Manual Generador Kohler

Operation
Residential/Light Commercial Generator Sets
Model:
48RCLB
60RCLA
Controller:
RDC2
TP-7102 7/18b
WARNING: This product can expose you
to chemicals, including carbon monoxide
and benzene, which are known to the State
of California to cause cancer and birth
defects or other reproductive harm.
For more information go to
www.P65warnings.ca.gov
Kohler strongly recommends

that only factory-authorized
distributors or dealers install
and service the generator.
Product Identification Information
Product identification numbers determine service parts. Accessory Number Accessory Description
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
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
2 TP 7102 7/18

Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section 1 Service Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Section 2 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Operating Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 Local Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.2 Automatic Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.3 Remote Starting and Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.4 Engine Start Crank Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.5 Engine Cooldown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.6 Automatic Operation with Model RXT Transfer Switch . . . . . . . . . . . . . . 17
2.4.7 Automatic Operation with Other Transfer Switches . . . . . . . . . . . . . . . . . 18
2.5 Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5.1 Unloaded Cycle Exercise with Complete System Diagnostics . . . . . . . . 18
2.5.2 Unloaded Full-Speed Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.3 Loaded Full-Speed Exercise (with RXT only) . . . . . . . . . . . . . . . . . . . . . . 19
2.5.4 Shutdown During Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.5 Power Failure During Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5.6 Exerciser Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.7 Setting the Exerciser at Power-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5.8 Changing the Exercise Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6.2 Shutdowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6.3 ATS Communication Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6.4 Resetting the Controller after a Fault Shutdown . . . . . . . . . . . . . . . . . . . . 23
2.6.5 Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Model RXT Transfer Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7.1 Source Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7.2 ATS Control Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.3 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.4 ATS Load Control Relay Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Section 3 RDC2 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 RDC2 Generator Set / Transfer Switch Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2.1 Controller Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2.2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2.3 LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.6 Controller Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.8 Overview Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9 Engine Metering Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.10 Generator Metering Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.11 Generator Set Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
TP-7102 7/18 Table of Contents 3

Table of Contents, continued
3.12 Genset Run Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.13 Genset System Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.14 ATS Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.15 ATS Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.16 Date and Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.17 Networking Information Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.17.1 Networking Status Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.17.2 Networking Configuration Submenu (OnCuer Plus Password) . . . . . . . 44
3.17.3 RBUS Information Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.17.4 Remote Devices Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.18 Programmable Interface Module (PIM) Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.19 Load Control Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Section 4 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1 General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3.1 Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3.2 Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3.3 Oil Additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3.4 Oil and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.4 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.6 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.6.1 Checking and Filling Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.6.2 Cooling System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.6.3 Draining Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.6.4 Flushing and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.6.5 Filling Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.7 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.8 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.8.1 Checking Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.8.2 Checking Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.9 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Section 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.4 Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.4.1 Load Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.4.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.4.3 Controller Internal Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.5 Generator Set Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.6 Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Table of Contents TP-7102 7/18

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
Accidental Starting WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or substantial
working on the generator set or open a sealed battery or mutilate the
property damage.
equipment connected to the set, battery case. If battery acid splashes in
disable the generator set as follows: the eyes or on the skin, immediately
(1) Press the generator set off/reset flush the affected area for 15 minutes
WARNING button to shut down the generator set. with large quantities of clean water.
(2) Disconnect the power to the battery Seek immediate medical aid in the case
Warning indicates the presence of a charger, if equipped. (3) Remove the of eye contact. Never add acid to a
hazard that can cause severe battery cables, negative (--) lead first. battery after placing the battery in
personal injury, death, or substantial Reconnect the negative (--) lead last service, as this may result in hazardous
property damage. when reconnecting the battery. Follow spattering of battery acid.
these precautions to prevent the
starting of the generator set by the Battery acid cleanup. Battery acid
CAUTION remote start/stop switch. can cause severe injury or death.
Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor Battery bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
personal injury or property damage.
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
NOTICE WARNING battery acid and continue to add the
Notice communicates installation,
neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator Sulfuric acid in batteries. Battery gases. Explosion can cause
or service technician to potential Can cause severe injury or death. severe injury or death. Battery gases
hazards and explain how to act safely. can cause an explosion. Do not smoke
The decals are shown throughout this Wear protective goggles and or permit flames or sparks to occur near
publication to improve operator clothing. Battery acid may cause a battery at any time, particularly when
recognition. Replace missing or blindness and burn skin. it is charging. Do not dispose of a
damaged decals. battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
TP-7102 7/18 Safety Precautions and Instructions 5

