator tip.

Caused by highly leaded fuel. Replace the sparkplug.

Pre-ignition damagedspark plug

Melted electrodes and possibly blisteredinsulator. Metallic deposits on insulatorsuggest internal engine damage.

Wrong type of fuel, incorrect timing or advance, toohot a plug, burned valves, or engine overheating.Replace the spark plug.

Overheated spark plug White or light gray insulator with small blackor gray/brown spots with bluish (burned)appearance on electrodes.

Engine overheating, wrong type of fuel, loose sparkplugs, too hot a plug, low fuel pressure or incorrectignition timing. Replace the spark plug.

Worn spark plug Severely eroded or worn electrodes. Caused by normal wear and failure to replace sparkplug at prescribed interval. Replace the spark plug.

Figure 4-10 Engine Evaluation Using Spark Plug Condition


4.8 BatteryConsult the battery manufacturer’s instructionsregarding battery care and maintenance.



WARNING

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid can causeblindness and burn skin. Always wear splashproof safetygoggles, rubber gloves, and boots when servicing the battery.Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediatelyflush the affected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case of eyecontact. Never add acid to a battery after placing the battery inservice, as this may result in hazardous spattering of batteryacid.

Battery acid cleanup. Battery acid can cause severeinjury or death. Battery acid is electrically conductive andcorrosive. Add 500 g (1 lb.) of bicarbonate of soda (bakingsoda) to a container with 4 L (1 gal.) of water and mix theneutralizing solution. Pour the neutralizing solution on thespilled battery acid and continue to add the neutralizingsolution to the spilled battery acid until all evidence of achemical reaction (foaming) has ceased. Flush the resultingliquid with water and dry the area.

Battery gases. Explosion can cause severe injury ordeath. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur near a battery at any time,particularly when it is charging. Do not dispose of a battery in afire. To prevent burns and sparks that could cause anexplosion, avoid touching the battery terminals with tools orother metal objects. Remove all jewelry before servicing theequipment. Discharge static electricity from your body beforetouching batteries by first touching a grounded metal surfaceaway from the battery. To avoid sparks, do not disturb thebattery charger connections while the battery is charging.Always turn the battery charger off before disconnecting thebattery connections. Ventilate the compartments containingbatteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injuryor death. Short circuits can cause bodily injury and/orequipment damage. Disconnect the battery before generatorset installation or maintenance. Remove all jewelry beforeservicing the equipment. Use tools with insulated handles.Remove the negative (--) lead first when disconnecting thebattery. Reconnect the negative (--) lead last whenreconnecting the battery. Never connect the negative (--)battery cable to the positive (+) connection terminal of thestarter solenoid. Do not test the battery condition by shortingthe terminals together.

Refer to this section for general battery information andmaintenance. Also consult the battery manufacturer’sinstructions for battery maintenance.

All generator set models use a negative ground with a12-volt engine electrical system. Consult the generatorset nameplate for the engine electrical system voltage.Consult the generator spec sheet for battery capacityrecommendations for replacement purposes. Wiringdiagrams provide battery connection information. SeeFigure 4-11 for typical battery connections.

EZ-273000-J

1 2

1. To positive (+) terminal on starter solenoid.2. To ground (--) terminal on or near starter motor.

Figure 4-11 12--Volt Engine Electrical System SingleStarter Motor, Typical Battery Connection

Clean the battery and cables and tighten batteryterminalsusing theserviceschedule recommendations.To prevent corrosion, maintain tight, dry electricalconnections at the battery terminals. To removecorrosion from battery terminals, disconnect the cablesfrom the battery and scrub the terminals with a wirebrush. Clean the battery and cables with a solution ofbaking soda and water. After cleaning, flush the batteryand cables with clean water and wipe them with a dry,lint-free cloth.

After reconnecting the battery cables, coat the batteryterminals with petroleum jelly, silicone grease, or othernonconductive grease.


4.8.1 Checking Electrolyte LevelCheck the electrolyte level of batteries with filler capsmonthly. Remove filler caps and verify that electrolytelevel reaches bottom of filler holes. Refill as necessarywith distilled water. DO NOT add fresh electrolyte.Tighten all filler caps. If water is added during freezingtemperatures, run the generator set for 20--30 minutesto mix the electrolyte and water to prevent batterydamage from freezing.

4.8.2 Checking Specific GravityUseabattery hydrometer to check the specific gravity ofthe electrolyte in each battery cell. While holding thehydrometer vertically, read thenumber on the glassbulbat the top of the electrolyte level or the number adjacentto the pointer. If the hydrometer used does not have acorrection table, use the correction factors inFigure 4-14. Determine specific gravity and electrolytetemperature of battery cells. Locate temperature inFigure 4-14 and adjust the specific gravity by theamount shown.

