Kohler 38RCL, 60RCL, 48RCL User Manual
Operation
Residential/Light Commercial Generator Sets
Model:
38RCL
48RCL
60RCL
Controller:
RDC2
TP-6810 11/13b
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts.
Record the product identificationnumbersin the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
TP-6810 11/132
Table of Contents
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 16............................................
2.4 Generator Set Operation 16................................................
2.4.1 Local Starting and Stopping 16.....................................
2.4.2 Automatic Starting and Stopping 16.................................
2.4.3 Remote Starting and Stopping 16...................................
2.4.4 Engine Start Crank Cycle 16.......................................
2.4.5 Engine Cooldown 16..............................................
2.4.6 Automatic Operation with Model RXT Transfer Switch 16..............
2.4.7 Automatic Operation with Model RDT or RSB Transfer Switches 17.....
2.5 Exercise 17..............................................................
2.5.1 Unloaded Cycle Exercise with Complete System Diagnostics 17........
2.5.2 Unloaded Full-Speed Exercise 18..................................
2.5.3 Loaded Full-Speed Exercise (with RXT only) 18......................
2.5.4 Shutdown During Exercise 18......................................
2.5.5 Power Failure During Exercise 18..................................
2.5.6 Exerciser Reset 18...............................................
2.5.7 Setting the Exerciser at Power-up 18................................
2.5.8 Changing the Exercise Setting 19...................................
2.6 Faults 22................................................................
2.6.1 Warnings 22.....................................................
2.6.2 Shutdowns 22....................................................
2.6.3 ATS Communication Errors 22.....................................
2.6.4 Resetting the Controller after a Fault Shutdown 22....................
2.6.5 Event Log 25....................................................
2.7 Model RXT Transfer Switch Operation 25....................................
2.7.1 Source Availability 25.............................................
2.7.2 ATS Control Sequence of Operation 26..............................
2.7.3 Time Delays 26..................................................
2.7.4 ATS Load Control Relay Time Delay 26.............................
Section 3 RDC2 Controller Operation 27.......................................................
3.1 RDC2 Generator Set / Transfer Switch Controller 27...........................
3.2 Controls and Indicators 27.................................................
3.2.1 Controller Keypad 28.............................................
3.2.2 LED Indicators 28................................................
3.2.3 LCD Display 29..................................................
3.3 Controller Power 30.......................................................
3.4 Battery Charging 30......................................................
3.5 Changing Settings 30.....................................................
3.6 Controller Menus 32
3.7 Main Menu 32............................................................
3.8 Overview Menu 33........................................................
3.9 Engine Metering Menu 33.................................................
3.10 Generator Metering Menu 34...............................................
3.11 Generator Set Information Menu 35.........................................
......................................................
TP-6810 11/13 Table of Contents 3
Table of Contents, continued
3.12 Genset Run Time Menu 35................................................
3.13 Genset System Menu 36..................................................
3.14 ATS Status Menu 37......................................................
3.15 ATS Configuration Menu 38................................................
3.16 Date and Time Menu 39...................................................
3.17 Networking Information Menus 40..........................................
3.17.1 Networking Status Submenu 41....................................
3.17.2 Networking Configuration Submenu (OnCue Password) 42............
3.17.3 RBUS Information Submenu 43....................................
3.17.4 Remote Devices Submenu 44......................................
3.18 Programmable Interface Module (PIM) Menus 45.............................
3.19 Load Control Menus 46...................................................
Section 4 Scheduled Maintenance 47..........................................................
4.1 General Maintenance 47..................................................
4.2 Service Schedule 48......................................................
4.3 Lubrication System 49....................................................
4.3.1 Oil Specifications 49..............................................
4.3.2 Oil Check 49.....................................................
4.3.3 Oil Additions 49..................................................
4.3.4 Oil and Filter Change 49...........................................
4.4 Air Cleaner 50...........................................................
4.5 Exhaust System 51.......................................................
4.6 Cooling System 51.......................................................
4.6.1 Checking and Filling Coolant 51....................................
4.6.2 Cooling System Inspection 52......................................
4.6.3 Draining Cooling System 52.......................................
4.6.4 Flushing and Cleaning 52..........................................
4.6.5 Filling Cooling System 52..........................................
4.7 Ignition System 53........................................................
4.8 Battery 54...............................................................
4.9 Storage Procedure 55.....................................................
Section 5 Troubleshooting 57.................................................................
