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Generator Operation Manual

1. Next Exercise HR MN PM MM DD YY Next Exercise See Section 2 5 8 Changing HR MN PM MM DD YY the Exercise Setting O rad y Exercise Mode Unloaded Cycle Exercise Mode None Unloaded Full Sp Un loaded Cycle Loaded Full SP Exercise Freq Weekly Y Exercise Freq Weekly Every Other Week NY Meas System English NA Contrast 50 Y Return Figure 2 3 Procedure to Set the Exerciser TP 6905 8 15 1p6809 Section 2 Generator Set Operation 23 2 6 Faults Selected fault conditions are shown in Figure 2 5 Fault conditions are classified as warnings or shutdowns Ifa fault occurs that is not listed in the table contact an authorized distributor dealer for service Note All ECM faults are grouped under one listing in Figure 2 5 If a programmable interface module PIM is connected to the generator set controller additional faults can be activated by customer supplied equipment See TT 1584 Installation Instructions forthe Programmable Interface Module for available inputs and outputs 2 6 1 Warnings The controller displays a fault message but the generator set does not shut down on a warning The controller resets automaticall
2. Y Next Exercise 09 00p 09Dec2014 Y Next Maintenance 150 h or Mar2015 Sample data shown 1p6810 Figure 3 5 Autopaging Displays Automatic Mode Section 3 RDC2 Controller Operation 33 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 controller power is disconnected and reconnected you will be prompted to setthe time date and exerciser The first setting will flash Press the Up and Down arrow buttons to change the setting Press Select to save the setting and move on to the next Repeat until all settings are saved and the controller returns to the main menu See Section 3 5 for more detailed instructions to change settings on the RDC2 See Section 2 5 for more detailed instructions to set the exerciser or change the exercise settings 3 4 Battery Charging The controller includes a built in battery charger to maintain the engine starting battery The RDC2 controller monitors the battery voltage and provides a constant 14 2 VDC voltage and maximum 2 5 amps to charge the battery The installer must connect utility power provided from the building 90 265 VAC 50 60 Hz on a breaker protected circuit for the built in battery charger See the Installation Manual for in
3. A 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 inthe 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 toa 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 o
4. RunRelCoil Shutdwn Run Relay Coil Overload Excessive current on the run 70 line Check for shorted relays or shorted wires Spd Sens FIt Shutdwn Speed Sensor Fault Engine speed sensor has failed or engine stalled ECM is no longer reporting valid speed Contact an authorized distributor dealer for service Volts L1 L2 High Shutdwn High Generator Voltage L1 L2 Generator Voltage High Output voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service Volts L1 L2 Low Shutdwn Low Generator Voltage L1 L2 Generator Voltage Low Output voltage falls below 8096 of the nominal system voltage for more than 10 seconds Reduce the load by turning off appliances and restart the generator set Contact an authorized distributor dealer for service Volts L2 L3 High Shutdwn High Generator Voltage L2 L3 Generator Voltage High Output voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service Volts L2 L3 Low Shutdwn Low Generator Voltage L2 L3 Generator Voltage Low Output voltage falls below 8096 of the nominal system voltage for more than 10 seconds Reduce the load by turning off appliances and restart the generator set Contact an authorized distributor dealer for service Volts L3 L1 High Shutdwn High Generator
5. Date gt Genset gt Information Genset gt Run Time and Time Network gt Information Load gt Control X ATS Status Event Log gt ATS Configuration appears only if a Model RXT transfer switch is connected PIM Status appears only if a programmable interface module is connected Load Control appears only if a load management device is connected Figure 3 7 RDC2 Main Menu 36 Section 3 RDC2 Controller Operation TP 6905 8 15 3 8 Overview Menu 3 9 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3 9 This menu displays status information only No settings can be changed O re ca from this menu A N Engine gt Eng Speed Metering PA 1800 RPM Genset Status Standby Y Voltage 240V Freq 60 0Hz Engine 95F Oil 40 PSI A Nu ZN Oil Pressure 40 PSI i Coolant Temp 73 F Battery 123V v Return Engine Runtime 27 4h Y Date 02DEC2014 Time HR MNpm Figure 3 9 Engine Metering Menu Y Next Exercise 09 00p 09Dec
6. Check coolant level Check radiator and fans for obstruction Contact an authorized distributor dealer for service and provide the fault code CoolntTemp O Shutdwn Coolant Temp O Shutdown The ECM reported a problem with the coolant temperature sensor reading O high temperature Check coolant level Check radiator and fans for obstruction Contact an authorized distributor dealer for service and provide the fault code CoolntTemp 3 Shutdwn Coolant Temp 3 Shutdown The ECM reported a problem with the coolant temperature sensor reading 3 high voltage Contact an authorized distributor dealer for service and provide the fault code CoolntTemp 4 Shutdwn Coolant Temp 4 Shutdown The ECM reported a problem with the coolant temperature sensor reading 4 low voltage Contact an authorized distributor dealer for service and provide the fault code CoolntTemp 5 Shutdwn Coolant Temp 5 Shutdown The ECM reported a problem with the coolant temperature sensor reading 5 open circuit Contact an authorized distributor dealer for service and provide the fault code Crank Lost Warning Crank Signal Lost Crankshaft Position Sensor CPS timeout error occurred Contact an authorized distributor dealer for service and provide the fault code Crank Noise Warning Crank Sync Noise Crankshaft Position Sensor CPS synchronization error occurred Contact an a
7. Exercise Diagnostics 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 e ATS connection The controller verifies that the Model RXT ATS interface board is connected e 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 e Coolant level check The coolant level is checked Section 2 Generator Set Operation 19 e Communication integrity tests J1939 RBUS Ethernet and USB are monitored for messages indicating that the controller and wiring are reliable e 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 e 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 e Oi
8. Maintain the coolant level in the coolant overflow bottle between the Hot and Cold markings See Section 1 Service Views for the coolant overflow bottle location Checking and Filling Coolant Note Periodically check the coolant level by removing the radiator s pressure cap Do not rely solely on the level in the coolant overflow bottle Ethylene glycol based long life coolant is recommended Use a coolant mixture of 50 long life coolant and 50 clean softened water to inhibit rust corrosion and prevent freezing Add fresh coolant until the level is just below the overflow tube opening A coolant solution of 5096 ethylene glycol based coolant provides freezing protection to 37 C 34 F and overheating protection to 149 C 300 F A coolant solution with less than 50 ethylene glycol may not provide adequate freezing 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 mix different types and or colors of long life coolants 4 6 2 Cooling System Inspection To prevent generator shutdown or damage because of overheating e Keep the cooling air inlets clean and unobstructed e Inspect the radiator s exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins e Check the hoses and connections for leaks and replace any cracked
9. In Active Y Output 2 In Active t Output 3 In Active f Output 4 In Active y Output 5 In Active i Output 6 In Active x y lt Return 1p6810 Figure 3 22 Programmable Interface Module PIM Status Menu TP 6905 8 15 Section 3 RDC2 Controller Operation 49 3 19 Load Control Menus The Load Control menu displays the status of the load management inputs and outputs and allows a test ofthe load management output relays This menu appears only if a load managmenet device is connected Generator current is displayed as a percent of the maximum generator capacity The load management device 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 referto TT 1609 provided with the load shed kit or TP 6807 RXT Transfer Switch Operation and Installation Manual gt Load gt Generator Control Current j Z Load gt Control 1 5 lt Return 123 ZN Test Outputs Push Select blinking N Input 1 In Active 1 Input 2 In Active 1 Output 1 Add Shed Output 2
10. Operation Residential Light Commercial Generator Sets Ah Mm oo hm ono Model 24RCL Controller RDC2 29001 NATIONALLY REGISTERE KOHLER Power SystemS essere California Proposition 65 A 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 identification numbers in 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 6905 8 15 Table of Contents Product Identification Information oooooccccccnnnccnc n nnn nnn 2 Safety Precautions and Instructions oooocccc
11. PC PCB pF PF ph Y PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt aty R rad RAM RBUS RDO ref rem Res Coml RFI RH RHM rly rms rnd RO ROM rot rpm RS RTDs normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory RS 485 proprietary communications relay driver output reference remote Residential Commercial radio frequency interference round head round head m
12. ure e ue a a a i 23 2 02 SNUIOWAS cata i 23 2 6 3 ATS Communication Errors Li 23 2 6 4 Resetting the Controller after a Fault Shutdown 23 2 655 Event LOG irrita per Seed dan eR pA Cet ee eee et 28 2 7 Model RXT Transfer Switch Operation 000 c cece eee eee eee 28 2 7 1 Source Availability LL 28 2 7 2 ATS Control Sequence of Operation 29 23 Time Delays ovina a 29 2 7 4 ATS Load Control Relay Time Delay 29 Section 3 RDC2 Controller Operation nnn nnn 31 3 1 RDC2 Generator Set Transfer Switch Controller 31 3 2 Controls and Indicators 0 cece eee eee eee eee 31 3 2 1 Controller Keypad III 32 3 2 2 LED Indicators 2 m pik penini PARE Eae ea nnus 32 39 29 LGD Display sz REALE REX E rd RC EA ES 33 3 3 Controller POWOt rues LL ia 34 3 4 Battery Charging ra 34 3 5 Changing Settings css vpi pio eie epexrivbeEu duet 34 3 6 Controller Menus ociosa taria eae ad A ai oe 36 3 7 Main Menu cerit AR LR a A 36 3 8 Overview Menu i 37 3 9 Engine Metering Menu 37 3 10 Generator Metering MENU 38 3 11 Generator Set Information Menu LL 39 TP 6905 8 15 Table of Contents 3 Table of Contents continued 3 12 Genset Run Time Menu 39 3 13 Genset System Menu en 40 9 14 ATS Status MENU a aida daa iii DR 41 3 15 ATS Configuration Menu LL 42 3 16 Date and Time Menu ie ux et che ula
13. 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 Engine oil pan heater Hazardous voltage can cause severe injury or death The engine oil pan heater can cause electrical shock Disconnect power to the engine oil pan heater and allow to cool before working on the oil pan 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 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 8 Safety Precautions and Instructions Hot Parts A WARNING 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 A WARNING Hot
14. Press the Select button to go to the Overview menu 2 Press Select again The active fault is displayed 3 PressSelect Confirm Clear Fault NO is displayed 4 Press the Up arrow button Confirm Clear Fault YES is displayed 5 Press the Select button to enter YES and clear the fault 6 Press the Select Button to return to the overview menu 7 Press AUTO to put the generator set into automatic mode Fault Message Confirm Clear gt Fault NO Press Up arrow button Confirm Clear Fault YES Figure 2 4 Clearing a Fault 24 Section 2 Generator Set Operation TP 6905 8 15 Fault RDC2 AC Sens Loss Warning 1 sec Shutdwn 3 sec Fault OnCue Plus AC Sensing Lost Condition AC Sensing Lost In Auto mode generator output AC sensing is lost Detection begins 10 seconds after crank disconnect Warning after 1 second if no output detected after crank disconnect Shutdown after 3 seconds if voltage was present and then lost Contact an authorized distributor dealer for service Accy PwrOver Warning Accessory Power Overload Accessory Power Overload An over current fault short circuit on the accessory controller power output Contact an authorized distributor dealer for service ATS ComError Warning ATS Communication Error ATS Communication Error Warning is displayed if RXT interface connection is lost See