Thebattery is fully charged if the specific gravity is 1.260at an electrolyte temperature of 80F (26.7C). Thedifference between specific gravities of each cell shouldnot exceed 0.01. Charge the battery if the specificgravity is below 1.215 at an electrolyte temperature of80F (26.7C). See Figure 4-12.

Specific Gravity,Corrected to 80F (26.7C)

BatteryCondition

Below 1.215 Needs charging

1.260 Fully charged

Figure 4-12 Specific Gravity Interpretation

Some battery testers have four or five beads in the testtube. Draw electrolyte into the tube as performed withthe battery hydrometer described previously. Use themanufacturer’s instructions. Figure 4-13 interpretstypical test results.

Number of Floating BeadsBattery

Condition

5 Overcharged

4 Fully charged

3 Good charge

1 or 2 Low charge

0 Dead battery

Figure 4-13 Bead-Type Test Interpretation

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

-- 12.2

-- 6.7

-- 1.1

4.4

10

21.1

26.7

32.2

37.8

43.3

48.9

54.4

60.0

65.6

71.1

15.6

+ .032

+ .030

+ .028

+ .026

+ .024

+ .022

+ .020

+ .018

+ .016

+ .014

+ .012

+ .010

+ .008

+ .006

+ .004

+ .002

0

-- .002

-- .004

--. 006

-- .008

-- .010

-- .012

-- .014

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

C F

EXAMPLE NO. 1—

Temperature below 80F (26.7C)

Hydrometer Reading 1.250

Acid Temperature 20F (--6.7C)

Subtract .024 Specific GravityCorrected Specific Gravity is 1.226

1.250 -- .024 = 1.226

EXAMPLE NO. 2—

Temperature above 80F (26.7C)

Hydrometer Reading 1.235

Acid Temperature 100F (37.8C)

Add .008 Specific GravityCorrected Specific Gravity is1.243

1.235 + .008 = 1.243

The temperature correction amounts to about .004 (4 points) ofspecific gravity for each 10F (5.5C) change in temperature.

Correction

1-787

Temperature

Figure 4-14 Specific Gravity Temperature Correction


4.9 Storage Procedure



DANGER

Connecting the battery and the battery charger.Hazardous voltage will cause severe injury or death.Reconnect the battery correctly, positive to positive andnegative to negative, to avoid electrical shock and damage tothe battery charger and battery(ies). Have a qualifiedelectrician install the battery(ies).

Follow the procedure below when storing yourgenerator set for a long period (3 months or more).

1. Start and run the generator set until it reachesoperating temperature or about 15 minutes.

2. Stop the generator set.

3. Change the oil and oil filter; see Section 4.3.4, Oiland Filter Change.

4. Check the engine coolant protection; seeSection 4.6.

Note: Use antifreeze capable of withstanding thelowest possible temperatures.

5. Keep spark plugs in their holes or seal spark plugholes with suitable threaded metal plugs.

6. Clean theexterior of thegenerator setandspreadalight film of oil or silicon spray over any exposedsurfaces that may be subject to rust or corrosion.

7. Seal the air inlet, exhaust pipe, and fuel tank capwith tape.

8. Disconnect and remove the battery. Place thebattery in a warm, dry location for the storageperiod. Recharge the battery once a month tomaintain a full charge.

9. Select a well-ventilated (not humid or dusty)location to store the generator.

10. Cover the entire unit with a dust cover.

Note: Run the generator set once a monthwhenever possible.

TP-6905 7/18 65Section 5 Troubleshooting

Section 5 Troubleshooting

5.1 Introduction

Use the troubleshooting charts in this section todiagnose and correct common problems. First check forsimple causes such as a dead engine starting battery,loose connections, or an open circuit breaker. Thecharts include a list of common problems, possiblecauses of the problem, and recommended correctiveactions.

If the procedures in this manual do not explain how tocorrect the problem, contact an authorized Kohlerdistributor/dealer. Maintain a record of repairs andadjustments performed on the equipment. Use therecord to help describe the problem and repairs oradjustments made to equipment.

5.2 USB Port

AUSBport is located on the front of the controller. Use aUSB cable with a mini-B connector to connect thecontroller to your personal computer (laptop).

Some controller settings can be adjusted using a laptopcomputer with Kohlerr SiteTecht software. SiteTechsoftware is available to Kohler authorized distributorsand dealers. See TP-6701, SiteTecht SoftwareOperation Manual, for more information.

5.3 Fault Messages

The RDC2 controller displays fault messages to aid introubleshooting. Fault messages, descriptions, andrecommended checks are listed in Figure 2-5.

Identify and correct the cause of the fault condition.Then reset the controller after a fault shutdown. SeeSection 2.6.4.

5.4 Circuit Protection

If the generator set circuit breaker trips or the fuses blowrepeatedly, contact an authorized Kohler distributor/dealer for service.