metal surface away from the battery. To minimize the risk of fire or explosion. possibility of carbon monoxide
avoid sparks, do not disturb the battery Equip the compartment or nearby area poisoning. Seek medical attention if
charger connections while the battery with a fully charged fire extinguisher. the condition of affected persons does
is charging. Always turn the battery Select a fire extinguisher rated ABC or not improve within minutes of breathing
charger off before disconnecting the BC for electrical fires or as fresh air.
battery connections. Ventilate the recommended by the local fire code or
compartments containing batteries to an authorized agency. Train all Carbon monoxide detectors.
prevent accumulation of explosive personnel on fire extinguisher Carbon monoxide can cause severe
gases. operation and fire prevention nausea, fainting, or death. Install
procedures. carbon monoxide detectors on each
Battery short circuits. Explosion level of any building adjacent to the
can cause severe injury or death. generator set. Locate the detectors to
adequately warn the building’s
Short circuits can cause bodily injury
and/or equipment damage.
Exhaust System occupants of the presence of carbon
Disconnect the battery before monoxide. Keep the detectors
generator set installation or WARNING operational at all times. Periodically
maintenance. Remove all jewelry test and replace the carbon monoxide
before servicing the equipment. Use detectors according to the
tools with insulated handles. Remove manufacturer’s instructions.
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when Carbon monoxide. Fuel System
reconnecting the battery. Never Can cause severe nausea,
connect the negative (--) battery cable fainting, or death.
to the positive (+) connection terminal WARNING
of the starter solenoid. Do not test the The exhaust system must be
battery condition by shorting the leakproof and routinely inspected.
terminals together.
Generator set operation. Carbon
monoxide can cause severe nausea,
Engine Backfire/Flash fainting, or death. Carbon monoxide
Explosive fuel vapors.
is an odorless, colorless, tasteless,
Fire nonirritating gas that can cause death if
Can cause severe injury or death.
inhaled for even a short time. Avoid Use extreme care when handling,
WARNING breathing exhaust fumes when working storing, and using fuels.
on or near the generator set. Never
operate the generator set inside a
building. Never operate the generator The fuel system. Explosive fuel
set where exhaust gas could seep vapors can cause severe injury or
inside or be drawn into a potentially death. Vaporized fuels are highly
Risk of fire. occupied building through windows, air explosive. Use extreme care when
Can cause severe injury or death. intake vents, or other openings. handling and storing fuels. Store fuels
in a well-ventilated area away from
Do not smoke or permit flames or Carbon monoxide symptoms. spark-producing equipment and out of
sparks near fuels or the fuel system. Carbon monoxide can cause severe the reach of children. Never add fuel to
nausea, fainting, or death. Carbon the tank while the engine is running
Servicing the fuel system. A flash monoxide is a poisonous gas present in because spilled fuel may ignite on
fire can cause severe injury or death. exhaust gases. Carbon monoxide is an contact with hot parts or from sparks.
Do not smoke or permit flames or odorless, colorless, tasteless, Do not smoke or permit flames or
sparks near the carburetor, fuel line, nonirritating gas that can cause death if sparks to occur near sources of spilled
fuel filter, fuel pump, or other potential inhaled for even a short time. Carbon fuel or fuel vapors. Keep the fuel lines
sources of spilled fuels or fuel vapors. monoxide poisoning symptoms include and connections tight and in good
Catch fuels in an approved container but are not limited to the following: condition. Do not replace flexible fuel
when removing the fuel line or D Light-headedness, dizziness lines with rigid lines. Use flexible
carburetor. D Physical fatigue, weakness in sections to avoid fuel line breakage
joints and muscles caused by vibration. Do not operate the
Servicing the air cleaner. A sudden D Sleepiness, mental fatigue, generator set in the presence of fuel
backfire can cause severe injury or inability to concentrate leaks, fuel accumulation, or sparks.
death. Do not operate the generator or speak clearly, blurred vision Repair fuel systems before resuming
set with the air cleaner removed. D Stomachache, vomiting, nausea generator set operation.
Combustible materials. A fire can If experiencing any of these symptoms
and carbon monoxide poisoning is Explosive fuel vapors can cause
cause severe injury or death. severe injury or death. Take
Generator set engine fuels and fuel possible, seek fresh air immediately
and remain active. Do not sit, lie down, additional precautions when using the
vapors are flammable and explosive. following fuels:
Handle these materials carefully to or fall asleep. Alert others to the
6 Safety Precautions and Instructions TP-7102 7/18