5.1 Introduction 57...........................................................
5.2 USB Port 57.............................................................
5.3 Fault Messages 57.......................................................
5.4 Circuit Protection 57......................................................
5.4.1 Load Circuit Breaker 57...........................................
5.4.2 Fuses 57........................................................
5.4.3 Controller Internal Circuit Protection 57..............................
5.5 Generator Set Troubleshooting 58..........................................
5.6 Controller Troubleshooting 59..............................................
Appendix A Abbreviations 61................................................................
TP-6810 11/13Table of Contents4
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,or
substantial property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or
substantial property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Press the generator set off/reset
button to shut down the generator set.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
Battery electrolyte is a diluted
sulfuric acid. Battery acid can
cause severe injury or death. Battery
acid can cause blindness and burn
skin. Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparks to occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
TP-6810 11/13 5Safety Precautions and Instructions
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Servicing the fuel system. A flash
fire can cause severe injury or
death. Do not smoke or permit flames
or sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
Generator set operation. Carbon
monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is an odorless, colorless,
tasteless, nonirritating gas that can
cause death if inhaled for even a short
time. Avoid breathing exhaust fumes
when working on or near the generator
set. Never operate the generator set
inside a building. Never operate the
generator set where exhaust gas could
seep inside or be drawn into a
potentially occupied building through
windows, air intake vents, or other
openings.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Carbon monoxide detectors.
Carbon monoxide can cause severe
nausea, fainting, or death. Install
carbon monoxide detectors on each
level of any building adjacent to the
generator set. Locate the detectors to
adequately warn the building’s
occupants of the presence of carbon
monoxide. Keep the detectors
operational at all times. Periodically
test and replace the carbon monoxide
detectors according to the
manufacturer’s instructions.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
TP-6810 11/136 Safety Precautions and Instructions
Explosive fuel vapors can cause
severe injury or death. Take
additional precautions when using the
following fuels:
Propane (LP)—Adequate ventilation
is mandatory. Because propane is
heavier than air, install propane gas
detectors low in a room. Inspect the
detectors per the manufacturer’s
instructions.
Natural Gas—Adequate ventilation is
mandatory. Because natural gas rises,
install natural gas detectors high in a
room. Inspect the detectors per the
manufacturer’s instructions.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. A successful
test depends on the ability of the
solution to bubble.
Hazardous Voltage/
Moving Parts
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Moving parts.
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect
the generator set from the load by
turning off the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
Welding on the generator set. Can
cause severe electrical equipment
damage. Before welding on the
generator set perform the following
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine batteryÂcharging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
TP-6810 11/13 7Safety Precautions and Instructions
Engine block heater. Hazardous
voltage can cause severe injury or
death. The engine block heater can
cause electrical shock. Remove the
engine block heater plug from the
electrical outlet before working on the
block heater electrical connections.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
WARNING
Airborne particles.
Can cause severe injury or blindÂness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.
Heavy Equipment
WARNING
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
Hot Parts
WARNING
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Servicing the alternator. Hot parts
can cause severe injury or death.
Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Notice
NOTICE
Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
NOTICE
Electrostatic discharge damage.
Electrostatic discharge (ESD)
damages electronic circuit boards.
Prevent electrostatic discharge
damage by wearing an approved
grounding wrist strap when handling
electronic circuit boards or integrated
circuits. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.
TP-6810 11/138 Safety Precautions and Instructions
Introduction
This manual provides operation instructions for Model
38RCL, 48RCL, and 60RCL residential/light
commercial generator sets equipped with the RDC2
generator set/transfer switch controller.
This generator set is approved for use in stationary
applications in locations served by a reliable utility
power source. Have the generator set installed by an
authorized Kohler distributor/dealer or service
technician. Refer to the Installation Manual for
installation instructions.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment maintenance requirements are very
important for safe and efficient operation. Inspect the
parts often and perform required maintenance at the
prescribed intervals. Obtain service from an authorized
Kohler distributor/ dealer or service technician to keep
equipment in top condition.
