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Kohler 38RCL, Operation, Page: 1 / 72

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Kohler 38RCL Operation Download Page 1

Residential/Light Commercial Generator Sets

Model:

38RCL

48RCL

48RCLA

60RCL

Controller:

RDC2

TP-6810 7/16d

Operation

Summary of Contents for 38RCL

Page 1: ...Residential Light Commercial Generator Sets Model 38RCL 48RCL 48RCLA 60RCL Controller RDC2 TP 6810 7 16d Operation...

Page 2: ...ermine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field...

Page 3: ...d Exercise with RXT only 19 2 5 4 Shutdown During Exercise 19 2 5 5 Power Failure During Exercise 20 2 5 6 Exerciser Reset 20 2 5 7 Setting the Exerciser at Power up 20 2 5 8 Changing the Exercise Set...

Page 4: ...ystem 52 4 3 1 Oil Specifications 52 4 3 2 Oil Check 52 4 3 3 Oil Additions 52 4 3 4 Oil and Filter Change 52 4 4 Air Cleaner 54 4 5 Exhaust System 55 4 6 Cooling System 56 4 6 1 Checking and Filling...

Page 5: ...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 Sulfuric acid i...

Page 6: ...r 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...

Page 7: ...l equip ment damage Never weld components of the generator set without first discon necting the battery controller wiring harness and engine electronic con trol module ECM CAUTION Grounding electrical...

Page 8: ...s before operating the generator set Heavy Equipment Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Lift the generator set using lifti...

Page 9: ...utions 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 equipme...

Page 10: ...ine Mechanical TP 6103 Service Manual 48RCL 48RCLA and 60RCL Engine Mechanical TP 6104 Service Manual Engine ECM Diagnostics TP 6724 Service Manual Alternator 38RCL TP 6353 Service Manual Alternator 4...

Page 11: ...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 1...

Page 12: ...TP 6810 7 16 12 Service Assistance Notes...

Page 13: ...it 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 o...

Page 14: ...anel 15 Load circuit breaker 16 Generator set master control buttons on RDC2 controller 17 RDC2 controller 18 Cooling air inlet remove this panel to access coolant drain 19 Access to coolant fill 20 O...

Page 15: ...ch 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 P...

Page 16: ...azardous voltage Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Moving parts WARNING Grounding electrical equipment Hazardous vo...

Page 17: ...tor 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 generato...

Page 18: ...the generator set to stop 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...

Page 19: ...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 sh...

Page 20: ...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 9 Press Select The controller exits the exercise menu 10 Press the Auto button and ver...

Page 21: ...d 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 K...

Page 22: ...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 Syst...

Page 23: ...e fault condition is corrected and the controller is reset See Section 2 6 4 to reset the controller after a fault shutdown 2 6 3 ATS Communication Errors When a Model RXT transfer switch is used an A...

Page 24: ...ery Voltage High W Engine starting battery voltage rises above 125 of the battery voltage setting for more than 10 seconds Inhibited during the engine crank cycle Clears when the battery voltage retur...

Page 25: ...onds Reduce the load and restart the generator set Contact an authorized distributor dealer for service Lo Crank Vlt W Low cranking voltage Battery voltage falls below 60 of system battery voltage for...

Page 26: ...MN event number W S I engine hours event name Press Select button at any time to return to the main menu Event codes W Warning S Shutdown I Informational Notice Figure 2 6 Event Log 2 7 Model RXT Tra...

Page 27: ...in the utility power source 2 7 4 ATS Load Control Relay Time Delay The load control time delay allows delayed starting of large motor loads such as air conditioners preventing simultaneous starting...

Page 28: ...TP 6810 7 16 28 Section 2 Generator Set Operation Notes...

Page 29: ...et status indicating LEDs OFF AUTO RUN D Up Down and Select buttons for navigation through menus and adjustments D Power system indicator LEDs to show utility and generator source status and to show w...

Page 30: ...h menus and change settings This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller Select Up arrow Figure 3 2 Pushbutton Operation LED LED Operat...

Page 31: ...es to the controller settings See Sections 3 6 through 3 19 for menu diagrams tp6810 Genset Status Running Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure 40 psi Battery 12 3V Engine Runtime 27 4 h...

Page 32: ...as been replaced D The voltage requires adjustment for a particular application D Troubleshooting generator set problems Havecontroller setupand adjustmentperformed onlyby an authorized Kohler distrib...

Page 33: ...date is shown press the Select button The saved date is shown 9 Press the down arrow button to step to the next menu 10 Repeat steps 5 and 6 using the arrow and select buttons to set and save the time...

Page 34: ...view is displayed See Figure 3 7 Press the down arrow button to step to the next menu Engine Metering Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 3 7 The co...

Page 35: ...Exercise 09 00p 09Dec2011 Next Maintenance 150 h or Mar2012 SW Version 4 03 Return Figure 3 8 Overview Menu 3 9 Engine Metering Menu The engine metering menu displays engine status information as sho...

Page 36: ...eteringmenu ContactaKohler authorized distributor dealer for service The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration if necessary See Figu...

Page 37: ...3 11 Generator Set Information Menu 3 12 Genset Run Time Menu The data shown in Figure 3 12 are displayed No changes are allowed from this menu The Next Maintenance menu shows the number of hours of...