Propane (LPG)—Adequate ventilation
is mandatory. Because propane is
Hazardous Voltage/ Grounding electrical equipment.
Hazardous voltage will cause severe
heavier than air, install propane gas Moving Parts injury or death. Electrocution is
detectors low in a room. Inspect the possible whenever electricity is
detectors per the manufacturer’s DANGER present. Ensure you comply with all
instructions. applicable codes and standards.
Electrically ground the generator set,
Natural Gas—Adequate ventilation is transfer switch, and related equipment
mandatory. Because natural gas rises, and electrical circuits. Turn off the main
install natural gas detectors high in a circuit breakers of all power sources
room. Inspect the detectors per the before servicing the equipment. Never
manufacturer’s instructions. Hazardous voltage. Moving parts.
Will cause severe injury or death. contact electrical leads or appliances
Gas fuel leaks. Explosive fuel when standing in water or on wet
vapors can cause severe injury or Operate the generator set only when ground because these conditions
death. Fuel leakage can cause an all guards and electrical enclosures increase the risk of electrocution.
explosion. Check the LPG vapor or are in place.
Disconnecting the electrical load.
natural gas fuel system for leakage by Hazardous voltage will cause severe
using a soap and water solution with WARNING injury or death. Disconnect the
the fuel system test pressurized to generator set from the load by turning
6--8 ounces per square inch off the line circuit breaker or by
(10--14 inches water column). Do not disconnecting the generator set output
use a soap solution containing either leads from the transfer switch and
ammonia or chlorine because both heavily taping the ends of the leads.
prevent bubble formation. A successful Hazardous voltage. High voltage transferred to the load
test depends on the ability of the Backfeed to the utility system can during testing may cause personal
solution to bubble. cause property damage, severe injury and equipment damage. Do not
injury, or death. use the safeguard circuit breaker in
place of the line circuit breaker. The
Hazardous Noise If the generator set is used for
safeguard circuit breaker does not
standby power, install an automatic
disconnect the generator set from the
transfer switch to prevent inadvertent
load.
CAUTION interconnection of standby and
normal sources of supply. Welding on the generator set. Can
cause severe electrical equipment
damage. Before welding on the
CAUTION generator set perform the following
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
Hazardous noise.
all engine electronic control module
Can cause hearing loss.
(ECM) connectors. (3) Disconnect all
Never operate the generator set generator set controller and voltage
without a muffler or with a faulty regulator circuit board connectors.
Welding the generator set. (4) Disconnect the engine battery-
exhaust system.
Can cause severe electrical equip- charging alternator connections.
ment damage. (5) Attach the weld ground connection
Engine noise. Hazardous noise can
Never weld components of the close to the weld location.
cause hearing loss. Generator sets
not equipped with sound enclosures generator set without first discon- Connecting the battery and the
can produce noise levels greater than necting the battery, controller wiring battery charger. Hazardous voltage
105 dBA. Prolonged exposure to noise harness, and engine electronic con- will cause severe injury or death.
levels greater than 85 dBA can cause trol module (ECM). Reconnect the battery correctly,
permanent hearing loss. Wear hearing positive to positive and negative to
protection when near an operating negative, to avoid electrical shock and
generator set. damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
TP-7102 7/18 Safety Precautions and Instructions 7