15. Time Date A 02Dec2014 MM Time 12 34pm Time Format 12hr 24hr Return tp6810 To change the date and time press the Select button See Figure 3 6 for instructions Figure 3 16 Date and Time Menu TP 6905 8 15 Section 3 RDC2 Controller Operation 43 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 load management device and for systems that use the Kohler OnCue Plus Home Networking gt Networking gt Information Status Networking gt Configuration RBUS gt Information Return Figure 3 17 Networking Information Menu 44 Section 3 RDC2 Controller Operation Generator Management System RBUS is a proprietary RS 485 communication protocol The Networking Information menu leads to submenus for network and RBUS communication settings See Figure 3 18 See Figure 3 19 See Figure 3 20 1p6810 TP 6905 8 15 3 17 1 Networking Status Submenu The Networking Status submenu contains settings for OnCue Plus See the OnCue Plus Software Operation Manual for information about the appropriate network settings for OnCue Plus If DHCP is ena
16. frayed or spongy hoses e Check the condition and tension of the drive belt e Check the rubber seal of the radiator s pressure cap and replace a cracked or deteriorated cap Remove dirt and other debris from the pressure cap and filler neck The pressure cap raises the boiling point of the coolant enabling higher operating temperatures If the cap leaks replace it with the same rating type of cap Find the pressure cap rating in Figure 4 4 97 kPa 14 psi Figure 4 4 Pressure Cap Rating 58 Section 4 Scheduled Maintenance 4 6 3 Draining Cooling System The radiator contains a coolant drain valve to drain the cooling system When draining the coolant remove the radiators pressure cap which will allow the entire system to drain and will prevent air pockets from forming and restricting coolant passage to the block 1 Remove the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow through the engine block 2 Open the coolant drain valve and allow the system to drain 3 If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease go to Section 4 6 4 Flushing and Cleaning Ifthe cooling system does not have mineral deposits refill the cooling system as instructed in Section 4 6 5 Filling Cooling System 4 6 4 Flushing and Cleaning For optimum protection drain flush and refill the cooling system at the interval listed in the servi
17. 19 Network Configuration Submenu 46 Section 3 RDC2 Controller Operation Return V tp6804 TP 6905 8 15 3 17 3 RBUS Information Submenu e Model RXT transfer switch The RBUS Information menu contains settings for e Programmable Interface Module PIM remote modules that communicate with the RDC2 controller using RBUS protocol This includes the e Load Shed Kit or RXT combined interface load following optional modules management board Networking gt Networking gt Information Status A 7 A Networking gt Configuration i RBUS gt Modules Connected Information 3 NA ZN lt Return Remote gt Devices t See Figure 3 21 Net Cycle Time 123ms Module Timeouts HHH Module Errors HHH lt Return Figure 3 20 RBUS Information Submenu TP 6905 8 15 Section 3 RDC2 Controller Operation 47 3 17 4 Remote Devices Submenu Check the status of remote devices communicating through RBUS Device types can include e Model RXT ATS e Programmable interface module PIM e Load Shed Kit or RXT combined interface load management board The serial numbers for the PIM and load shed kit are printed on the circuit boards inside the enclosures S N IHHHHHHHEHE S
18. Actual settings may vary Figure 3 13 Genset System Menu tp6804 TP 6905 8 15 3 14 ATS Status Menu The ATS Status menu displays Model RXT transfer switch and source information ATS menus appear if a Model RXT transfer switch is connected to the generator set If no transfer switch is The voltage shown in these menus can be calibrated connected or another model ATS is connected to the Contact an authorized distributor or dealer for service if engine start connections Remote ATS is displayed on calibration is required the ATS Status screen 2 Note If there is no Model RXT transfer Y switch connected to the generator set i ATS Position Remote ATS is displayed and the other Normal screens on this page do not appear ATS Status ZLA Normal Status Not Acceptable t Emerg Status Standby Single phase Three phase y y Voltage Voltage L1 L2 Y Frequency Voltage L2 L3 60 0 Hz 240V A Y Voltage L3 L1 240V y Frequency 60 0 Hz Y Reset Reset Calibration Calib No SZ v Reset lt Return Calib Yes 240 V Figure 3 14 ATS Status Menu with Calibration TP 6905 8 15 Section 3 RDC2 Controller Operation 41 3 15 ATS Configur
19. Add Shed 1 Output 3 Add Shed 1 Output 4 Add Shed 1 Output 5 Add Shed i Output 6 Add Shed 1 lt Return tp6810 Figure 3 23 Load Control Status Menu 50 Section 3 RDC2 Controller Operation TP 6905 8 15 Section 4 Scheduled Maintenance 4 1 General Maintenance A WARNING aS x 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 connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot en
20. Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e 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 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 shorttime 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 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 Peri
21. N IHHHHHHHEE Return lt lt DeviceType gt gt lt lt DeviceType gt gt xx MM Device Status Connected 1 Comm Errors HHHHH Comm Timeouts HHHHH ModBus ID HH i Firmware Ver i Connected Connected Displays date time device was connected MM DD YY 12 12 Disconnected Displays date time of the last successful com f munication Return Figure 3 21 Remote Devices Submenu 48 Section 3 RDC2 Controller Operation TP 6905 8 15 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 the RDC2 controller s user interface PIM Status X Return A personal computer running Kohler9 SiteTech software is required to change the input and output settings Contact an authorized distributor or dealer for service The Kohler OnCue Plus Management System can be used to turn outputs on and off See the OnCue Plus Software Operation Manual for instructions Input 1 In Active ZB Input 2 In Active t Output 1
22. connections and wires Fuel System 5 Years or 2000 hours Fuel lines for leaks Quarterly Fuel regulator pressure Yearly or 120 hours Fuel shutoff valve for leaks and function Ignition System 5 Years or 2000 hours Spark plug wires for cuts abrasions or hardening 3 Years or 500 hours Secondary ignition coil wires 3 Years or 500 hours Spark plugs Generator 3 Years or 500 hours Brushes and collector ring Yearly or 300 hours Not necessary for maintenance free batteries Service more frequently under extremely dusty dirty conditions Long life coolant is recommended 8 Long life coolant is recommended When long life coolant is used the change interval is 5000 hours or 5 years Do not mix coolant types TP 6905 8 15 X Action D Authorized distributor dealer only R Replace as necessary Authorized distributor dealer only R Replace as necessary Section 4 Scheduled Maintenance 53 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 engines CC or CD classification oils even when labeled Heavy Duty or For Natural Gas Engines are not acceptable Multi viscosity synthetic oils are recommended For best performance in colder environments such a
23. 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 Section 2 Generator Set Operation 15 A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective clothing goggles and Battery acid may cause blindness and burn skin A 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 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 itis charging Do not dispose of a battery ina 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 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
24. menu Date MO DA YEAR Event Log gt __ time HR MN event number W S I engine hours event name Press UP and Down arrow but tons to scroll through events DA N Date MO DA YEAR time HR 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 Informational Notice Figure 2 6 Event Log TP 6905 8 15 2 7 Model RXT Transfer Switch Operation The RDC2 generator set transfer switch controller manages automatic transfer switch ATS functions when connectedto a Kohler Model RXT transfer switch through the ATS interface board Refer to the Model RXT Operation Installation Manual for information about the transfer switch operation 2 7 1 Source Availability The Model RXT transfer switch supplies voltage sensing data to the RDC2 controller through the ATS interface board If the source voltage falls below the undervoltage dropout setting the source is considered to have failed See Figure 2 7 Accuracy x 596 9096 of Pickup 90 of Nominal Undervoltage Dropout Undervoltage Pickup Figure 2 7 Voltage Sensing Parameters The RDC2 controller also has a set of power system LEDs below the pushbuttons The power system LEDs indicate which power sources are available and which source is supplying power to the building See Figure 3 1 Note The power system LEDs operate
25. meter kilograms per cubic meter kilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level A weighted low water level low water temperature meter milli 1 1000 mega 108 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQmilliohm MOhm MQmegohm MOV MPa mpg mph MS ms nat gas NBS metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards 70 Appendix NC NEC NEMA NFPA Nm NO no nos NPSC NPT NPTF NR ns OC OD OEM OF opt OS OSHA OV oz P PP
26. only if a Model RXT transfer switch is connected They will not operate if a Model RDT transfer switch is used Section 2 Generator Set Operation 29 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 the emergency source becomes available 5 The normal to emergency time delay times out 6 The transfer switch transfers to the emergency Source 7 The load control contact time delay times out 8 The load control contact closes Normal Source Returns 1 The emergency to normal time delay times out 2 The contactor transfers to the normal source 3 The engine cooldown time delay times out 4 The generator is signaled to stop Time Delay Engine Start 3 seconds 2 7 3 Time Delays Time delays are factory set to the values shown in Figure 2 8 An authorized distributor dealer can adjust time delays using a personal computer and Kohler SiteTech software Time delays described in this section operate only when the controller is connected to a Kohler Model RXT transfer switch The engine start and load transfer time delays prevent engine start and load transfer caused by brief variations in the utility power source 2 7 4 ATS Load Control Relay Time Delay The load control time delay allows delayed startin
27. 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 KOHLER Power Systems Genset Model Spec Number Serial Number Material Number Service Duty Voltage Alt Model Insulation MFG Date Figure 2 Nameplate Typical Introduction 9 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 24RCL G4 228 Installation Manual Generator Set TP 6906 Operation Manual KG2204 Engine TP 6901 Service Manual Generator Set TP 6907 Service Manual KG2204 Engine Mechanical TP 6902 Service Manual Engine ECM Diagnostics TP 6903 Parts Catalog KG2204 Engine TP 6904 Parts Catalog 24RCL Generator Set TP 6908 Installation Instructions Programmable Interface Module PIM TT 1584 Operation Manual OnCue Plus Software TP 6928 Operation Installation Manual RXT ATS TP 6807 Operation Installation Manual RDT ATS TP 6345 Figure 3 Related Literature 10 Introduction TP 6905 8 15 Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest authorized Kohler distributor or dealer e Consult the Yellow Pages under the h
