Page 2 - WARNING; California Proposition 65; Product Identification Information; Generator Set Identification Numbers; Accessory Number; Controller Identification
TP-6905 6/14 2 Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. WARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts. Record the prod...
Page 3 - Table of Contents
Table of Contents TP-6905 6/14 Table of Contents 3 Product Identification Information 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions and Instructions 5 . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 4 - Table of Contents, continued; Section 4 Scheduled Maintenance
Table of Contents, continued TP-6905 6/14 Table of Contents 4 3.12 Genset Run Time Menu 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 Genset System Menu 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5 - Safety Precautions and Instructions; DANGER; Accidental Starting; Battery
TP-6905 6/14 5 Safety Precautions and Instructions Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installe...
Page 6 - Engine Backfire/Flash; Exhaust System; Fuel System
TP-6905 6/14 6 Safety 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 containi...
Page 7 - Hazardous Noise
TP-6905 6/14 7 Safety Precautions and Instructions 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 nat...
Page 8 - Hot Parts; Notice; NOTICE
TP-6905 6/14 8 Safety Precautions and Instructions 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...
Page 9 - Introduction; Figure 1; Nameplate; Figure 2
TP-6905 6/14 9 Introduction Introduction This manual provides operation instructions for Model24RCL and 30RCLH residential/light commercialgenerator sets equipped with the RDC2 generatorset/transfer switch controller. This generator set is approved for use in stationaryapplications in locations serv...
Page 10 - List of Related Literature; Literature Type; Figure 3; Related Literature
TP-6905 6/14 10 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 Specifi...
Page 11 - Service Assistance; Headquarters Europe, Middle East
TP-6905 6/14 11 Service Assistance Service Assistance For professional advice on generator set powerrequirements and conscientious service, please contactyour nearest authorized Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power S...
Page 12 - Notes
Page 13 - Section 1 Service Views; Cooling System Detail; 4RCL and 30RCLH Service Views for Maintenance
TP-6905 6/14 13 Section 1 Service Views Section 1 Service Views 6 1. Oil check (dipstick) 2. Oil fill location (on valve cover) 3. See cooling system detail 4. Exhaust outlet 5. Enclosure locking tool (shipping location only) 6. Spark plugs 7. EPR (electronic fuel pressure regulator) 8. Engine ECM 9...
Page 15 - Section 2 Generator Set Operation; Can; Carbon monoxide symptoms. Carbon monoxide can; Keep the generator set area clear.; Prestart Checklist; Carbon Monoxide Detectors.
TP-6905 6/14 15 Section 2 Generator Set Operation Section 2 Generator Set Operation 2.1 Operating Area Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. WARNING Carbon monoxide symptoms. Carbon monoxide can cause severe nausea...
Page 16 - Exercising the Generator Set; Automatic Start
TP-6905 6/14 16 Section 2 Generator Set Operation 2.3 Exercising the Generator Set 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 ex...
Page 17 - Automatic Stop; Automatic Operation with Model; Unloaded Cycle Exercise with; System Diagnostics
TP-6905 6/14 17 Section 2 Generator Set Operation Automatic Stop 1. When the utility source is restored, the Emergency-to-Normal time delay starts. 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 M...
Page 18 - Communication integrity tests.; Unloaded Full-Speed Exercise
TP-6905 6/14 18 Section 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 healt...
Page 19 - Changing the Exercise Setting; Procedure to Change the Exercise Setting
TP-6905 6/14 19 Section 2 Generator Set Operation 2. Press Select button to save the year and move to the month. 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 se...
Page 20 - RDC2 Main Menu
TP-6905 6/14 20 Section 2 Generator Set Operation Overview -- --> 1.2 h Engine -- --> Metering tp6810 Generator-- --> Metering Genset -- --> Information Genset -- --> Run Time Date -- --> and Time ATS -- --> Configuration Genset -- --> System Event Log-- --> Load -- -->...
Page 21 - the Exercise Setting
TP-6905 6/14 21 Section 2 Generator Set Operation 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/Unload...
Page 22 - Procedure to Reset the Controller after a Fault
TP-6905 6/14 22 Section 2 Generator Set Operation 2.6 Faults Selected fault conditions are shown in Figure 2-5. Fault conditions are classified as warnings or shutdowns. If a fault occurs that is not listed in the table, contact an authorized distributor/dealer for service. Note: All ECM faults are ...
Page 23 - Condition
TP-6905 6/14 23 Section 2 Generator Set Operation Fault (RDC2) Fault (OnCue r Plus) Condition Check AC Sens LossWarning (1 sec.)Shutdwn (3 sec.) AC Sensing Lost AC Sensing Lost. In Auto mode, generator output AC sensing is lost. Detection begins 10 seconds after crank disconnect.Warning: after 1 sec...