Short circuits. Hazardous
voltage/current will cause severe
Hot Parts Notice
injury or death. Short circuits can NOTICE
cause bodily injury and/or equipment WARNING
Canadian installations only. For
damage. Do not contact electrical
standby service connect the output of
connections with tools or jewelry while
the generator set to a suitably rated
making adjustments or repairs.
transfer switch in accordance with
Remove all jewelry before servicing the
Canadian Electrical Code, Part 1.
equipment.
Hot coolant and steam.
Engine block heater. Hazardous Can cause severe injury or death. NOTICE
voltage will cause severe injury or Electrostatic discharge damage.
death. The engine block heater can Before removing the pressure cap, Electrostatic discharge (ESD)
cause electrical shock. Remove the stop the generator set and allow it to damages electronic circuit boards.
engine block heater plug from the cool. Then loosen the pressure cap Prevent electrostatic discharge
electrical outlet before working on the to relieve pressure. damage by wearing an approved
block heater electrical connections. grounding wrist strap when handling
electronic circuit boards or integrated
Electrical backfeed to the utility.
Hazardous backfeed voltage can
WARNING circuits. An approved grounding wrist
strap provides a high resistance (about
cause severe injury or death. Install
1 megohm), not a direct short, to
a transfer switch in standby power
ground.
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility Hot engine and exhaust system.
electrical system can cause severe Can cause severe injury or death.
injury or death to utility personnel
working on power lines. Do not work on the generator set until
it cools.
Servicing the generator set when it
is operating. Exposed moving parts
will cause severe injury or death. Servicing the alternator. Hot parts
Keep hands, feet, hair, clothing, and can cause severe injury or death.
test leads away from the belts and Avoid touching the alternator field or
pulleys when the generator set is exciter armature. When shorted, the
running. Replace guards, screens, and alternator field and exciter armature
covers before operating the generator become hot enough to cause severe
set. burns.
Servicing the exhaust system. Hot
parts can cause severe injury or
Heavy Equipment death. Do not touch hot engine parts.
The engine and exhaust system
WARNING components become extremely hot
during operation.
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
8 Safety Precautions and Instructions TP-7102 7/18

Introduction
This manual provides operation instructions for Model Nameplate

48RCLB and 60RCLA residential/light commercial
generator sets equipped with the RDC2 generator Figure 2 shows a typical generator set nameplate.
set/transfer switch controller. Copy the model, serial, and specification numbers from
the nameplate into the spaces provided in the product
This generator set is approved for use in stationary information section on the inside front cover of this
applications in locations served by a reliable utility manual. See the service view in Section 1 for the
power source. Have the generator set installed by an nameplate location.
authorized Kohler distributor/dealer or service
technician. Refer to the Installation Manual for
installation instructions.
Information in this publication represents data available Genset Model

at the time of print. Kohler Co. reserves the right to Spec Number
change this publication and the products represented Serial Number
without notice and without any obligation or liability Material Number
whatsoever. Service Duty Amps kW
Voltage Phase kVA
Read this manual and carefully follow all procedures Alt Model RPM PF
and safety precautions to ensure proper equipment Insulation Battery Hz
MFG Date Fuel

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 Figure 2 Nameplate, Typical
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.
Figure 1 Model 48RCLB Generator Set
TP-7102 7/18 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, 48RCLB G4-276
Specification Sheet, 60RCLA G4-277
Installation Manual, Generator Set TP-7101
Operation Manual, Engine TP-7095
Parts Catalog, Engine TP-6731
Parts Catalog, Generator Set TP-6812
Accessory Literature Part Number
Installation Instructions, Block Heaters TT-1587
Installation Instructions, Load Shed Kit TT-1609
Installation Instructions, Programmable
Interface Module (PIM) TT-1584
Installation Instructions, Power Relay
Modules TT-1646
User Guide, OnCuer Plus Program TP-7006
Technical Manual, OnCuer Plus Program TP-7007
Operation/Installation Manual, RXT ATS TP-6807
Operation/Installation Manual, RDT ATS TP-6345
Figure 3 Related Literature
10 Introduction TP-7102 7/18