28. set only when all guards and electrical enclosures are in place A WARNING 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 A DANGER Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel A CAUTION n C j 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 A WARNING 4 Airborne particles Can cause severe injury or blind ness Wear protective goggles and clothing when using power tools hand tools or compressed air 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
29. the OFF button on the RDC2 generator set controller Reconnect the generator set engine starting battery negative lead last Reconnect the power for the battery charger Start the generator set and check for leaks around the oil filter Stop the generator set and tighten the oil filter to stop any leaks Reinstall the housing side panel 5 Stop the generator set Check the oil level Add oil as necessary to bring the level up to the Full mark Note Too high an oil level causes high oil consumption and engine carbonizing Too low a level damages the engine 6 Reset the maintenance timer on the RDC2 a In the Overview menu step down to theGenset Run Time menu Press the Select button and then step down to the Next Maintenance screen Press the Select button Press the Up arrow button so that Reset Maint Timer Yes is displayed Section 4 Scheduled Maintenance 55 4 4 Air Cleaner A 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 t
30. the Select button The selected setting flashes 6 Press the up or down arrow buttons to increase or decrease the setting 7 When the desired setting is shown press Select The value stops flashing If there are additional adjustable settings on the screen the next setting flashes For example in the date menu the year month and day can be adjusted 8 Repeat steps 5 through 7 for each setting on the Screen 9 Press the down arrow to step to the next screen 10 To exit press the down arrow button until Return is displayed Press the Select button to exitthe menu 11 Press the AUTO or OFF button to exit the main menu Note If no buttons are pushed the controller exits the menus and returns to the generator set status display after 5 minutes TP 6905 8 15 Changing Settings on the RDC2 Controller 1 Press the Select button to enter the main menu Overview gt Display 12h 2 Press the down arrow button until the desired menu is displayed See Figure 3 7 Date and Time are used for this example Date Press Display and Time 3 Pressthe Select button to enter the Date and Time menu Press Date Display 05Dec2013 4 To change the date and time settings press the Select button again The year will flash Displ Date isplay 2 ud 05Dec2013 5 Press the up or down arrow buttons to chan
31. the risk of electrocution 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 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 TP 6905 8 15 Drive Belt Check the belt condit
32. 1 Service Views for oil fill oil check and oil filter locations Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner Note Reset the maintenance timer on the RDC2 controller after changing the oil TP 6905 8 15 Oil Change Procedure Whenever possible drain the oil while it is still warm 1 Drain the oil a Press the OFF button on the RDC2 generator set controller Disconnect the power for the battery charger Disconnect the generator set engine starting battery negative lead first Remove the housing side panel Remove the plug from the oil drain fitting and install a drain hose Open the oil drain valve on the engine Allow time for the engine oil to drain completely Close the oil drain valve Replace the oil drain plug 2 Replace the oil filter a Remove the oil filter by rotating it counterclockwise with an oil filter wrench Clean any surfaces that the oil filter contacts Apply a light coat of clean oil to the gasket ofthe new oil filter Lightly thread the new oil filter by hand until you feel resistance Then tighten the filter an additional 3 4 turn with an oil filter wrench Torque 25 Nm 18 4 ft lbs 3 Fill with oil Use 5W 30 for oil selection and Figure 4 2 for oil capacity Model Oil Capacity L at so 420644 4 2 4 4 Figure 4 2 Oil Capacity TP 6905 8 15 4 Check for leaks a f Press
33. 2014 Y Next Maintenance 150 h or Mar2015 Y SW Version 4 03 lt Return e 1p6809 Figure 3 8 Overview Menu TP 6905 8 15 Section 3 RDC2 Controller Operation 37 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 Generator gt O Metering A Three phase Voltage Calibration A DANGER Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel The voltage calibration mode can be entered from the Generator Metering menu Contacta Kohler 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 Figure 3 10 Single phase Volts L1 L2 240 V i t Volts L2 L3 Frequency 240 V 60 0 Hz i A Volts L3 L1 240 V t Frequency 6 O Hz gt Y Reset Calibration Reset Calib No N Return Reset Calib Yes Figure 3 10 Generator Metering
34. 8 15 4 2 Service Schedule System Component or Procedure General Maintenance See Section Procedure Visually Inspect Check Change Frequency Fluid leaks Daily Engine oil level Daily Coolant level Daily Obstructions or combustible materials near exhaust outlet Weekly Leaks hissing and gas odor Weekly Bolts and nuts for tightness Quarterly or 20 hours Engine oil and filter y Yearly or 120 hours Belts and belt tension Yearly or 120 hours Inspect wiring for cuts abrasions or corrosion 5 Years Inspect vacuum lines and fittings Air Intake System 5 Years Air cleaner element t Quarterly or 20 hr 3 years or 400 hr Hours shown Air induction for leaks X 3 Years or 500 hours Intake manifold for vacuum leaks Cooling System X 3 Years or 500 hours Clamps and hoses tightness and leaks Daily Radiator exterior Yearly or 120 hours Coolant condition 3 Years or 500 hours Hoses condition Electrical System 3 Years or 500 hours Battery charge Yearly or 120 hours Battery fluid level 3 Yearly or 120 hours Battery for cracks and corrosion Yearly or 120 hours Clean battery cables X Exhaust System Yearly or 120 hours Exhaust manifold for leaks 5 Years or 2000 hours Exhaust piping for leaks 5 Years or 2000 hours Check HEGO oxygen sensor
35. ARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin 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 Ib 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 parti
36. Menu 38 Section 3 RDC2 Controller Operation 1p6810 TP 6905 8 15 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 that the controller is being replaced A personal computer running Kohler SiteTech software is required to enter the generator set model number and serial numbers on a replacement controller Contact an authorized Kohler distributor dealer for service Genset M N 24RCL 8 Genset S N HERA or Al Controller S N HHHHHHHH Return Genset gt Information 1p6810 Figure 3 11 Generator Set Information Menu TP 6905 8 15 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 generator set operation until maintenance is required The estimated date for the next scheduled maintenance is also displayed The maintenance reminder intervals are based on the engine manufacturer s recommendation for changing the oil Refer to Section 4 Scheduled Maintenance for maintenance instructions After changing the oil and performing other recommended maintenance go to the Over
37. RCL 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 GM91044 MA2 Figure 1 Model 24RCL Generator Set TP 6905 8 15 Introduction Nameplate Figure 2 shows atypical generator set nameplate Copy the model serial and specification numbers from the nameplate into the spaces
38. SO external Fahrenheit female flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight height by width by depth hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second International Building Code integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 210 bytes Kohler communication protocol kilogram Appendix 69 kg cm2 kgm kg m3 kHz kJ km kOhm kQ kPa kph kV kVA kVAR m3 m3 hr m9 min mA man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilograms per square centimeter kilogram
39. Section 2 6 3 Check communication wiring between transfer switch interface board and generator set ATS PhaseRot Warning ATS Phase Rotation Mismatch ATS Phase Rotation Mismatch Transfer switch phase rotation does not match ATS will not transfer Correct the ATS connection Refer to the ATS Installation manual wiring diagrams and labels on the transfer switch Aux Input Shutdwn Auxiliary Input Auxiliary Input An optional customer connected input is closed Digital input from optional PIM Check customer supplied equipment Batt Chg FIt Warning Battery Charger Fault Engine starting battery voltage rises above 150 18 Volts of the battery voltage setting for more than 10 seconds Inhibited during the engine crank cycle Clears when the battery voltage returns to an acceptable level Check external battery charger Battery CrLo Warning Critically Low Battery Voltage Engine starting battery voltage falls below 11 V for more than 10 seconds Inhibited during the engine crank cycle Clears when the battery voltage returns to an acceptable level Check the battery rating and condition Check the battery charger operation Charge or replace the battery Battery High Warning High Battery Voltage Engine starting battery voltage rises above 133 16 V of the battery voltage setting for more than 10 seconds Inhibited during the engine crank cycle Clears when t
40. Voltage L3 L1 Generator Voltage High Output voltage exceeds 120 of the system nominal voltage for more than 2 seconds Contact an authorized distributor dealer for service Volts L3 L1 Low Shutdwn Low Generator Voltage L3 L1 Generator Voltage Low Output voltage falls below 8096 of the nominal system voltage for more than 10 seconds Figure 2 5 Controller Fault Messages 28 Section 2 Generator Set Operation Reduce the load by turning off appliances and restart the generator set Contact an authorized distributor dealer for service TP 6905 8 15 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 of the event a code to indicate whether the event was a warning W shutdown S or informational notice 1 the engine hours at the time of the event and the event description Procedure to View Event History 1 Press Select to enter the main menu 2 Press the down arrow to step down to the event log 3 Press Select to display the most recent event 4 Press the down arrow to step to the next event 5 Use the up and down arrow buttons to view events 6 Press the Select button to exit the event log To stop viewing the event history before the last event press the select button to return to the main
41. achine screw relay root mean square round read only read only memory rotate rotating revolutions per minute right side Resistance Temperature Detectors RTU RTV RW SAE scfm SCR S Sec SI SI EO sil SMTP SNMP SPDT SPST spec specs Sq Sq cm Sq in SMS SS std stl tach TB TCP TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo typ UF UHF UIF UL UNC UNF univ URL US VAC VAR VDC VFD VGA VHF WCR w WO w o xfmr remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer simple mail transfer protocol serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor tolerance turbocharger typical same in multiple locations un
42. ands are ignored Lights for 2 seconds then flashes every 2 seconds when the generator set and controller are off Remote start stop commands have no effect The exercise cycle will not run In Auto mode OFF LED flashes quickly to indicate a fault shutdown Attention required Identify and correct the fault condition before resetting the controller Lights when the generator is in automatic standby mode Generator set will respond to engine start and stop commands from the controller for example exercise start and stop commands an ATS or OnCue Plus Time delays operate as described in Section 2 4 Utility Power Available Lights when utility power is available Building on Utility Power Lights when the building load is connected to utility power through the RXT transfer Switch Generator Power Available Lights when generator power is available Building on Generator Power Lights when the building load is connected to generator power through the RXT transfer Switch These LEDs operate only if a Model RXT transfer switch is connected Figure 3 3 RDC2 Controller LED Operation 32 Section 3 RDC2 Controller Operation TP 6905 8 15 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 Figure 3 4 W