5.4.1 Load Circuit Breaker

The load circuit breaker interrupts the generator outputin the event of a fault in thewiring between the generatorand the load. If the circuit breaker trips, reduce the loadand switch the breaker back to theONposition. Refer tothe service views in Section 1 for the location of thecircuit breaker.

5.4.2 Fuses

Always identify and correct the cause of a blown fusebefore restarting the generator set. Refer to Figure 5-1,Troubleshooting Chart, for conditions that may indicatea blown fuse. Obtain replacement parts and servicefrom an authorized Kohler distributor/dealer.

Fan Fuses. Three 30 amp fan fuses are located in thefan fuseand relaybox.SeeSection1,ServiceViews, forlocation.

5.4.3 Controller Internal CircuitProtection

The controller is equipped with internal circuitprotection. Press OFF to reset.

TP-6905 7/1866 Section 5 Troubleshooting

5.5 Generator Set TroubleshootingFigure 5-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connectionsbefore replacing parts.

Problem Possible Cause Corrective Action

The generatorset does notcrank.

Battery weak or dead. Recharge or replace the battery.

Battery connections reversed or poor. Check the connections.

Blown fuse(s). Replace the fuse. Contact an authorized Kohlerdistributor/dealer for service if fuse blows repeatedly.

Generator set is OFF. Press the RUN button to start the engine or press AUTOto allow remote starting.

The generatorset cranks butdoes not start,starts hard,lacks power, oroperateserratically.

Air cleaner clogged. Clean and/or replace the air cleaner.

Battery weak or dead. Recharge or replace the battery.

Battery connection poor. Clean and tighten the battery connections.

Spark plug wire connection loose. Check the spark plug wires.

Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil ifnecessary.

Fuel pressure insufficient. Check the fuel supply and valves.

Engine malfunction. Contact an authorized Kohler distributor/dealer.

No AC output. AC circuit breaker in the OFF position. Place the circuit breaker in the ON position.

AC circuit breaker tripping because of overload. Reduce the load on the generator set.

AC circuit breaker tripping because of shortcircuit.

Contact an authorized Kohler distributor/dealer forservice.

Low output orexcessive dropin voltage.

Generator set overloaded. Reduce the load.

Generator setstops suddenly.

Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil ifnecessary.

Out of fuel. Check fuel supply.

Overcrank shutdown. Reset the controller. If the overcrank fault occurs again,contact an authorized Kohler distributor/dealer.

Blown fuse(s). Replace the fuse. If the fuse blows again, contact anauthorized Kohler distributor/dealer.

Overspeed shutdown. Reset the controller. If the overspeed fault occurs again,contact an authorized Kohler distributor/dealer.

Generator set is OFF. Press the RUN button to start the engine or press AUTOto allow remote starting.

Remote stop command received from a remoteswitch, ATS, or OnCuer Plus.

Check the remote switch position.

Engine malfunction. Contact an authorized Kohler distributor/dealer.

Fans run afterengine shutsdown.

The fans continue to run for 2 minutes after theengine shuts down to evacuate the enginecompartment.

None.

Figure 5-1 General Troubleshooting Chart

TP-6905 7/18 67Section 5 Troubleshooting

5.6 Controller TroubleshootingFigure 5-2 contains basic troubleshooting information for the RDC2 controller.

Problem Possible Cause Corrective Action

Controller LCDdisplay is off.

Low or no battery voltage. Check connections.Check generator set battery. See Figure 5-1.

Controller displaybacklight is off.

Backlight turns off after about 1 minute with noactivity.

Backlight will turn on when a button is pressed orthe generator set starts.

Loss ofcommunication toaccessory modules

Bad connections. Check wiring and connections. Verify that cable sizeand length of run comply with the instructions in theInstallation manual.

Low or no battery voltage. Check battery connections.Check generator set battery. See Figure 5-1.

Load managementrelays do notoperate.

Bad connections. Check wiring and connections. Verify that cable sizeand length of run comply with the instructions in theInstallation manual.

Low or no battery voltage. Check battery connections.Check generator set battery. See Figure 5-1.

Date is flashing. Controller power was disconnected and thenreconnected.

Check battery connections. See Figure 5-1.

Check utility power connection for the built-in batterycharger.

Reset the time, date, and exercise schedule. SeeSection 2.5.7, Setting the Exerciser at Power-Up.

Figure 5-2 RDC2 Troubleshooting Chart

TP-6905 7/1868 Section 5 Troubleshooting

Notes

TP-6905 7/18 Appendix 69

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)BMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hourcfm cubic feet per minute

CG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)exh. exhaust

ext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6905 7/1870 Appendix

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gasNBS National Bureau of Standards

NC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRBUS RS-485 proprietary

communicationsRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

E 2014, 2015, 2016, 2018 by Kohler Co. All rights reserved.

TP-6905 7/18cKOHLER CO., Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

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