Service Assistance
For professional advice on generator set power Asia Pacific

requirements and conscientious service, please contact Kohler Asia Pacific Headquarters
your nearest authorized Kohler distributor or dealer. Singapore, Republic of Singapore
Phone: (65) 6264-6422
D Visit the Kohler Co. website at KOHLERPower.com. Fax: (65) 6264-6455
D Look at the labels and decals on your Kohler product

China
or review the appropriate literature or documents North China Regional Office, Beijing
included with the product. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Call toll free in the US and Canada 1-800-544-2444. (86) 10 6518 7952
Fax: (86) 10 6518 7955
D Outside the US and Canada, call the nearest regional East China Regional Office, Shanghai
office. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
Headquarters Europe, Middle East, Africa
(EMEA) India, Bangladesh, Sri Lanka
Kohler EMEA Headquarters India Regional Office
Netherlands B.V. Bangalore, India
Kristallaan 1 Phone: (91) 80 3366208
4761 ZC Zevenbergen (91) 80 3366231
The Netherlands Fax: (91) 80 3315972
Phone: (31) 168 331630 Japan, Korea
Fax: (31) 168 331631 North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
TP-7102 7/18 Service Assistance 11

Notes
12 Service Assistance TP-7102 7/18

Section 1 Service Views
1 2 3 4 5
19
18
17
16
15 14 13 12 11 10 9 8 7
SERVICE SIDE
21 22 29 30
31
20 28
28
32
ADV-8954 GM103966
27 7 26 25 24 23
Cooling System Detail
NON-SERVICE SIDE
1. Nameplate location 17. Generator set master control buttons (on RDC2 controller)
2. Engine ECM and EPR (electronic fuel pressure regulator) 18. RDC2 controller
3. Oil check (dipstick) 19. Air cleaner
4. See cooling system detail 20. Cooling air inlet (remove this panel to access coolant drain)
5. Exhaust outlet 21. Access to coolant fill
6. Enclosure locking tool (shipping location only) 22. Fan fuses
7. Spark plugs 23. Battery
8. Block heater connection valve 24. Oil drain valve
9. Block heater (optional) 25. Lube oil filter
10. Fuel inlet (1 in. NPT) 26. Block heater connection valve
11. Fuel solenoid valve 27. Coolant drain
12. Fuel conversion lead location 28. Fans (qty. 3)
13. Oil fill location (on valve cover) 29. Radiator
14. Customer load lead access 30. Pressure cap (engine coolant fill)
15. Customer connection access panel 31. Coolant overflow tube
16. Line circuit breaker 32. Coolant overflow bottle
Figure 1-1 Service Views
TP-7102 7/18 Section 1 Service Views 13

Notes
14 Section 1 Service Views TP-7102 7/18

Section 2 Generator Set Operation
2.1 Operating Area WARNING

DO NOT locate the generator set near patios, decks,
WARNING play areas, or animal shelters. Keep items such as
lawn furniture, toys, sports equipment, and all
combustible materials away from the generator set
exhaust outlet.
Carbon monoxide. Remind family members, children, and visitors to use