43. arameters and enter the information If an error occurs while setting a parameter an error message is displayed and then the controller exits the edit mode Previous settings are preserved Networking gt Information Networking gt Status A Note 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 enter it into the OnCue Plus software To reset the password follow the instructions in Figure 3 19 Note The password is displayed for only 10 seconds Be sure to write down the password and serial number Anew password is generated each time the reset password procedure is performed If the password is reset after the OnCue Plus system has been set up the connection will be lost Disconnect the battery power to the controller wait a minute then reconnect power Networking Configuration Reset OnCue Password Reset OnCue Password No NY DAD UP arrow for YES Down arrow for NO Reset OnCue Password Yes Press Select to enter YES G or NO as displayed New DHCP password is displayed for approximately 10 seconds Enabled A v S N HEHHBHHE New PW Figure 3
44. atigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e 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 the building 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 CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools 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 Atthe interval specified in the service schedule inspect the exhaust system components e
45. ation 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 if necessary Changing ATS Configuration Settings To enable editing press the select button The value flashes 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 value to be changed Repeat the adjustment process until all values are correct Press the down arrow until Return is displayed Press the select button to return to the main menu 42 Section 3 RDC2 Controller Operation ATS gt Configuration A Normal Freq 60 0 Hz r Normal Voltage 240 0 V Emerg Freq 60 0 Hz f Emerg Voltage 240 0 V Emerg Engine Start 3 sec t Transfer From Normal 3 sec 1 Transfer From Emerg 120 sec l lt Return Figure 3 15 ATS Configuration Menu tp6810 TP 6905 8 15 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 Date and 7
46. bled IP parameters are not displayed If DHCP is disabled i e ifa 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 17 2 Networking gt Networking gt Information Status OnCue Status Connected y A Y DHCP Enabled 1 IP Address THEE THER HHH ARA Subnet Mask HHH HHH HHH HEU Gateway HHH HHH AHH HHH Y DNS 1 HHH HHH HHH HE f DNS 2 HHH HHH HIE HE Y Ethernet Status Disconnected Y OnCue Server HHH HHH ARA HEU Return Figure 3 18 Network Status Submenu TP 6905 8 15 tp6804 Section 3 RDC2 Controller Operation 45 3 17 2 Networking Configuration Submenu OnCue Plus Password The networking Configuration menu includes settings used for communication with the Kohler OnCue Plus Generator Management System For most applications DHCP is enabled and the IP settings cannot be changed from the controller keypad If DHCP is enabled IP parameters are not displayed If DHCP is disabled i e if a static IP address is required then the IP parameters can be modified For applications that require static IP addresses press and hold the select button to enable editing disable DHCP and then step to the next p
47. buildings 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 A 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 Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels TP 6905 8 15 Propane LPG Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a ro
48. ccn nnn nn nnn 5 Introduction iii A a a a a a 9 Service Assistance 2 cp A Howie Se ee alk a a MUR RE 11 Section 1 Service VIEWS Jl y i eu 49 ec au ERENERRUMSDUURREUE GG A TERRE RR wee RO M en 13 Section 2 Generator Set Operation oooooccccccnn n nnn nnn 15 2 1 Operating Area nd REIR ted eb Et Rs 15 2 2 Prestar Checklist usen Ren ERREUR RR ERE ER ORA 15 2 3 Exercising the Generator Set 0 0 cece cece eee eee eee eee ene 17 2 4 Generator Set Operation 17 2 4 1 Local Starting and Stopping 0 cee 17 2 4 Automatic Starting and Stopping 0 cc cece eee eee ees 17 2 4 8 Remote Starting and Stopping 0 cece eee 17 2 4 4 Engine Start Crank Cycle LL 17 2 45 Engine Cooldown cc cece cette nn 17 2 4 6 Automatic Operation with Model RXT Transfer Switch 17 2 4 7 Automatic Operation with Other Transfer Switches 18 2 55 E A 18 2 5 1 Unloaded Cycle Exercise with Complete System Diagnostics 18 2 5 2 Unloaded Full Speed Exercise LL 19 2 5 8 Loaded Full Speed Exercise with RXT only LL 19 2 5 4 Shutdown During Exercise 0 cece eee eee eee eee eens 19 2 5 5 Power Failure During Exercise 19 2 5 6 Exerciser Reset ay ike ci 19 2 5 7 Setting the Exerciser at Power up cece eee eee eee ees 19 2 5 8 Changing the Exercise Setting 20 2 6 Pauly rra ditties Ai A gan OS nares 23 2 6 1 Warnings
49. ce schedule Flushing and Cleaning Procedure 1 Flush the system with clean water 2 Drain clean and flush the coolant overflow bottle 3 Refill the cooling system as instructed in Section 4 6 5 4 6 5 Filling Cooling System Coolant Capacity L qt Generator Set 12 4 13 1 Figure 4 5 Coolant Capacity Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until engine has cooled 1 Closethe radiator s coolant drain valve and tighten the hose clamps 2 Fill the radiator with the recommended coolant mixture of 5096 ethylene glycol and 50 clean softened waterto inhibit rust corrosion and prevent freezing The coolant capacity is shown in Figure 4 5 TP 6905 8 15 3 Operate the engine with the radiator cap removed until the thermostat opens and the upper radiator hose becomes hot 4 Stop the engine and allow it to cool 5 Add coolant to the radiator to just below the overflow tube on the filler neck See Section 1 Service Views for the overflow tube location 6 Replace the radiator s pressure cap 7 Maintain the coolant level in the coolant overflow bottle between the Hot and Cold markings See Section 1 Service Views for the coolant overflow bottle location 4 7 Ignition System A WARNING 4 Airborne particles Can cause severe injury or blindness Wear protective goggles and clothing when usi
50. controller The RDC2 controls the following power system components e Model 24RCL generator set e Model RXT automatic transfer switch ATS e Load management device e Programmable interface module PIM RDC2 Controller features include e Two line x 16 character backlit LCD display with adjustable contrast e OFF AUTO and RUN generator set master control buttons e Generator set status indicating LEDs OFF AUTO RUN e Up Down and Select buttons for navigation through menus and adjustments e Power system indicator LEDs to show utility and generator source status and to show which source utility or generator is supplying power to the building TP 6905 8 15 3 2 Controls and Indicators Figure 3 1 illustrates the keypad display and indicators on the controller s user interface 2 line LCD display Up button Select button Down button RUN button and LED Generator power available LED Generator supplying power to the building LED Utility supplying power to the building LED Utility power available LED OFF button and LED AUTO button and LED These LEDs operate only if a Model RXT transfer switch is connected 4 2 3 4 5 6 7 8 9 10 GM77569 Figure 3 1 RDC2 User Interface Section 3 RDC2 Controller Operation 31 3 2 4 Controller Keypad The Run Off and Auto buttons contro
51. 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 restartthe 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 ATS transfers 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 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 disp
52. cularly when itis charging Do not dispose of a battery ina 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 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 TP 6905 8 15 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 Refer to this section for general battery information and maintenance Also consult the battery manufacturer s instructions for battery maintenance All generator set models use a negative g
53. 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 TP 6905 8 15 Accidental Starting A 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 A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin
54. derfrequency ultrahigh frequency user interface Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal uniform resource locator web address undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with write only without weight transformer TP 6905 8 15 TP 6905 8 15a O 2014 2015 by Kohler Co All rights reserved KOHLER Power Systems 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 service and sales dealer in the US and Canada Call 1 800 544 2444 or visit KOHLERPower com
55. dures in this manual do not explain how to correct the problem contact an authorized Kohler distributor dealer Maintain a record of repairs and adjustments performed on the equipment Use the record to help describe the problem and repairs or adjustments made to equipment 5 2 USB Port A USB port is located on the front of the controller Use a USB cable with a mini B connector to connect the controller to your personal computer laptop Some controller settings can be adjusted using a laptop computer with Kohler9 SiteTech software SiteTech software is available to Kohler authorized distributors and dealers See TP 6701 SiteTech Software Operation Manual for more information 5 3 Fault Messages The RDC2 controller displays fault messages to aid in troubleshooting Fault messages 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 TP 6905 8 15 Section 5 Troubleshooting 5 4 Circuit Protection If the generator set circuit breaker trips or the fuses blow repeatedly contact an authorized Kohler distributor dealer for service 5 4 1 Load Circuit Breaker The load circuit breaker interrupts the generator output inthe event of afaultin the wiring between the generator and the load If the circuit breaker trips reduce the load and switch the breaker backto the ON position Refer to th
56. e DUC ea 43 3 17 Networking Information Menus II 44 3 17 1 Networking Status Submenu LL 45 3 17 2 Networking Configuration Submenu OnCue Plus Password 46 3 17 3 RBUS Information Submenu LL 47 3 17 4 Remote Devices Submenu LL 48 3 18 Programmable Interface Module PIM Menus eere 49 3 19 Load Control Menus err 50 Section 4 Scheduled Maintenance nnn nnn nnn 51 4 1 General Maintenance e 51 42 Service Schedule ccd ee gateway ood eae ea UD EP EY RE 53 4 3 Lubrication System i5 rd A ii 54 4 3 1 Qil Specifications iii a T am 54 4 3 2 r Oil Checks ia Lom LERRA uote 54 43 9 Oil Additions uste ERE ve P xa md 54 43 4 Oil and Filter Change 54 474 Air Cleaner tard tact head Rett get ea hee ated ee ees 56 45 Exhaust System caprino cde cacy PER EIL EET T REM e Ere en Eg 56 4 6 Cooling System aire DRuEPT e de aequ aire x REY E Roh 57 4 6 1 Checking and Filling Coolant sese 58 4 6 0 Cooling System Inspection 0 0 ccc cece 58 4 6 3 Draining Cooling System 58 4 6 8 Flushing and Cleaning 58 4 65 Filling Cooling System 58 47 Ignition Systemi cip AAA e AR E E 59 4 8 gt Battery nit A A AA C ERA Eh 61 4 8 1 Checking Electrolyte Level cece cece eee eee eens 62 4 8 2 Checking Specific Gravity 62 49 Storage Procedure 0c cece eee nn 63 Section 5 Troubleshooting wee se we Boe weed