Nameplate
Figure 2 shows a typical generator set nameplate.
Copy the model, serial, and specification numbers from
the nameplate into the spaces provided in the product
information section on the inside front cover of this
manual. See the service view in Section 1 for the
nameplate location.
GM12070
Figure 2 Nameplate, Typical
Figure 1 Model 48RCL Generator Set
TP-6810 11/13 9Introduction
List of Related Literature
Figure 3 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.
Literature Type Part Number
Specification Sheet, 38RCL G4-214
Specification Sheet, 48RCL G4-211
Specification Sheet, 60RCL G4--233
Installation Manual, Generator Set TP-6809
Operation Manual, Engine TP-6101
Service Manual, Generator Set TP-6811
Service Manual, 38RCL Engine
Mechanical
Service Manual, 48/60RCL Engine
Mechanical
Service Manual, Engine ECM
Diagnostics
Service Manual, Alternator, 38RCL TP-6353
Service Manual, Alternator, 48/60RCL TP-6783
Parts Catalog, 38RCL Engine TP-6730
Parts Catalog, 48/60RCL Engine TP-6731
Parts Catalog, Generator Set TP-6812
Installation Instructions, Load Control
Module (LCM)
Installation Instructions, Programmable
Interface Module (PIM)
Operation Manual, OnCuet Software TP-6796
Operation/Installation Manual, RXT ATS TP-6807
Operation/Installation Manual, RDT ATS TP-6345
Installation Manual, RSB Transfer Switch TP-6486
Operation Manual, RSB Transfer Switch TP-6487
Figure 3 Related Literature
TP-6103
TP-6104
TP-6724
TT-1574
TT-1584
TP-6810 11/1310 Introduction
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest authorized Kohler distributor or dealer.
D Consult the Yellow Pages under the heading
Generators—Electric.
D Visit the Kohler Power Systems website at
KohlerPower.com.
D Look at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product.
D Call toll free in the US and Canada 1-800-544-2444.
D Outside the US and Canada, call the nearest regional
office.
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler Power Systems Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: (31) 168 331630
Fax: (31) 168 331631
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax: (863) 701-7131
TP-6810 11/13 11Service Assistance
Notes
TP-6810 11/1312 Service Assistance
Section 1 Service Views
16
15
14
17
13
18
12
1
11
SERVICE SIDE
19
10
42 3
5
6
8
9
20
21
7
28
27
29
30
27
31
GM85088
26
ADV-8494
24
25
7
23
22
Cooling System Detail
NON-SERVICE SIDE
1. Nameplate location
2. Engine ECM and EPR (electronic fuel pressure regulator)
3. Oil check (dipstick)
4. See cooling system detail
5. Exhaust outlet
6. Enclosure locking tool (shipping location only)
7. Spark plugs
8. Block heater connection valve
9. Block heater (optional)
10. Fuel inlet (1 in. NPT)
11. Fuel solenoid valves (qty. 2 shown)
12. Customer load lead access
13. Customer connection access panel
14. Line circuit breaker
15. Generator set master control buttons (on RDC2 controller)
16. RDC2 controller
17. Cooling air inlet (remove this panel to access coolant drain)
18. Access to coolant fill
19. Oil fill location (on valve cover)
20. Air cleaner
21. Fan fuses
22. Battery
23. Oil drain valve
24. Lube oil filter
25. Block heater connection valve
26. Coolant drain
27. Fans (qty. 3)
28. Radiator
29. Pressure cap (engine coolant fill)
30. Coolant overflow tube
31. Coolant overflow bottle
Figure 1-1 38/48RCL Service Views for Maintenance (38RCL shown)
TP-6810 11/13 13Section 1 Service Views
17
16
15
1
2
543
6
7
14
13
12
11
10
9
SERVICE SIDE
19
20
18
26
8
25
24
23
NON-SERVICE SIDE
1. Air cleaner
2. Nameplate location
3. Oil check (dipstick)
4. Engine ECM and EPR (electronic fuel pressure regulator)
5. See cooling system detail
6. Exhaust outlet
7. Enclosure locking tool (shipping location only)
8. Spark plugs
9. Block heater connection valve
10. Block heater (optional)
11. Fuel inlet (1 in. NPT)
12. Fuel solenoid valves (two required for UL 2200)
13. Customer load lead access
14. Customer connection access panel
15. Load circuit breaker
16. Generator set master control buttons (on RDC2 controller)
22
8
21
28
29
30
27
27
31
ADV-8545
GM85088
Cooling System Detail
17. RDC2 controller