Can cause severe nausea, caution near the generator set. Generator sets
fainting, or death. connected to automatic transfer switches start
automatically during exercise periods and power
The exhaust system must be
leakproof and routinely inspected.
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.
Carbon monoxide symptoms. Carbon monoxide can
cause severe nausea, fainting, or death. Carbon monoxide
is a poisonous gas present in exhaust gases. Carbon 2.2 Prestart Checklist
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 WARNING
the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
Accidental starting.
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide Disconnect the battery cables before
poisoning is possible, seek fresh air immediately and remain working on the generator set.
active. Do not sit, lie down, or fall asleep. Alert others to the Remove the negative (--) lead first
possibility of carbon monoxide poisoning. Seek medical when disconnecting the battery.
attention if the condition of affected persons does not improve Reconnect the negative (--) lead last
within minutes of breathing fresh air. when reconnecting the battery.
Generator set operation. Carbon monoxide can cause
severe nausea, fainting, or death. Carbon monoxide is an Disabling the generator set. Accidental starting can
odorless, colorless, tasteless, nonirritating gas that can cause cause severe injury or death. Before working on the
death if inhaled for even a short time. Avoid breathing exhaust generator set or equipment connected to the set, disable the
fumes when working on or near the generator set. Never generator set as follows: (1) Press the generator set off/reset
operate the generator set inside a building. Never operate the button to shut down the generator set. (2) Disconnect the
generator set where exhaust gas could seep inside or be power to the battery charger, if equipped. (3) Remove the
drawn into a potentially occupied building through windows, air battery cables, negative (--) lead first. Reconnect the negative
intake vents, or other openings. (--) lead last when reconnecting the battery. Follow these
Carbon monoxide detectors. Carbon monoxide can precautions to prevent the starting of the generator set by the
cause severe nausea, fainting, or death. Install carbon remote start/stop switch.
monoxide detectors on each level of any building adjacent to
the generator set. Locate the detectors to adequately warn the
building’s occupants of the presence of carbon monoxide.
Keep the detectors operational at all times. Periodically test
and replace the carbon monoxide detectors according to the
manufacturer’s instructions.
Keep the generator set area clear. Maintain at least

0.9 m (3 ft.) of clearance on all sides of the generator
set. Verify that there are no windows, air vents, or other
openings in the building within 1.5 m (5 ft.) of the
generator set exhaust outlet in any direction.
TP-7102 7/18 Section 2 Generator Set Operation 15

WARNING DANGER
Hazardous voltage. Moving parts.

Sulfuric acid in batteries. Will cause severe injury or death.
Can cause severe injury or death. Operate the generator set only when
Wear protective goggles and all guards and electrical enclosures
clothing. Battery acid may cause are in place.
blindness and burn skin.
Grounding electrical equipment. Hazardous voltage will
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
WARNING applicable codes and standards. Electrically ground the
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
Explosion. electrocution.
Relays in the battery charger Connecting the battery and the battery charger.
cause arcs or sparks. Hazardous voltage will cause severe injury or death.
Reconnect the battery correctly, positive to positive and
Locate the battery in a well-ventilated negative to negative, to avoid electrical shock and damage to
area. Isolate the battery charger from the battery charger and battery(ies). Have a qualified
explosive fumes. electrician install the battery(ies).
Short circuits. Hazardous voltage/current will cause
Battery gases. Explosion can cause severe injury or severe injury or death. Short circuits can cause bodily injury
death. Battery gases can cause an explosion. Do not smoke and/or equipment damage. Do not contact electrical
or permit flames or sparks to occur near a battery at any time, connections with tools or jewelry while making adjustments or
particularly when it is charging. Do not dispose of a battery in a repairs. Remove all jewelry before servicing the equipment.
fire. To prevent burns and sparks that could cause an
explosion, avoid touching the battery terminals with tools or To ensure continued satisfactory operation perform the
other metal objects. Remove all jewelry before servicing the following checks or inspections before or at each
equipment. Discharge static electricity from your body before startup, as designated, and at the intervals specified in
touching batteries by first touching a grounded metal surface the service schedule. In addition, some checks require
away from the battery. To avoid sparks, do not disturb the
verification after the unit starts.
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the Air Cleaner. Check for a clean and installed air cleaner
battery connections. Ventilate the compartments containing element to prevent unfiltered air from entering the
batteries to prevent accumulation of explosive gases. engine.
Battery electrolyte is a diluted sulfuric acid. Battery acid Air Inlets. Check for obstructions that could block the
can cause severe injury or death. Battery acid can cause flow of cooling air. Keep the air intake area clean. Do not
blindness and burn skin. Always wear splashproof safety
leave rags, tools, or debris on or near the generator set.
goggles, rubber gloves, and boots when servicing the battery.
Do not open a sealed battery or mutilate the battery case. If Battery. Check for tight battery connections. Consult
battery acid splashes in the eyes or on the skin, immediately the battery manufacturer’s instructions regarding
flush the affected area for 15 minutes with large quantities of battery care and maintenance.
clean water. Seek immediate medical aid in the case of eye
contact. Never add acid to a battery after placing the battery in Coolant Level. Check the coolant level according to the
service, as this may result in hazardous spattering of battery cooling system maintenance information.
acid.
16 Section 2 Generator Set Operation TP-7102 7/18