Page 26 - Controller Fault Messages
TP-6905 6/14 26 Section 2 Generator Set Operation Fault (RDC2) Fault (OnCue r Plus) Condition Check Over Crank Shutdwn Over Crank Three unsuccessful starting attempts. Check the fuel supply, spark plug, and battery.Check for loose connections.Contact an authorized distributor/dealer for service. Pri...
Page 27 - Event Log; Procedure to View Event History; Model RXT Transfer Switch; Source Availability; Item
TP-6905 6/14 27 Section 2 Generator Set Operation 2.6.5 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1--1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number o...
Page 28 - ATS Control Sequence of; Normal Source Returns:; Time Delays; Time Delay
TP-6905 6/14 28 Section 2 Generator Set Operation 2.7.2 ATS Control Sequence of Operation 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 t...
Page 29 - Section 3 RDC2 Controller Operation; Switch Controller
TP-6905 6/14 29 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set / Transfer Switch Controller Model 24RCL and 30RCLH generator sets are equipped with the RDC2 generator set/transfer switch controller. The RDC2 controls the following power system componen...
Page 30 - Controller Keypad; Button
TP-6905 6/14 30 Section 3 RDC2 Controller Operation 3.2.1 Controller Keypad The Run, Off, and Auto buttons control the generator set as described in Figure 3-2. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.4 for opera...
Page 31 - LCD Display
TP-6905 6/14 31 Section 3 RDC2 Controller Operation 3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit liquid crystal diode (LCD) display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figur...
Page 32 - Changing Settings; Procedure to Change Settings
TP-6905 6/14 32 Section 3 RDC2 Controller Operation 3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect the battery and the utility power to the generator set. If controlle...
Page 33 - Changing Settings on the RDC2 Controller
TP-6905 6/14 33 Section 3 RDC2 Controller Operation 1. Press the Select button to enter the main menu. 2. Press the down arrow button until the desired menu is displayed. See Figure 3-7. Date and Time are used for this example. 3. Press the Select button to enter the Date and Time menu. 4. To change...
Page 35 - Overview Menu; The engine metering menu displays engine status; Engine Metering Menu
TP-6905 6/14 35 Section 3 RDC2 Controller Operation 3.8 Overview Menu Overview -- --> 1.2 h Active Alert (if any) tp6809 Genset Status Standby Voltage: 240V Freq: 60.0Hz Engine: 95F Oil: 40 PSI Battery 12.3V Engine Runtime: 27.4 h Date: 02DEC2014 Time: HR:MNpm Next Exercise: 09:00p 09Dec2014 Next...
Page 36 - Generator Metering Menu; Voltage Calibration; Will cause severe injury or death.
TP-6905 6/14 36 Section 3 RDC2 Controller Operation 3.10 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See Figure 3-10. The voltage calibration mode can be entered from the generator metering menu. Voltage Calibration Hazardous voltage. Will cause ...
Page 37 - Generator Set Information; Genset Run Time Menu
TP-6905 6/14 37 Section 3 RDC2 Controller Operation 3.11 Generator Set Information Menu The generator set model number and serial numbers are displayed. No changes are allowed from this menu. Model and serial numbers are factory set and should not require changes in the field, except in the event th...
Page 38 - Genset System Menu; Setting the Exerciser
TP-6905 6/14 38 Section 3 RDC2 Controller Operation 3.13 Genset System Menu The genset system menu displays the system information shown in Figure 3-13. Generator sets are factory set and should not require changes to the system settings in the field. A Kohler authorized distributor or dealer can ad...
Page 40 - ATS Configuration Menu; Changing ATS Configuration Settings
TP-6905 6/14 40 Section 3 RDC2 Controller Operation 3.15 ATS Configuration Menu Note: The ATS Configuration menu appears only if a Model RXT transfer switch is connected. Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the settings...
Page 41 - The date and time will typically be set at controller; Date and Time Menu
TP-6905 6/14 41 Section 3 RDC2 Controller Operation 3.16 Date and Time Menu The date and time will typically be set at controller power-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|...
Page 42 - Networking Information Menus
TP-6905 6/14 42 Section 3 RDC2 Controller Operation 3.17 Networking Information Menus Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or LCM, and for systems that use the Kohler r OnCue r Plus Generator Management System. RBUS is ...
Page 44 - OnCue Plus Password
TP-6905 6/14 44 Section 3 RDC2 Controller Operation 3.17.2 Networking Configuration Submenu (OnCue Plus Password) The networking Configuration menu includes settings used for communication with the Kohler r OnCue r Plus Generator Management System. For most applications, DHCP is enabled and the IP s...
Page 46 - Check the status of remote devices communicating; Remote Devices Submenu
TP-6905 6/14 46 Section 3 RDC2 Controller Operation 3.17.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: D Model RXT ATS D Programmable interface module (PIM) D Load control module (LCM) tp6810 Device Status: Connected RD Firmware Ver...