18. Cooling air inlet (remove this panel to access coolant drain)
19. Access to coolant fill
20. Oil fill (on valve cover)
21. Fan fuses
22. Battery
23. Lube oil filter
24. Oil drain valve
25. Block heater connection valve
26. Coolant drain
27. Fans (qty. 3)
28. Radiator
29. Pressure cap (engine coolant fill)
30. Coolant overflow tube
31. Coolant overflow bottle
Figure 1-2 60RCL Service Views
TP-6810 11/1314 Section 1 Service Views
Section 2 Generator Set Operation
2.1 Operating Area
WARNING
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
Carbon monoxide symptoms. Carbon monoxide can
cause severe nausea, fainting, or death. Carbon monoxide
is a poisonous gas present in exhaust gases. Carbon
monoxide is an odorless, colorless, tasteless, nonirritating gas
that can cause death if inhaled for even a short time. Carbon
monoxide poisoning symptoms include but are not limited to
the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide
poisoning is possible, seek fresh air immediately and remain
active. Do not sit, lie down, or fall asleep. Alert others to the
possibility of carbon monoxide poisoning. Seek medical
attention if the condition of affected persons does not improve
within minutes of breathing fresh air.
Keep the generator set area clear. Maintain at least
0.9 m (3 ft.) of clearance on all sides of the generator
set. Verify that there are no windows, air vents, or other
openings in the building within 1.5 m (5 ft.) of the
generator set exhaust outlet in any direction.
Notice
Do not locate patios, decks, play areas, or animal
shelters near the generator set. Keep items such as
lawn furniture, toys, sports equipment, and all
combustible materials away from the generator set
exhaust outlet. Remind family members, children,
and visitors to use caution near the generator set.
2.2 Prestart Checklist
To ensure continued satisfactory operation perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering the
engine.
Air Inlets. Check for obstructions that could block the
flow of cooling air. Keep the air intake area clean. Do not
leave rags, tools, or debris on or near the generator set.
Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.
Coolant Level. Check the coolant level according to the
cooling system maintenance information.
Note: Block heater damage. The block heater will fail
if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
the system before energizing the block heater.
Drive Belt(s). Check the belt condition of the water
pump and battery charging alternator belt(s).
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components for cracks and
corrosion (exhaust manifold, exhaust pipe, exhaust
clamps, and silencer).
D Check for corroded or broken metal parts and replace
them as needed.
D Check that there are no combustible materials near
the exhaust outlet.
D Check that the exhaust outlet is unobstructed.
Generator sets connected to automatic transfer
switches start automatically during exercise periods
and power outages. Some generator set
components become hot when the generator set is
running and remain hot for a time after the generator
set shuts down.
TP-6810 11/13 15Section 2 Generator Set Operation
Carbon Monoxide Detectors. Check for the
installation and operation of carbon monoxide (CO)
detectors on each level of any building near the
generator set.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
2.3 Exercising the Generator Set
2.4.5 Engine Cooldown
Operate the generator set without load every week or
every other week for 20 minutes. Perform all of the
prestart checks before starting the exercise procedure.
See Section 2.5 for instructions to set the automatic
exerciser.
2.4 Generator Set Operation
2.4.1 Local Starting and Stopping
Start: Press the RUN button to immediately start the
generator set.
Stop: Press the OFF button. The engine stops.
Run the generator set with no load for at least 2 minutes
to ensure adequate engine cooldown.
2.4.2 Automatic Starting and Stopping
An automatic transfer switch monitors the utility power
and signals the generator set to start when utility power
is lost. The ATS then transfers the load to the generator
set.