Note: Block heater damage. The block heater will fail with no load to cool down the engine, and then stops the
if the energized heater element is not immersed generator set engine. The electric fans continue to run
in coolant. Fill the cooling system before turning for two minutes after the engine shuts down to evacuate
on the block heater. Run the engine until it is the engine compartment.
warm, and refill the radiator to purge the air from
the system before energizing the block heater.
2.4.3 Remote Starting and Stopping
Drive Belt(s). Check the belt condition of the water
pump and battery charging alternator belt(s). A remote switch connected to terminals 3 and 4 can be
used to start and stop the generator set. Close the
Exhaust System. Check for exhaust leaks and
switch to start and run the generator set. Open the
blockages. Check the silencer and piping condition and
switch to stop the generator set.
check for tight exhaust system connections.
Inspect the exhaust system components for cracks and Run the generator set with no load for at least 2 minutes
corrosion (exhaust manifold, exhaust pipe, exhaust to ensure adequate engine cooldown.
clamps, and silencer).
D Check for corroded or broken metal parts and replace 2.4.4 Engine Start Crank Cycle
them as needed.
The controller attempts to start the generator set three
D Check that there are no combustible materials near
times (three crank cycles, 15 seconds crank and
the exhaust outlet.
15 seconds off). If the generator set does not start in
D Check that the exhaust outlet is unobstructed. three attempts, the system shuts down on an overcrank
Carbon Monoxide Detectors. Check for the fault. See Section 2.6.
installation and operation of carbon monoxide (CO)
detectors on each level of any building near the Pressing the OFF button during the crank cycle stops
generator set. the cranking. No other buttons are acknowledged
during the crank cycle.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
2.4.5 Engine Cooldown
2.3 Exercising the Generator Set The engine cooldown time delay allows the engine to
run after the loads have been removed.
Operate the generator set every week or every other
week for 20 minutes. Perform all of the prestart checks The engine cooldown time delay is set to 5 minutes. The
before starting the exercise procedure. See Section 2.5 engine stops before the cooldown time delay expires if
for instructions to set the automatic exerciser. the temperature drops below the cooled-down
temperature level, or if the temperature rises above the
high limit during the cooldown cycle.
2.4 Generator Set Operation
The electric fans continue to run for two minutes after the
engine shuts down to evacuate the engine
2.4.1 Local Starting and Stopping
compartment.
Start: Press the RUN button to immediately start the
generator set. If a transfer switch other than the Model RXT is used, an
additional engine cooldown time delay may be
Stop: Press the OFF button. The engine stops. programmed on the transfer switch. To allow the smart
engine cooldown on the RDC2 controller to operate
Run the generator set with no load for at least 2 minutes most efficiently, set the cooldown time on the transfer
to ensure adequate engine cooldown. switch controller to zero or the minimum time allowed.
Refer to the instructions provided with the transfer
switch for more information.
2.4.2 Automatic Starting and Stopping
An automatic transfer switch monitors the utility power 2.4.6 Automatic Operation with Model
and signals the generator set to start when utility power
is lost. The ATS then transfers the load to the generator
RXT Transfer Switch
set. The Model RXT transfer switch connects to the RDC2
controller through the ATS interface board on the
When utility power is restored, the transfer switch
transfers the load back to utility, runs the generator set