Page 47 - Programmable Interface
TP-6905 6/14 47 Section 3 RDC2 Controller Operation 3.18 Programmable Interface Module (PIM) Menus The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). This is a status display menu only. Input and output settings cannot be changed from ...
Page 48 - Load Control Menus
TP-6905 6/14 48 Section 3 RDC2 Controller Operation 3.19 Load Control Menus The generator set may be connected to a Load Control Module (LCM) or a Model RXT transfer switch equipped with a Load Shed kit. The Load Control menu displays the status of the load control inputs and outputs, and allows a t...
Page 49 - General Maintenance
TP-6905 6/14 49 Section 4 Scheduled Maintenance Section 4 Scheduled Maintenance 4.1 General Maintenance 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. Reconn...
Page 50 - Generator Set Service.
TP-6905 6/14 50 Section 4 Scheduled Maintenance The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts. See the Safety Precautions and Instructions at the beginning of this manual before attempting to...
Page 52 - Lubrication System; Oil Specifications; Oil Change Procedure
TP-6905 6/14 52 Section 4 Scheduled Maintenance 4.3 Lubrication System 4.3.1 Oil Specifications Use oil that displays the American Petroleum Institute (API) Starburst certification mark FOR GASOLINE ENGINES on the container. Do not use straight-weight oils recommended for industrial or stationary en...
Page 53 - Replace the oil filter.; Model; Stop the generator set.
TP-6905 6/14 53 Section 4 Scheduled Maintenance 2. Replace the oil filter. a. Remove the oil filter by rotating it counterclockwise with an oil filter wrench. Note: On model 30RCLH only, ensure that the oil cooler adapter nut is tightened to specification [Torque = 40 Nm (29.5 ft.lbs.)] and that oil...
Page 54 - Air Cleaner Service Procedure; Generator set operation. Carbon monoxide can cause
TP-6905 6/14 54 Section 4 Scheduled Maintenance 4.4 Air Cleaner At the interval specified in the service schedule (Section 4.2), inspect and clean or replace the air cleaner element. Clean the element more frequently in dirty, dusty conditions. Check the element for accumulated oil or dirt that coul...
Page 55 - Can cause hearing loss.; CAUTION; Exhaust System Inspection Points; Hot coolant and steam.; Do not mix
TP-6905 6/14 55 Section 4 Scheduled Maintenance Carbon monoxide detectors. Carbon monoxide cancause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of the building. Locate thedetectors to adequately warn the building’s occupants of thepresence of carbon monoxide. K...
Page 56 - Cooling System Inspection; Draining Cooling System; Flushing and Cleaning Procedure; Filling Cooling System
TP-6905 6/14 56 Section 4 Scheduled Maintenance 4.6.2 Cooling System Inspection To prevent generator shutdown or damage because of overheating: D Keep the cooling air inlets clean and unobstructed D Inspect the radiator’s exterior for obstructions and remove dirt and foreign material with a soft bru...
Page 58 - Means of Identification
TP-6905 6/14 58 Section 4 Scheduled Maintenance Problem/Condition Means of Identification Possible Cause/Solution Gap-bridged spark plug Built-up deposits and gap between electrodes closing. Oil or carbon fouling. Clean and regap the spark plug. Oil-fouled spark plug Wet, black deposits on the insul...
Page 59 - Consult the battery manufacturer’s instructions
TP-6905 6/14 59 Section 4 Scheduled Maintenance 4.8 Battery Consult the battery manufacturer’s instructions regarding battery care and maintenance. Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. WARN...
Page 60 - Storage Procedure; Connecting the battery and the battery charger.
TP-6905 6/14 60 Section 4 Scheduled Maintenance 4.9 Storage Procedure Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect ...
Page 61 - Section 5 Troubleshooting; Circuit Protection; Load Circuit Breaker
TP-6905 6/14 61 Section 5 Troubleshooting Section 5 Troubleshooting 5.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts...
Page 62 - Generator Set Troubleshooting; before replacing parts.; Problem; General Troubleshooting Chart
TP-6905 6/14 62 Section 5 Troubleshooting 5.5 Generator Set Troubleshooting Figure 5-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action The generator set does not crank. Battery we...
Page 63 - Controller Troubleshooting; RDC2 Troubleshooting Chart
TP-6905 6/14 63 Section 5 Troubleshooting 5.6 Controller Troubleshooting Figure 5-2 contains basic troubleshooting information for the RDC2 controller. Problem Possible Cause Corrective Action Controller LCD display is off. Low or no battery voltage. Check connections. Check generator set battery. S...
Page 65 - Appendix A Abbreviations
TP-6905 6/14 Appendix 65 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control; analog to digital converter adj. adjust, adjustment ...
Page 68 - For the nearest KOHLER authorized
E 2014 by Kohler Co. All rights reserved. TP-6905 6/14 KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER authorized installation, s...
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