When utility power is restored, the transfer switch
transfers the load back to utility, runs the generator set
with no load to cool down the engine, and then stops the
generator set engine. The electric fans continue to run
for two minutes after the engine shuts down to evacuate
the engine compartment.
The engine cooldown time delay allows the engine to
run after the loads have been removed.
The engine cooldown time delay is set to 5 minutes. The
engine stops before the cooldown time delay expires if
the temperature drops below the cooled-down
temperature level, or if the temperature rises above the
high limit during the cooldown cycle.
The electric fans continue to run for two minutes after the
engine shuts down to evacuate the engine
compartment.
If a transfer switch other than the Model RXT is used, an
additional engine cooldown time delay may be
programmed on the transfer switch. To allow the smart
engine cooldown on the RDC2 controller to operate
most efficiently, set the cooldown time on the transfer
switch controller to zero or the minimum time allowed.
Refer to the instructions provided with the transfer
switch for more information.
2.4.6 Automatic Operation with Model
RXT Transfer Switch
The Model RXT transfer switch connects to the RDC2
controller through the ATS interface board on the
transfer switch. Also see Section 2.7, Model RXT
Transfer Switch Operation.
The RDC2 controller must be in AUTO mode for
automatic transfer switch operation.
2.4.3 Remote Starting and Stopping
A remote switch connected to terminals 3 and 4 can be
used to start and stop the generator set. Close the
switch to start and run the generator set. Open the
switch to stop the generator set.
Run the generator set with no load for at least 2 minutes
to ensure adequate engine cooldown.
2.4.4 Engine Start Crank Cycle
The controller attempts to start the generator set three
times (three crank cycles, 15 seconds crank and
15 seconds off). If the generator set does not start in
three attempts, the system shuts down on an overcrank
fault. See Section 2.6.
Pressing the OFF button during the crank cycle stops
the cranking. No other buttons are acknowledged
during the crank cycle.
Automatic Start
The RDC2 controller receives utility source voltage
sensing data from the Model RXT transfer switch.
1. If the utility source voltage falls below an
acceptable level, the controller starts the engine
start time delay.
2. If the utility source is not restored before the time
delay expires, the generator set starts.
3. After the Normal-to-Emergency time delay, the
ATS is signaled to transfer the load to the
emergency source.
TP-6810 11/1316 Section 2 Generator Set Operation
Automatic Stop
1. When the utility source is restored, the
Emergency-to-Normal time delay starts.
If a Model RDT or RSB transfer switch is used, refer to
the instructions provided with the transfer switch to set a
loaded exercise at the ATS, if desired.
2. When the Emergency-to-Normal time delay
expires, the load is transferred to the utility.
3. The generator set stops.
2.4.7 Automatic Operation with Model
RDT or RSB Transfer Switches
If a Kohler Model RDT or RSB transfer switch is used,
the engine start contacts from the ATS must be
connected to engine start leads 3 and 4 on the generator
set.
The RDC2 generator set controller must be in AUTO
mode to respond to remote start/stop signals from an
ATS or remote switch. Press the AUTO button on the
RDC2 controller to put the generator set into automatic
mode.
Automatic Start
The engine start contacts on the ATS close to signal the
generator set to start, and remain closed while the
generator set is running.
Automatic Stop
The engine start contacts on the ATS open to signal the
generator set to stop.
2.5.1 Unload ed Cycle Exercise with
Complete System Diagnostics
An unloaded cycle exercise runs the generator set
without signalling the transfer switch to transfer the
electrical load from the utility source to the generator set.
The Unloaded Cycle exercise with diagnostics is the
recommended exercise mode and is the factory-default
exercise setting.
The Unloaded Cycle exercise runs the engine for
20 minutes in the cycle shown in Figure 2-1 and
described below.
D Runs at reduced speed for 10 minutes to warm up
and exercise the engine.
D Ramps up and runs at full speed for 3 minutes.
Engine diagnostics are performed during this
full-speed portion of the cycle, which provides the
best test of engine and alternator power backup
capability. Diagnostic tests at full speed can identify
potential problems with the power output and alert the
operator before an emergency event.