Page 38: ...vice Refer to the generator set Installation Manual for instructions to adjust the voltage Fuel Type The fuel type LP or natural gas is shown Do not change the fuel type in this menu unless the genera...

Page 39: ...shown in these menus can be calibrated Contact an authorized distributor or dealer for service if calibration is required tp6810 Frequency 60 0 Hz Voltage L1 L2 240 V Voltage L2 L3 240 V Voltage L3 L...

Page 40: ...es to indicate that it can be changed Press the up and down arrow buttons to change the value Press the Select button to save the value shown Use the up and down arrow buttons to move to the next valu...

Page 41: ...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 24hr Date and Time Retur...

Page 42: ...PIM or load management device and for systems that use the Kohlerr OnCuer Plus Home Generator Management System The Networking Information menu leads to submenus for network and RBUS communication set...

Page 43: ...layed If DHCP is disabled i e if a static IP address is used the IP parameters are displayed To enable or disable DHCP and change the IP settings go to the Networking Configuration menu See Section 3...

Page 44: ...Use the OnCue password shown on the controller display for OnCue Plus applications For the initial OnCue Plus setup you will be required to reset the OnCue password on the RDC2 controller and then en...

Page 45: ...des the following optional modules D Model RXT transfer switch D Programmable Interface Module PIM D Load Shed Kit or RXT combined interface load management board tp6804 Modules Connected 3 Module Tim...

Page 46: ...erface load management board The serial numbers for the PIM and load shed kit are printed on the circuit boards tp6810 Device Status Connected RD Firmware Ver 122 ModBus ID 12 S N XXXXXXXXX DeviceType...

Page 47: ...ter running Kohlerr SiteTecht software is required to change the input and output settings Contact an authorized distributor or dealer for service The Kohlerr OnCuer Plus Generator Management System c...

Page 48: ...ice adds and sheds loads based on the generator current The test function cycles the relays in the order of their priority For detailed information about load management operation refer to TT 1609 pro...

Page 49: ...touch hot engine parts The engine and exhaust system components become extremely hot during operation Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator...

Page 50: ...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 succes...

Page 51: ...ator exterior X X Replace engine coolant w X Inspect coolant hoses X ELECTRICAL SYSTEM Check battery charge and fluid level X X Inspect electrical system X Clean battery cables X EXHAUST SYSTEM Inspec...

Page 52: ...The amount varies with generator set usage Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device See Section 1 Service Views for the oil check and oil...

Page 53: ...pacity Model Oil Capacity L qt 38RCL 48RCL 48RCLA and 60RCL 4 7 5 0 Figure 4 3 Oil Capacity 4 Check for leaks a Press the OFF button on the RDC2 generator set controller b Reconnect the generator set...

Page 54: ...ath Do not operate the generator set with the air cleaner removed At the interval specified in the service schedule inspect and clean or replace the air cleaner element Clean the element more frequent...

Page 55: ...s 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 the buil...

Page 56: ...zing and overheating protection A coolant solution with more than 50 ethylene glycol can cause engine or component damage Do not mix long life coolant and conventional coolants Do not use alcohol or m...

Page 57: ...tion 1 Service Views for the coolant overflow bottle location 8 Re energize the block heater if equipped 4 7 Ignition System Airborne particles Can cause severe injury or blindness Wear protective gog...

Page 58: ...gap 38RCL 48RCL 48RCLA and 60RCL 0 9 mm 0 035 in Figure 4 7 Recommended Spark Plug Gap 1 514 1 2 1 0 9 mm 0 035 in gap 2 Spark plug electrodes Figure 4 8 Spark Plug Gap Inspection 10 Use a gapping too...

Page 59: ...regap the spark plug Lead fouled spark plug Dark gray black yellow or tan deposits or a glazed coating on the insulator tip Caused by highly leaded fuel Replace the spark plug Pre ignition damaged sp...

Page 60: ...oid 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 cont...

Page 61: ...avity is below 1 215 at an electrolyte temperature of 80 F 26 7 C See Figure 4 12 Specific Gravity Corrected to 80 F 26 7 C Battery Condition Below 1 215 Needs charging 1 260 Fully charged Figure 4 12...

Page 62: ...3 4 Oil and Filter Change 4 Check the engine coolant protection see Section 4 6 Note Use antifreeze capable of withstanding the lowest possible temperatures 5 Keep spark plugs in their holes or seal...

Page 63: ...ssages descriptions and recommended checks are listed in Figure 2 5 Identify and correct the cause of the fault condition Then reset the controller after a fault shutdown See Section 2 6 4 5 4 Circuit...

Page 64: ...ler 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 beca...

Page 65: ...fy that cable size and length of run comply with the instructions in the Installation manual Low or no battery voltage Check battery connections Check generator set battery See Figure 5 1 Load managem...

Page 66: ...TP 6810 7 16 66 Section 5 Troubleshooting Notes...

Page 67: ...s cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resista...

Page 68: ...titer screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per million PROM programmable re...

Page 69: ...TP 6810 7 16 69 Notes...

Page 70: ...TP 6810 7 16 70 Notes...

Page 71: ......

Page 72: ...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 service...

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