57. e or replace the battery Battery connection poor Clean and tighten the battery connections Spark plug wire connection loose Check the spark plug wires Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary Fuel pressure insufficient Check the fuel supply and valves Engine malfunction Contact an authorized Kohler distributor dealer No AC output AC circuit breaker in the OFF position Place the circuit breaker in the ON position AC circuit breaker tripping because of overload Reduce the load on the generator set AC circuit breaker tripping because of short circuit Contact an authorized Kohler distributor dealer for service Low output or excessive drop in voltage Generator set overloaded Reduce the load Generator set stops suddenly Low oil pressure shutdown Check for oil leaks Check the oil level and add oil if necessary Out of fuel Check fuel supply Overcrank shutdown Reset the controller If the overcrank fault occurs again contact an authorized Kohler distributor dealer Blown fuse s Replace the fuse If the fuse blows again contact an authorized Kohler distributor dealer Overspeed shutdown Reset the controller If the overspeed fault occurs again contact an authorized Kohler distributor dealer Generator set is OFF Press the RUN button to start the en
58. e service views in Section 1 for the location of the circuit breaker 5 4 2 Fuses Always identify and correct the cause of a blown fuse before restarting the generator set Refer to Figure 5 1 Troubleshooting Chart for conditions that may indicate a blown fuse Obtain replacement parts and service from an authorized Kohler distributor dealer Fan Fuses Three 30 amp fan fuses are located in the fan fuse and relay box See Section 1 Service Views for location 5 4 3 Controller Internal Circuit Protection The controller is equipped with internal circuit protection Press OFF to reset Section 5 Troubleshooting 65 5 5 Generator Set Troubleshooting Figure 5 1 contains generator set troubleshooting diagnostic and repair information Check for loose connections before replacing parts Problem The generator set does not crank Possible Cause Battery weak or dead Corrective Action Recharge or replace the battery Battery connections reversed or poor Check the connections Blown fuse s Replace the fuse Contact an authorized Kohler distributor dealer for service if fuse blows repeatedly Generator set is OFF Press the RUN button to start the engine or press AUTO to allow remote starting The generator set cranks but does not start starts hard lacks power or operates erratically Air cleaner clogged Clean and or replace the air cleaner Battery weak or dead Recharg
59. eading Generators Electric e Visit the Kohler Power Systems website at KohlerPower com e Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outsidethe 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 TP 6905 8 15 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 Service Assistance 11 Notes 12 Service Assistance TP 6905 8 15 OANDABRWN 8 7 SERVICE SIDE 25 NON SERVICE SIDE Oil check dipstick Oil fill location on valve cover See cooling
60. 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 Servicing the engine oil pan heater Heated components can cause severe injury The oil pan heater will rapidly become hot when energized Do nottouch the oil pan heater while it is hot Disconnect power to the engine oil pan heater and allow to cool before servicing it or nearby parts 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 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 6905 8 15 This manual provides operation instructions for Model 24
61. essed the controller returns to the status display after 5 minutes Section 3 RDC2 Controller Operation 3 6 Controller Menus The following sections showthe RDC2 controller menus and submenus Use the Select button and the up and down arrow buttons to navigate the menus as shown in the diagrams Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable If a setting on the controller display is flashing edit mode has been enabled Pressthe OFF or AUTO button to exit the edit mode 3 7 Main Menu Press the Select button once to bring up the main menu Overview 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 controller will exit the main menu after 5 minutes if no buttons are pressed To exit the main menu immediately press the controllers OFF or AUTO button Status Overview gt Displays 1 2h NA ES Press the Up and Down arrow buttons to move between menus Press OFF or AUTO to exit the menus Engine Metering ATS Configuration Generator gt Metering
62. g of large motor loads such as air conditioners preventing simultaneous starting of large motors after transfer to the generator set The load control time delay is fixed at 5 minutes It is not adjustable The load must be connected to the load control output on the interface board of the Model RXT transfer switch See the transfer switch operation and installation manual for connection instructions Description Time delay after utility source is lost until the engine start cycle begins Guards against starting the generator set because of a brief change in the utility source Transfer Normal to Emergency 3 seconds Time delay after emergency source becomes available until transfer to emergency source 2 minutes Transfer Emergency to Normal Time delay after the utility source returns until transfer back to normal Ensures that the the utility source is stable before transferring from the emergency source Load Control 5 minutes Figure 2 8 Time Delays 30 Section 2 Generator Set Operation See Section 2 7 4 Allows delayed connection of selected loads to the generator set to prevent simultaneous starting of large motors after transfer to the emergency source Recommended for delayed starting of air conditioners TP 6905 8 15 Section 3 RDC2 Controller Operation 3 1 RDC2 Generator Set Transfer Switch Controller Model 24RCL generator sets are equipped with the RDC2 generator set transfer switch
63. ge the year FX Date Display pay 05Dec2014 NE 6 When the correct year is shown press the Select button The year is saved and the next setting month flashes Display Date O P 05Dec2014 7 Repeat steps 5 and 6 using the arrow and select buttons to set the month and the date Figure 3 6 Changing Settings TP 6905 8 15 8 When the correct date is shown press the Select button The saved date is shown Displ Date isplay 2 vid 03Jan2014 9 Press the down arrow button to step to the next menu Press Time Display 01 49pm 10 Repeat steps 5 and 6 using the arrow and select buttons to set and save the time Note To change from am to pm press the up arrow key to increase the hour until the correct hour and pm is displayed 11 Repeat to set the time format to 12 hr or 24 hr 12 Press the down arrow button Return is displayed lt Return Press aZ Display 13 Press Select to return to the Date and Time menu Date Display and Time 14 Press the Up or Down arrow buttons to step to a different menu 15 Press Auto to signal the controller to exit the menus and return to the generator set status display Press IO AUTO Genset State Display Standby Note If no buttons are pr
64. gine or press AUTO to allow remote starting Remote stop command received from a remote Switch ATS or OnCue Plus Check the remote switch position Engine malfunction Contact an authorized Kohler distributor dealer Fans run after engine shuts down Figure 5 1 The fans continue to run for 2 minutes after the engine shuts down to evacuate the engine compartment General Troubleshooting Chart 66 Section 5 Troubleshooting None TP 6905 8 15 5 6 Controller Troubleshooting Figure 5 2 contains basic troubleshooting information for the RDC2 controller Problem Possible Cause Controller LCD Low or no battery voltage display is off Corrective Action Check connections Check generator set battery See Figure 5 1 Controller display Backlight turns off after about 1 minute with no backlight is off activity Backlight will turn on when a button is pressed or the generator set starts Loss of Bad connections communication to accessory modules Check wiring and connections Verify 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 management Bad connections relays do not operate Check wiring and connections Verify that cable size and length of run comply with the instructions in the Installation manual Low
65. gine 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 field or exciter armature When shorted the alternator field and exciter armature become hot enough to cause severe burns TP 6905 8 15 Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when itis 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 A WARNING Risk of fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Section 4 Scheduled Maintenance 51 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 vapo
66. he battery voltage returns to an acceptable level Check the battery rating and condition Check the battery charger operation Battery Low Warning Low Battery Voltage Engine starting battery voltage falls below the battery voltage setting typically 12 5 volts for more than 90 seconds when the engine is not running Inhibited during the engine crank cycle Clears when the battery voltage returns to an acceptable level Check the battery rating and condition Check the battery charger operation Charge or replace the battery Chk DateTime Warning Verify Date Time Setting The time and date have not been set on the generator controller Enter the date and time using the RDC2 controller See Figure 3 8 and Figure 3 16 Coolant Lvl Low Shutdwn TP 6905 8 15 Low Coolant Level Shutdown The coolant level switch input has been activated Check coolant level Check radiator hoses for leaks Contact an authorized distributor dealer for service Section 2 Generator Set Operation 25 Fault RDC2 Fault OnCue Plus Condition Check CoolTempHigh Warning Ect Higher Than Expected 1 Coolant temperature is too high Check coolant level Check radiator and fans for obstruction Contact an authorized distributor dealer for service and provide the fault code CoolTemp Vhi Shutdwn Ect Higher Than Expected 2 Coolant temperature is extremely high
67. he cooled down temperature level or if the temperature rises above the high limit during the cooldown cycle The electric fans continue to run fortwo minutes after the engine shuts down to evacuate the engine compartment If atransfer 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 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 Automatic Stop 1 When the utility source is restored the Eme
68. he 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 A WARNING Risk of fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Atthe 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 could cause poor performance Replace a damaged air cleaner element Follow the procedure described below Air Cleaner Service Procedure A dry type air cleaner silences and filters the intake air The air intake silencer assembly connects to the intake manifold via a rubber hose Refer to Figure 4 3 during this procedure 56 Section 4 Scheduled Maintenance 1 Air Cleaner Cover Figure 4 3 Air Cleaners 1 Release the retaining clips to open the cover and then remove the air cleaner element 2 Tap the element lightly against a flat surface to dislodge loose surface dirt Do not clean the element in any liquid or use compre
69. hen the system is in AUTO the LCD display scrolls through the status messages shown in Figure 3 5 When a fault or warning condition exists the controller will show the corresponding message See Section 2 6 for more information on fault and warning messages Controller menus display power system information including status information for the engine generator and optional RBUS accessories exercise settings and event history Some menus allow changes to the controller settings See Sections 3 6 through 3 19 for menu diagrams Active Alert Y Genset Status Running Y Voltage 240V Freq 60 0Hz Engine 123F Oil Pressure 40 psi Y 12 3V Engine Runtime 27 4h Y Date 02DEC2014 Time HR MNpm Battery Sample data shown 1p6810 Figure 3 4 Autopaging Displays Generator Running TP 6905 8 15 The display contrast is adjustable Navigate to the Genset System menu and step down to the Contrast screen Press the Select button and then use the up and down arrow buttons to adjust the contrast See Section 3 5 Changing Settings and Section 3 11 Generator Set System Menu The display backlight turns off after about a minute of no activity The backlight turns on when a button is pressed or when the generator set starts Genset Status Standby Engine Runtime 27 4h Y Date 02DEC2014 Time HR MNpm