D Ramps down and runs at reduced speed for
5 minutes to cool down the engine before shutting
down automatically.
2.5 Exercise
The RDC2 controller can be set to automatically run the
generator set at the same time and day every week or
every other week. Exercising the generator set every
week or every two weeks is required in order to keep the
engine and alternator in good operating condition.
Three exercise modes are available: unloaded cycle,
unloaded full speed, and loaded full speed. See
Sections 2.5.1 through 2.5.3 for information about the
exercise modes. A loaded exercise can be set at the
RDC2 controller only if a Model RXT transfer switch is
connected.
Note: With the RDT and RSB transfer switches, it is
possible to have two exercise settings (one
unloaded exercise set at the generator set
controller, and another exercise set at the ATS
controller). If the exercise times overlap, the ATS
exercise setting takes priority.
3min.
1min.
Engine Speed, RPM
10 min. 5 min.
Engine
Exercise
Full-Speed
Diagnostics
1min.
Cooldown
Figure 2-1 Unloaded Exercise Cycle
System Diagnostics
During the unloaded cycle exercise, the controller
monitors the following data. The controller display
indicates an unloaded exercise run during the
diagnostics, unless a fault is detected as described
below.
TP-6810 11/13 17Section 2 Generator Set Operation
D ATS connection. The controller verifies that the
Model RXT ATS interface board is connected.
D Battery voltage. Battery voltage is checked before
exercise to verify engine starting capability. Battery
voltage provides a measurement of battery health. If
the controller detects low battery voltage, low battery
or low charging battery is displayed and the exercise
does not start.
generator set. To set a loaded exercise, follow the
procedure in Section 2.5.8 and select Exercise Type:
Loaded.
For a loaded exercise with a transfer switch other than a
Kohlerr Model RXT, program the exercise at the
transfer switch controller. Refer to the transfer switch
operation manual for instructions.
D Coolant level check. The coolant level is checked.
D Communication integrity tests. J1939, RBUS,
Ethernet, and USB are monitored for messages
indicating that the controller and wiring are reliable.
D Engine speed. Engine speed is measured at low
speed and full speed. An overspeed or underspeed
condition will result in a fault condition and shutdown.
D Generator output frequency and voltage.
Operating the generator at full speed allows the
RDC2 controller to check the output power for correct
voltage, frequency, and stability. When the engine is
running at full speed, the controller verifies that the
voltage and frequency are within acceptable limits. A
fault message is displayed if the voltage or frequency
is out of range.
D Oil pressure. Oil pressure is verified to ensure
proper lubrication of critical engine components.
Pressure is monitored at both low and full speeds. If
the oil pressure is low, low oil pressure is displayed
and the generator set shuts down.
2.5.2 Unloaded Full-Speed Exercise
The unloaded full speed exercise runs the generator set
at full speed for 20 minutes without transferring the load.
To set an unloaded full speed exercise, follow the
procedure in Figure 2-3 and select Exercise Mode:
Unloaded Full.
2.5.4 Shutdown During Exercise
The following advanced diagnostic operation applies to
RDC2 controllers with firmware versions 5.04 and
higher.
If the generator set shuts down on a fault during an
exercise, the controller will try to restart the engine. If the
engine starts, the generator set will run at full speed for
two minutes and then stop. The event history will show
Advanced Diagnostic Active. The exercise schedule is
maintained.
If the engine does not start, the shutdown message will
be displayed. Correct the fault condition and reset the
fault as described in Section 2.6.
2.5.5 Power Failure During Exercise
If the utility power is lost during an unloaded exercise,
the ATStransfers to the emergency source, the exercise
is ended and the control remains in the AUTO mode.
If the utility power is lost during a loaded exercise, the
exercise is ended. The ATS remains in the emergency
position and the control goes into the AUTO mode.
The generator set continues to run and supply power to
the load for the duration of the utility power outage.
When Utility power is restored, the ATS will re-transfer to
the utility source through normal timing sequences.
2.5.6 Exerciser Reset
2.5.3 Loaded Full-Speed Exercise (with
RXT only)
A loaded exercise starts the generator set, ramps up to
full speed, and then transfers the electrical load from the
utility source to the generator set. The load is
transferred back to the utility source before the
generator set shuts down.
