Page 2 - WARNING; California Proposition 65; Product Identification Information; Generator Set Identification Numbers; Accessory Number; Controller Identification
TP-6810 11/13 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 pro...
Page 3 - Table of Contents
Table of Contents TP-6810 11/13 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-6810 11/13 Table of Contents 4 3.12 Genset Run Time Menu 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 Genset System Menu 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - Safety Precautions and Instructions; DANGER; Accidental Starting; Battery
TP-6810 11/13 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 install...
Page 6 - Engine Backfire/Flash; Exhaust System; Fuel System
TP-6810 11/13 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 contain...
Page 7 - Hazardous Noise; CAUTION; Moving Parts
TP-6810 11/13 7 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. I...
Page 8 - Heavy Equipment; Hot Parts; Notice; NOTICE
TP-6810 11/13 8 Safety 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. E...
Page 9 - Introduction; Figure 1; Nameplate; Figure 2
TP-6810 11/13 9 Introduction Introduction This manual provides operation instructions for Model38RCL, 48RCL, and 60RCL residential/light commercial generator sets equipped with the RDC2generator set/transfer switch controller. This generator set is approved for use in stationaryapplications in locat...
Page 10 - List of Related Literature; Literature Type; Figure 3; Related Literature
TP-6810 11/13 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, 38RCL G4-214 Specif...
Page 11 - Service Assistance; Headquarters Europe, Middle East
TP-6810 11/13 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 ...
Page 12 - Notes
Page 13 - Section 1 Service Views; Cooling System Detail
TP-6810 11/13 13 Section 1 Service Views Section 1 Service Views 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 c...
Page 14 - 0RCL Service Views
TP-6810 11/13 14 Section 1 Service Views 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...
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-6810 11/13 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 nause...
Page 16 - Exercising the Generator Set; Automatic Start
TP-6810 11/13 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 e...
Page 17 - Automatic Stop; Automatic Operation with Model; Unloaded Cycle Exercise with; System Diagnostics
TP-6810 11/13 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 ...
Page 18 - Communication integrity tests.; Unloaded Full-Speed Exercise
TP-6810 11/13 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 heal...
Page 19 - Changing the Exercise Setting; Procedure to Change the Exercise Setting
TP-6810 11/13 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 s...
Page 20 - RDC2 Main Menu
TP-6810 11/13 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-6810 11/13 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/Unloa...
Page 22 - Procedure to Reset the Controller after a Fault
TP-6810 11/13 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. If a programmable interf...
Page 23 - Fault
TP-6810 11/13 23 Section 2 Generator Set Operation Fault Warning (W) or Shutdown (SD) Condition Check AC Sens Lost W (1 sec.) SD (3 sec.) AC Sensing Lost. In Auto mode, generator output AC sensing is lost. Starts 10 seconds after crank disconnect.Warning: after 1 second if no output detected after c...
Page 24 - Controller Fault Messages
TP-6810 11/13 24 Section 2 Generator Set Operation Fault Warning (W) or Shutdown (SD) Condition Check Exer Not Sch W Exercise Not Scheduled. No exercise has been scheduled on the RDC2 controller. See Section 2.5 for instructions to set the exerciser. Generator Frequency High SD Governed frequency ex...
Page 25 - Event Log; Procedure to View Event History; Model RXT Transfer Switch; Source Availability; Item
TP-6810 11/13 25 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 ...
Page 26 - ATS Control Sequence of; Preferred Source Fails:; Time Delays; Time Delay
TP-6810 11/13 26 Section 2 Generator Set Operation 2.7.2 ATS Control Sequence of Operation See Figure 2-8 for time delay settings. Preferred 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 a...
Page 27 - Section 3 RDC2 Controller Operation; Switch Controller
TP-6810 11/13 27 Section 3 RDC2 Controller Operation Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set / Transfer Switch Controller Model 38 RCL, 48RCL, and 60RCL generator sets are equipped with the RDC2 generator set/transfer switch controller. The RDC2 controls the following power system...