70. ieee De ee ee xr ne eee wee wee ee eee 65 BAT ntroductiom ti A bes 65 5 2 USB PO ria a a 65 5 3 Fault Messages iii er xp ERR E Ra ER ee 65 5 4 Circuit Protection RI 65 5 4 1 Load Circuit Breaker nnana 65 5 4 2 Euses TA eR aerei edam Ee Pr qeu 65 5 4 8 Controller Internal Circuit Protection 65 5 5 Generator Set Troubleshooting eee 66 5 6 Controller Troubleshooting LL 67 Appendix A Abbreviations oooooccccccnnncc ehh Hh hh eh 69 4 Table of Contents TP 6905 8 15 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 A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property
71. 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 Safety Precautions and Instructions 7 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 battery charging 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
72. ion of the water pump and battery charging alternator belt 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 e Check for corroded or broken metal parts and replace them as needed TP 6905 8 15 e Check that there are no combustible materials near the exhaust outlet e Check that the exhaust outlet is unobstructed 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 Section 2 Generator Set Operation 17 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 exerciser 2 4 Generator Set Operation 2 4 1 Start Press the RUN button to immediately start the generator set Local Starting and Stopping 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 u
73. l 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 3 Loaded Full Speed Exercise with RXT only A loaded exercise starts the generator set ramps up to full speed andthen transfers the electricalload 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 bythe RDC2 controller a Model RXT transfer switch must be connected to the 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 Kohler Model RXT program the exercise at the transfer switch controller Refer to the transfer switch operation manual for instructions 20 Section 2 Generator Set Operation 2 5 4 Shutdown During Exercise The following advanced diagnostic operation applies to RDC2
74. l 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 operation instructions 3 2 2 LED Indicators LEDs above the RUN OFF and AUTO buttons indicate the mode of operation as shown in Figure 3 2 The RDC2 controller also has a set of power system LEDs below the pushbuttons The power system LEDs indicate which power sources are available and which source is supplying power to the building based on the position of the Model RXT transfer switch See Figure 3 1 Note The power system LEDs operate only if a Model RXT transfer switch is connected They will not operate if a Model RDT transfer switch is used Button Button Function Starts the generator set The engine start time delay is ignored Stops the generator set The cooldown time delay is ignored During the engine crank cycle pressing OFF will stop the crank cycle Press OFF to clear faults and reset the controller AUTO Down arrow Places the generator set in Automatic standby mode Use to navigate through menus and change settings This manual contains instructions to navigate the Select controller menus and adjust settings on the RDC2 controller Up arrow Figure 3 2 Pushbutton Operation LED Operation Lights when the generator set has been started locally by pressing the RUN button Remote start and stop comm
75. layed with the year flashing Use the up or down arrow key to step to the current year 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 TP 6905 8 15 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 Pressthe Select button to save the hour and move to minutes 6 Use the up or down arrow button to change the minutes 7 Press Selectto 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 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 The exercise will run every 7 days at the same time 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 Setthe date and time on the controller before setting the exercise schedule Set the exerciser to automatically runthe generator setfo
76. ltage The ECM reported an Engine Air Temperature Manifold Absolute Pressure Sensor TMAP error Contact an authorized distributor dealer for service and provide the fault code Invalid Csum Warning Flash Csum Invalid An ECM error occurred Contact an authorized distributor dealer for service and provide the fault code Lo Crank Vit Warning Low Cranking Voltage Low cranking voltage Battery voltage falls below 60 of system battery voltage for more than 6 seconds while the starter is engaged Charge or replace the battery Locked Rotor Shutdwn Locked Rotor No engine rotation is sensed during cranking Shuts down 3 seconds after the fault is detected Check the battery Check for loose connections Check for obstruction of alternator or engine Contact an authorized distributor dealer for service MainPwrOverL Shutdwn Main Power Overload Main power overload An over current fault on the 70 controller power output short circuit Check for shorted run relay Check wiring for short circuits Contact an authorized distributor dealer for service Maint Req d Warning Maintenance Required Warning Engine maintenance is due Check the maintenance schedule in the operation manual for tasks such as changing the oil spark plugs or the air filter Not in Auto Warning Not In Auto The generator set is not in Automatic standby mode Remote start and stop c
77. ng power tools hand tools or compressed air A WARNING Az 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 TP 6905 8 15 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 set engine starting battery negative lead first 4 Use a cloth to wipe dirt and oil away from the area around each of the four spark plug wires 5 Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling Do not pullthe wire Pulling onthe wire ratherthan the boot may damage the wire o
78. nhaled 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 e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e 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
79. odically test and replace the carbon monoxide detectors according to the manufacturer s instructions 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 5m 5 ft of the generator set exhaust outlet in any direction TP 6905 8 15 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 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 2 2 Prestart Checklist A 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 setas follows 1 Press the
80. off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases 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 16 Section 2 Generator Set Operation DANGER Hazardous voltage Will cause severe injury or death This equipment must be installed and serviced by qualified electrical personnel 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
81. om 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 LPG vapor 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 Noise A 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 TP 6905 8 15 Hazardous Voltage Moving Parts Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator
82. ommands from a transfer switch or remote Switch will be ignored Press AUTO to place the generator set in Automatic mode when appropriate Oil Pres Low Shutdwn TP 6905 8 15 Low Oil Pressure The engine ECM indicates low oil pressure Note The low oil pressure shutdown does not protect against low oil level Check the engine oil level regularly as recommended in Section 4 Check for leaks in the lubrication system Check the oil level and add oil if the level is low Check the oil pressure switch and wiring Section 2 Generator Set Operation 27 Fault RDC2 Fault OnCue 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 PrimLoopOpn Warning Primary Loop Open Ignition coil 1 voltage is below normal or there is an open circuit Check the battery voltage Contact an authorized distributor dealer for service and provide the fault code PrimLoopSht Warning Primary Loop Shorted Ignition coil 1 voltage is abnormal Check the battery voltage Contact an authorized distributor dealer for service and provide the fault code RAM Failure Warning Ram Failure An ECM memory error occurred Contact an authorized distributor dealer for service and provide the fault code
83. or death Fuel leakage can cause an explosion Check the LPG liquid withdrawal fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi 621 kPa 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 52 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 service repair or operate the generator set Have an authorized Kohler distributor dealer perform generator set service Engine Service Perform generator set engine service at the intervals specified by the engine operation manual Generator Set Service Perform generator set service at the intervals specified by the generator set operation manual Routine Maintenance Refer to the following generator set service schedule the engine service schedule and the runtime hours shown on the RDC2 controller to determine when to schedule routine maintenance Service generator sets that are subject to extreme weather or dusty or dirty conditions more frequently Maintenance and Service Parts Obtain maintenance and service parts from an authorized Kohler distributor dealer TP 6905
84. or no battery voltage Check battery connections Check generator set battery See Figure 5 1 Date is flashing Controller power was disconnected and then reconnected Figure 5 2 RDC2 Troubleshooting Chart TP 6905 8 15 Check battery connections See Figure 5 1 Check utility power connection for the built in battery charger Reset the time date and exercise schedule See Section 2 5 7 Setting the Exerciser at Power Up Section 5 Troubleshooting 67 Notes 68 Section 5 Troubleshooting TP 6905 8 15 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx APU AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk BMEP bps br BTDC Btu Btu min C cal CAN CARB CAT5 CB CC cc CCA CCW CEC cert cfh cfm ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control Distric
85. p the threads or alter the electrode gap setting 13 Use a gapping tool to gently bend the side electrode closer to or farther from the center electrode to set the correct gap See Figure 4 8 Position the side electrode directly over the center electrode 17 Checkthe spark plug wire connector in the boot for accumulated dirt grease and other debris and clean as necessary Note Ensure thatthe spark plug tubes are seated before installing the spark plugs Ifthe tubes were removed reinstall them before installing the spark plugs 18 Firmly push the spark plug boot onto the spark plug 19 Reconnect the generator set engine starting 14 Reinstallthe spark plug Do not bump the electrode battery negative lead last against the cylinder head Rotate the spark plug 20 Reconnect the power for the battery charger clockwise until you feel resistance 15 Use a torque wrench to torque each spark plug to 18 Nm 13 3 ft Ibs Otherwise hand tighten the spark plug until you feel resistance Possible Cause Solution Oil or carbon fouling Clean and regap the spark plug Excessive oil entering combustion chamber through worn rings and pistons excessive clearance between valve guides and stems or worn or loose bearings Replace the spark plug Means of Identification Built up deposits and gap between electrodes closing Problem Condition Gap bridged spark plug Oil fouled spark plug Wet black deposit