Note: With a loaded exercise, power to the building is
lost for up to 10 seconds during load transfer.
For a loaded exercise controlled by the RDC2 controller,
a Model RXT transfer switch must be connected to the
To reset the exerciser to run at a different day and/or
time or to change the exercise mode, follow the
procedure in Section 2.5.7 to change the exerciser
settings.
2.5.7 Setting the Exerciser at Power-up
When power is connected to the controller, you will be
prompted to set the date, time, and exercise schedule.
1. At power--up, the date is displayed with the year
flashing. Use the up or down arrow key to step to
the current year.
TP-6810 11/1318 Section 2 Generator Set Operation
2. Press Select button to save the year and move to
the month.
2. Press the Select button to go to the main menu.
SeeFigure2-2.
3. Use the arrow and select buttons to set the month
and the day.
4. The time is displayed with the hour flashing. Use
the up or down arrow key to step to the current hour
and am or pm setting.
Note: Check the am/pm setting displayed. If pm is
displayed and you need to change it to am,
use the down arrow button to step down in
time until the correct hour and am are
displayed.
5. Press the Select button to save the hour and move
to minutes.
6. Use the up or down arrow button to change the
minutes.
7. Press Select to save the time and move to the next
screen.
8. Next Exercise is displayed. Use the up, down, and
select buttons to set the exercise time and date. Be
sure to set a time and date in the future.
3. Press the down arrow button to step to the Genset
System menu.
4. Press the Select button to enter the Genset system
menu. See Figure 2-3.
5. Use the down arrow button to step to the next
Exercise menu.
6. Press the Select button. The setting flashes to
show that it can be changed. For example, the hour
flashes to show that the hour can be changed.
7. Press the UP or Down arrow buttons to change the
setting.
8. Press the Select button to save the setting and
move to the next. For example, save the hour
setting and move to minutes.
9. Repeat steps 5 through 8 to change the next item
on the line until the desired settings are displayed.
10. Press Select to save after all settings have been
selected. Settings will stop flashing.
9. Press Select. The controller exits the exercise
menu.
10. Press the Auto button and verify that the AUTO
LED is lit. The generator set must be in automatic
mode for the exercise to run as scheduled.
Theexercisewillrunevery7daysatthesametime,
starting on the date set. To change the exerciser to run
every other week or on a different day and time, use the
following procedure.
2.5.8 Changing the Exercise Setting
Set the date and time on the controller before setting the
exercise schedule. Set the exerciser to automatically
run the generator set for 20 minutes every week or every
two weeks. Follow the procedure below and see the
flowchart 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.
11. If the generator set is connected to a Kohlerr Model
RXT transfer switch, the exercise can be changed
to a loaded exercise. Set the Exercise Mode to
loaded full speed, unloaded full speed, or unloaded
cycle as shown in Figure 2-3.
12. Set the exercise frequency (weekly or every two
weeks). Weekly exercises are recommended.
13. Press the down arrow button to step to the Return
menu. Press the Select button to return to the main
menu.
14. Check that the AUTO LED is lit. The generator set
must be in automatic mode for the exercise to run
as scheduled.
After a scheduled exercise run, the next exercise time
and date will be updated automatically based on the
Exercise Frequency setting.
Other transfer switches: For a loaded exercise with a
transfer switch other than a Kohlerr Model RXT,
program the exercise at the transfer switch controller.
Refer to the transfer switch operation manual for
instructions.
TP-6810 11/13 19Section 2 Generator Set Operation
Status
Displays
Overview -- -->
1.2 h
Engine ---->
Metering
Generator---->
Metering
Genset -- -->
Information
Genset -- -->
Run Time
Genset -- -->
System
ATS -- - ->
Status
ATS -- - ->
Configuration
D a t e -- -- >
and Time
Network ---->
Information
PIM ---->
Status
Load ---->
Control
Event Log-- -->
tp6810
Figure 2-2 RDC2 Main Menu
TP-6810 11/1320 Section 2 Generator Set Operation
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