Page 28 - Controller Keypad; Button
TP-6810 11/13 28 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 oper...
Page 29 - LCD Display
TP-6810 11/13 29 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 Figu...
Page 30 - Changing Settings; Procedure to Change Settings
TP-6810 11/13 30 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 controll...
Page 31 - Changing Settings on the RDC2 Controller
TP-6810 11/13 31 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 chang...
Page 33 - Overview Menu; The engine metering menu displays engine status; Engine Metering Menu
TP-6810 11/13 33 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: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09Dec2011 Nex...
Page 34 - Generator Metering Menu; Voltage Calibration; Will cause severe injury or death.
TP-6810 11/13 34 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 35 - Generator Set Information; Genset Run Time Menu
TP-6810 11/13 35 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 t...
Page 36 - Genset System Menu; Setting the Exerciser
TP-6810 11/13 36 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 a...
Page 38 - ATS Configuration Menu; Changing ATS Configuration Settings
TP-6810 11/13 38 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 setting...
Page 39 - The date and time will typically be set at controller; Date and Time Menu
TP-6810 11/13 39 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:02Dec2011 Time:12:34pm Time Format:12hr...
Page 40 - Networking Information Menus
TP-6810 11/13 40 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 Home Generator Management System. RBUS is...
Page 42 - OnCue Password
TP-6810 11/13 42 Section 3 RDC2 Controller Operation 3.17.2 Networking Configuration Submenu (OnCue Password) The networking Configuration menu includes settings used for communication with the Kohler r OnCue r Home Generator Management System. For most applications, DHCP is enabled and the IP setti...
Page 44 - Check the status of remote devices communicating; Remote Devices Submenu
TP-6810 11/13 44 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 Ve...
Page 45 - Programmable Interface
TP-6810 11/13 45 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 46 - Load Control Menus
TP-6810 11/13 46 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 ...
Page 47 - General Maintenance; Generator Set Service.
TP-6810 11/13 47 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. Recon...
Page 49 - Lubrication System; Oil Specifications; Ambient Temperature; Oil Check; Oil Change Procedure
TP-6810 11/13 49 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 e...
Page 50 - Model; Stop the generator set.
TP-6810 11/13 50 Section 4 Scheduled Maintenance d. Install the new oil filter following the instructions provided with the filter. 3. Fill with oil. See Figure 4-1 for oil selection and Figure 4-3 for oil capacity. Model Oil Capacity, L (qt.) 38RCL, 48RCL, and 60RCL 4.7 (5.0) Figure 4-3 Oil Capacit...
Page 51 - Exhaust System Inspection Points
TP-6810 11/13 51 Section 4 Scheduled Maintenance 4.5 Exhaust System Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. WARNING Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carb...
Page 52 - Cooling System Inspection; Draining Cooling System; Flushing and Cleaning Procedure; Filling Cooling System
TP-6810 11/13 52 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 br...
Page 53 - Means of Identification
TP-6810 11/13 53 Section 4 Scheduled Maintenance 4.7 Ignition System Service the spark plugs at the interval specified in the service 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 se...
Page 55 - Battery short circuits. Explosion can cause severe injury; Storage Procedure
TP-6810 11/13 55 Section 4 Scheduled Maintenance 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 equipm...
Page 57 - Section 5 Troubleshooting; Circuit Protection; Load Circuit Breaker
TP-6810 11/13 57 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 chart...
Page 58 - Generator Set Troubleshooting; before replacing parts.; Problem; General Troubleshooting Chart
TP-6810 11/13 58 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 w...
Page 59 - Controller Troubleshooting; RDC2 Troubleshooting Chart
TP-6810 11/13 59 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. ...
Page 61 - Appendix A Abbreviations
TP-6810 11/13 Appendix 61 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 64 - For the nearest KOHLER authorized
E 2012, 2013 by Kohler Co. All rights reserved. TP-6810 11/13b 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 install...