86. r 20 minutes every week or every two weeks Follow the procedure below and see the flowchart in Figure 2 3to setthe exercise time and date mode and frequency Procedure to Change the Exercise Setting 1 Press the AUTO button on the controller 2 Press the Select button to go to the main menu See Figure 2 2 TP 6905 8 15 3 Press the down arrow button to step to the Genset System menu 4 Pressthe 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 showthatit can be changed For example the hour flashes to show that the hour can be changed 7 Pressthe 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 11 Ifthe generator setis connectedto a Kohler 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 Re
87. r 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 Reconnectthe negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch A WARNING Gh 4 Risk of 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 Change the oil yearly after every 120 hours of use or before generator set storage Change the oil more frequently if the generator set operates under dirty dusty conditions Change the oil while the engine is still warm See Section
88. r 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 Safety Precautions and Instructions 5 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 A WARNING 7 e 4 Risk of fire Can cause
89. r terminal 6 Wipe the interior of the spark plug tubes 7 Loosen the spark plug with a ratchet and 13 16 in spark plug socket with a rubber insert to prevent spark plug damage 8 Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber 9 Remove spark plugs one at a time and examine Identify a normal spark plug in good operating condition by observing a light tan or gray deposit on firing tip See Figure 4 9 to evaluate engine condition by color condition of a problem spark plug 10 Check that the spark plug washer is in good condition 11 Clean spark plugs by wiping them with a rag Note Do not sandblast wire brush scrape or otherwise service spark plugs in poor condition Obtain a new plug for best results 12 Check the spark plug gap before installing any spark plug See Figure 4 6 and Figure 4 7 Attain a correct gap when the feeler or wire passes between the spark plug electrodes It should pass easily but with some resistance or drag otherwise adjust as necessary Model Spar plug gap 0 9 1 0 mm 0 036 0 040 in Figure 4 6 Recommended Spark Plug Gap Section 4 Scheduled Maintenance 59 1 0 9 1 0 mm 0 036 0 040 in gap 2 Spark plug electrodes Figure 4 8 Spark Plug Gap Adjustment Figure 4 7 Spark Plug Gap Inspection 16 Use a ratchet wrench to tighten an additional 1 4 turn Do not overtighten as doing so may stri
90. resh electrolyte Tighten all filler caps If water is added during freezing temperatures run the generator set for 20 30 minutes to mix the electrolyte and water to prevent battery damage from freezing 4 8 2 Checking Specific Gravity Use a battery hydrometer to checkthe specific gravity of the electrolyte in each battery cell While holding the hydrometer vertically read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer If the hydrometer used does not have a correction table use the correction factors in Figure 4 13 Determine specific gravity and electrolyte temperature of battery cells Locate temperature in Figure 4 13 and adjust the specific gravity by the amount shown The battery is fully charged if the specific gravity is 1 260 at an electrolyte temperature of 80 F 26 7 C The difference between specific gravities of each cell should not exceed 0 01 Charge the battery if the specific gravity is below 1 215 at an electrolyte temperature of 80 F 26 7 C See Figure 4 11 Battery Condition Below 1 215 Needs charging 1 260 Fully charged Figure 4 11 Specific Gravity Interpretation Specific Gravity Corrected to 80 F 26 7 C Some battery testers have four or five beads in the test tube Draw electrolyte into the tube as performed with the battery hydrometer described previously Use the manufacturer s instructions Figure 4 12 interprets typical test resul
91. rgency 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 TP 6905 8 15 2 4 7 Automatic Operation with Other Transfer Switches If a Kohler Model RDT 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 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 orderto 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 transfer switches it i
92. round with a 12 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator spec sheet for battery capacity recommendations for replacement purposes Wiring diagrams provide battery connection information See Figure 4 10 for typical battery connections EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 4 10 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Clean the battery and cables and tighten battery terminals using the service schedule recommendations To prevent corrosion maintain tight dry electrical connections at the battery terminals To remove corrosion from battery terminals disconnect the cables from the battery and scrub the terminals with a wire brush Clean the battery and cables with a solution of baking soda and water After cleaning flush the battery and cables with clean water and wipe them with a dry lint free cloth After reconnecting the battery cables coat the battery terminals with petroleum jelly silicone grease or other nonconductive grease Section 4 Scheduled Maintenance 61 4 8 1 Checking Electrolyte Level Check the electrolyte level of batteries with filler caps monthly Remove filler caps and verify that electrolyte level reaches bottom of filler holes Refill as necessary with distilled water DO NOT add f
93. rs Catch fuels in an approved container when removing the fuel line or carburetor 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 ina 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 Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuelleakage can cause an explosion Check the LPG vapor or natural gas fuel system for leakage by using asoap 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 LPG liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury
94. s on the insulator shell bore and electrodes Carbon fouled spark plug Black dry fluffy carbon deposits on insulator tips exposed shell surfaces and electrodes Incorrect spark plug weak ignition clogged air intake overrich fuel mixture or excessive no load operation Clean and 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 spark plug Melted electrodes and possibly blistered insulator Metallic deposits on insulator suggest internal engine damage Wrong type of fuel incorrect timing or advance too hot a plug burned valves or engine overheating Replace the spark plug Overheated spark plug White or light gray insulator with small black or gray brown spots with bluish burned appearance on electrodes Engine overheating wrong type of fuel loose spark plugs too hot a plug low fuel pressure or incorrect ignition timing Replace the spark plug Worn spark plug Severely eroded or worn electrodes Figure 4 9 Engine Evaluation Using Spark Plug Condition 60 Section 4 Scheduled Maintenance Caused by normal wear and failure to replace spark plug at prescribed interval Replace the spark plug TP 6905 8 15 4 8 Battery Consult the battery manufacturer s regarding battery care and maintenance instructions A W
95. s 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 If a Model RDT transfer switch is used refer to the instructions provided with the transfer switch to set a loaded exercise at the ATS if desired 2 5 1 Unloaded Cycle Exercise with Complete System Diagnostics An unloaded cycle exercise runs the generator set without signalling the transfer switch to transfer the electricalload fromthe utility sourcetothe generator set The Unloaded Cycle exercise with diagnostics is the TP 6905 8 15 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 e Runs at reduced speed for 10 minutes to warm up and exercise the engine e 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 e Ramps down and runs at reduced speed for 5 minutes to cool down the engine before shutting down automatically n a c o o o n o o c LL Engine Full Speed Cooldown
96. s the United States and Canada use Society of Automotive Engineers SAE 5W 30 API service class SJ or higher In extremely hot environments where temperatures are never or rarely below 0 C 32 F use a synthetic oil with a viscosity designation of 10W 30 API service class SJ or higher 4 3 2 Oil Check Check the oil level in the crankcase every 24 hours of operation or before the engine is started each day Do not check the oil level while operating the unit Stop the generator set and keep the generator set level to get an accurate reading To check the oil level remove the dipstick and wipe the end clean Reinsert the dipstick and wait at least 30 seconds Remove the dipstick and check the level Maintain the oil level between the Full and Add marks on the dipstick as shown in Figure 4 1 See Section 1 Service Views for the dipstick location Note Do not operate the set if the oil level is below the Add mark or above the Full mark on the dipstick 1 Full mark 2 Add mark Figure 4 1 Oil Level Check 4 3 3 Oil Additions Adding some oil between oil changes is normal 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 fill locations 54 Section 4 Scheduled Maintenance 4 3 4 Oil and Filter Change A WARNING a Accidental starting Can cause severe injury o
97. 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 6 Safety Precautions and Instructions 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 A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 i
98. ssed air as these will damage the filter element Replace the element and precleaner at the intervals shown in the service schedule 3 Examine the element and housing for damage Replace the element and housing if damaged 4 Wipe the cover and housing with a clean rag to remove dirt Make sure the sealing surfaces fit correctly 5 Replace the air cleaner cover 4 5 Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea 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 TP 6905 8 15 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 e Light headedness dizziness e Physical f
99. st E Stop etc exh center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator EEPROM electrically erasable programmable read only memory emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge estimated emergency stop et cetera and so forth exhaust int ext 1 0 IP I
100. structions 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 generator s fuel system has been converted by an authorized distributor or dealer Setting the Exerciser Use the Genset System menus to set the generator set exerciser Refer to Section 2 5 for instructions to set the exerciser and for more information about exercising the generator set After a scheduled exercise run the Next Exercise time and date will be updated automatically based on the Exercise Frequency setting Adjusting the Display Contrast To adjust the display contrast use the down arrow button to step to the Contrast menu Press the Select button and then use the up and down arrow buttons to adjust the contrast Press the Select button to save the contrast setting 40 Section 3 RDC2 Controller Operation Genset System gt System Voltage 240 V 4 ES System Freq 60 Hz VR Voltage Adj 240 0V System Phase Single System Battery 12V Fuel Type LP Next Exercise 06 30p 15Dec2011 i Exercise Mode Unloaded Variable i Exercise Freq Weekly Language English O Meas System English l Contrast 50 i lt Return Note
101. structions to connect the utility power for the battery charger 3 5 Changing Settings Some settings can be changed from the controller keypad The controller settings and generator setoutput are factory set and should not require field adjustment under normal circumstances Check and adjust the settings and or output when e The controller has been replaced e The voltage requires adjustment for a particular application e Troubleshooting generator set problems Have controller setup and adjustment performed only by an authorized Kohler distributor dealer or authorized representative 34 Section 3 RDC2 Controller Operation The following procedure explains how to change settings See Figure 3 6 for an example using the Date and Time settings Note Use caution when navigating the controller menus and changing the settings In some menus pressing the Select button can enable editing of the controller settings Changing some settings to incorrect values can adversely affect generator set operation or render the unit inoperable Procedure to Change Settings 1 Press the Select button to enter the main menu 2 Pressthe down arrow button until the desired menu is displayed The Date and Time menu is used for the example in Figure 3 6 3 Pressthe Select button to enter the selected menu See Figure 3 6 4 Press the down arrow button to step through the parameters in the selected menu 5 To change a setting press
102. system detail Exhaust outlet Enclosure locking key shipping location only Spark plugs Fuel pressure regulator Engine ECM Fuel inlet 1 in NPT Fuel solenoid valves qty 2 shown Lube oil filter Customer load lead access Customer connection access panel Line circuit breaker Generator set master control buttons on RDC2 controller Nameplate location Figure 1 1 24RCL Service Views for Maintenance TP 6905 8 15 Section 1 Service Views GM90230 ADV 8641 Cooling System Detail RDC2 controller Fan fuses Cooling air inlet remove this panel to access coolant drain Access to coolant fill Air fuel mixer Throttle body Air cleaner Battery Oil Drain Coolant drain Fans qty 3 Radiator Pressure cap engine coolant fill Coolant overflow tube Coolant overflow bottle Section 1 Service Views 13 Notes 14 Section 1 Service Views TP 6905 8 15 Section 2 Generator Set Operation 2 1 Operating Area A WARNING Carbon monoxide Can cause severe fainting or death nausea 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
103. t American Petroleum Institute approximate approximately Auxiliary Power Unit Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board Category 5 network cable circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour cubic feet per minute TP 6905 8 15 CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept dia DI EO DIN DIP DPDT DPST DS DVR E2PROM E emer ECM EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ER ES ESD e
104. tility 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 2 4 8 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 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 Engine Start Crank Cycle Pressing the OFF button during the crank cycle stops the cranking No other buttons are acknowledged during the crank cycle 2 4 5 Engine Cooldown The engine cooldown time delay allows the engine to run after the loads have been removed 18 Section 2 Generator Set Operation The engine cooldown time delay is setto 5 minutes The engine stops before the cooldown time delay expires if the temperature drops below t
105. tion 2 5 for instructions to set the exerciser TP 6905 8 15 Fault RDC2 Fault OnCue Plus Condition Check Frequency High Shutdwn High Frequency Governed frequency exceeds 110 of the system s frequency setpoint for more than 10 seconds Function becomes active 10 seconds after engine start 10 second inhibit Contact an authorized distributor dealer for service Frequency Low Shutdwn Low Frequency Governed frequency falls below 9096 of the system frequency setting for more than 10 seconds or 1 Hz below the system frequency setting for more than 60 seconds Function becomes active 10 seconds after engine start 10 second inhibit Reduce the load by turning off appliances and restart the generator set Contact an authorized distributor dealer for service Genset S N Unaval Warning Unavailable Genset Serial Number Generator set serial number is unavailable Contact an authorized distributor dealer for service See section 3 11 IAT High 1 Warning lat Higher Than Expected 1 Engine manifold air temperature is too high Contact an authorized distributor dealer for service and provide the fault code IAT Volt Hi Warning lat High Voltage The ECM reported an Engine Air Temperature Manifold Absolute Pressure Sensor TMAP error Contact an authorized distributor dealer for service and provide the fault code IAT Volt Lo Warning lat Low Vo
106. ts Battery Number of uie Beads Condition Overcharged Fully charged Good charge Low charge Dead battery Figure 4 12 Bead Type Test Interpretation 62 Section 4 Scheduled Maintenance Temperature C SF 71 1 160 EXAMPLE NO 1 Temperature below 80 F 26 7 C Hydrometer Reading 1 250 Acid Temperature 20 F 6 7 C Subtract 024 Specific Gravity Corrected Specific Gravity is 1 226 1 250 024 1 226 EXAMPLE NO 2 Temperature above 80 F 26 7 C Hydrometer Reading 1 235 Acid Temperature 100 F 37 8 C Add 008 Specific Gravity Corrected Specific Gravity is 1 243 1 235 008 1 243 The temperature correction amounts to about 004 4 points of specific gravity for each 10 F 5 5 C change in temperature 1 787 Figure 4 13 Specific Gravity Temperature Correction TP 6905 8 15 4 9 Storage Procedure A DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure 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 Follow the procedure below when storing your generator set for a long period 3 months or more 1 Start and run the generator set
107. turn menu Press the Select button to return to the main menu 14 Checkthat 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 Kohler Model RXT program the exercise at the transfer switch controller Refer to the transfer switch operation manual for instructions Section 2 Generator Set Operation 21 Status Displays Overview gt 1 2h Figure 2 2 RDC2 Main Menu 22 Section 2 Generator Set Operation Ob M Engine Metering Y ATS gt Configuration Generator gt Metering Y Y Date gt and Time Genset gt Information Y Y Network gt Information Genset Run Time Y Y PIM gt Y y Load gt ATS gt Status Control Event Log gt 1p6810 TP 6905 8 15 If the exerciser has not been set No Exercise Sch will be displayed System Voltage 240 V EN System Freq 60 Hz Y VR Voltage Adj 240 0V Y System Phase Single System Battery 12V
108. until it reaches operating temperature or about 15 minutes 2 Stop the generator set 3 Change the oil and oil filter see Section 4 3 4 Oil and Filter Change TP 6905 8 15 10 Check the engine coolant protection see Section 4 6 Note Use antifreeze capable of withstanding the lowest possible temperatures Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs Cleanthe exterior ofthe generator set and spread a light film of oil or silicon spray over any exposed surfaces that may be subject to rust or corrosion Seal the air inlet exhaust pipe and fuel tank cap with tape Disconnect and remove the battery Place the battery in a warm dry location for the storage period Recharge the battery once a month to maintain a full charge Select a well ventilated not humid or dusty location to store the generator Cover the entire unit with a dust cover Note Run the generator set once a month whenever possible Section 4 Scheduled Maintenance 63 Notes 64 Section 4 Scheduled Maintenance TP 6905 8 15 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 include a list of common problems possible causes of the problem and recommended corrective actions If the proce
109. uthorized distributor dealer for service and provide the fault code ECM warnings any warnings with ECM in the fault name ECM warnings any warnings with ECM in the fault name This group of faults includes a wide variety of faults that originate from the engine ECM and also contain ECM in the fault name Contact an authorized distributor dealer for service and provide the fault code Emerg Stop Shutdwn Emergency Stop Shutdown The emergency stop switch has been activated or there has been an open circuit in the wiring Contact an authorized distributor dealer for service Eng Derate Engine Derate Active The ECM reported a torque limiting error caused by coolant overheating Check coolant level Contact an authorized distributor dealer for service and provide the fault code Eng Speed High Shutdwn High Engine Speed Engine speed exceeds 11596 of the normal running speed for more than 0 3 seconds Contact an authorized distributor dealer for service Eng Speed Low Shutdwn Low Engine Speed Engine speed drops below 85 of the normal running speed for more than 3 seconds Reduce the load by turning off appliances Contact an authorized distributor dealer for service Exer Not Sch Warning ATS Exercise Not Scheduled 26 Section 2 Generator Set Operation Exercise Not Scheduled No exercise has been scheduled on the RDC2 controller See Sec
110. view menu to reset the maintenance timer See Section 4 3 4 for instructions to reset the maintenance timer Genset gt Eng Runtime Run Time 274h A 37 Eng Starts 1 Next Maintenance 150 h or Mar2014 i lt Return Figure 3 12 Generator Set Run Time Menu Section 3 RDC2 Controller Operation 39 3 13 Genset System Menu The genset system menu displays the system information shown in Figure 3 13 Generator sets are factory setand should not require changestothe system settings in the field A Kohler authorized distributor or dealer can adjust these settings if necessary If the generator set is reconnected to a different voltage orthe system settings require adjustment for some other reason see Section 3 5 for instructions to enable editing and change the System settings Note Use caution when navigating the controller menus In some menus pressing the Select button can enable editing of the controller settings Changing the settings to incorrect values can adversely affect generator set operation or render the unit inoperable Voltage Regulator VR Voltage Adjust The generator set voltage is factory set and typically does not require adjustment in the field If voltage adjustment is required contact a Kohler authorized distributor or dealer for service Refer to the generator set Installation Manual for in
111. xhaust manifold exhaust outlet exhaust line exhaust clamps and muffler for cracks leaks and corrosion TP 6905 8 15 Exhaust System Inspection Points e Check for corroded or broken metal parts and replace them as needed e Check that the exhaust outlet is unobstructed e Check the exhaust gas color If the exhaust is blue or black contact your local authorized Kohler distributor dealer e Visually inspectfor exhaustleaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed e Check that all covers and doors are undamaged in place and locked e Check for the installation and operation of carbon monoxide CO detectors on each level of any building near the generator set 4 6 Cooling System A WARNING 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 Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank Section 4 Scheduled Maintenance 57 4 6 1
112. y after a warning condition is corrected 2 6 2 Shutdowns Under a fault shutdown condition the generator set shuts down automatically and the controller displays a fault message The OFF LED flashes See Figure 2 5 Shutdown switches such as the low coolant level switch or high engine temperature switch on the generator set will automatically reset when the problem is corrected However the fault condition at the controller does not clear until the controller is reset The generator set cannot be restarted until the fault condition is corrected and the controller is reset See Section 2 6 4 to reset the controller after a fault shutdown Overview gt 1 2h Fault Message 2 6 3 ATS Communication Errors When a Model RXT transfer switch is used an ATS fault indicates that the connection to the interface board on the transfer switch has been lost Check the connection to the ATS interface board 2 6 4 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller Check the fault message displayed on the controller and refer to Figure 2 5 to identify and correct the fault condition before proceeding Contact an authorized distributor dealer for service if necessary Press the OFF button to resetthe controller or follow the procedure below See Figure 2 4 Procedure to Reset the Controller after a Fault Shutdown 1

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