transfer switch. Also see Section 2.7, Model RXT 2.5 Exercise
Transfer Switch Operation.
The RDC2 controller can be set to automatically run the
The RDC2 controller must be in AUTO mode for generator set at the same time and day every week or
automatic transfer switch operation. every other week. Exercising the generator set every
week or every two weeks is required in order to keep the
Automatic Start engine and alternator in good operating condition.
The RDC2 controller receives utility source voltage Three exercise modes are available: unloaded cycle,
sensing data from the Model RXT transfer switch. unloaded full speed, and loaded full speed. See
Sections 2.5.1 through 2.5.3 for information about the
1. If the utility source voltage falls below an exercise modes. A loaded exercise can be set at the
acceptable level, the controller starts the engine RDC2 controller only if a Model RXT transfer switch is
start time delay. connected.
2. If the utility source is not restored before the time Note: With the RDT transfer switches, it is possible to
delay expires, the generator set starts. have two exercise settings (one unloaded
exercise set at the generator set controller, and
3. After the Normal-to-Emergency time delay, the another exercise set at the ATS controller). If the
ATS is signaled to transfer the load to the exercise times overlap, the ATS exercise setting
emergency source. takes priority.
Automatic Stop If a Model RDT transfer switch is used, refer to the

instructions provided with the transfer switch to set a
1. When the utility source is restored, the loaded exercise at the ATS, if desired.
Emergency-to-Normal time delay starts.
2. When the Emergency-to-Normal time delay 2.5.1 Unloaded Cycle Exercise with
expires, the load is transferred to the utility. Complete System Diagnostics
3. The generator set stops. An unloaded cycle exercise runs the generator set
without signalling the transfer switch to transfer the
electrical load from the utility source to the generator set.
2.4.7 Automatic Operation with Other The Unloaded Cycle exercise with diagnostics is the
Transfer Switches recommended exercise mode and is the factory-default
exercise setting.
If a Kohler Model RDT transfer switch is used, the
engine start contacts from the ATS must be connected The Unloaded Cycle exercise runs the engine for
to engine start leads 3 and 4 on the generator set. 20 minutes in the cycle shown in Figure 2-1 and
described below.
The RDC2 generator set controller must be in AUTO
mode to respond to remote start/stop signals from an D Runs at reduced speed for 10 minutes to warm up
ATS or remote switch. Press the AUTO button on the and exercise the engine.
RDC2 controller to put the generator set into automatic
D Ramps up and runs at full speed for 3 minutes.
mode.
Engine diagnostics are performed during this
full-speed portion of the cycle, which provides the
Automatic Start best test of engine and alternator power backup
The engine start contacts on the ATS close to signal the capability. Diagnostic tests at full speed can identify
generator set to start, and remain closed while the potential problems with the power output and alert the
generator set is running. operator before an emergency event.
D Ramps down and runs at reduced speed for

Automatic Stop 5 minutes to cool down the engine before shutting
down automatically.
The engine start contacts on the ATS open to signal the
generator set to stop.

2.5.2 Unloaded Full-Speed Exercise
3 min.
The unloaded full speed exercise runs the generator set
Engine Speed, RPM
at full speed for 20 minutes without transferring the load.
1 min. To set an unloaded full speed exercise, follow the

1 min.
procedure in Figure 2-3 and select Exercise Mode:
Unloaded Full.
10 min. 5 min.
2.5.3 Loaded Full-Speed Exercise (with
Engine Full-Speed Cooldown
Exercise Diagnostics RXT only)
A loaded exercise starts the generator set, ramps up to
Figure 2-1 Unloaded Exercise Cycle full speed, and then transfers the electrical load from the
utility source to the generator set. The load is
System Diagnostics transferred back to the utility source before the
generator set shuts down.
During the unloaded cycle exercise, the controller
monitors the following data. The controller display Note: With a loaded exercise, power to the building is
indicates an unloaded exercise run during the lost for up to 10 seconds during load transfer.
diagnostics, unless a fault is detected as described
below. For a loaded exercise controlled by the RDC2 controller,
a Model RXT transfer switch must be connected to the
D ATS connection. The controller verifies that the generator set. To set a loaded exercise, follow the
Model RXT ATS interface board is connected. procedure in Section 2.5.8 and select Exercise Type:
Loaded.
D Battery voltage. Battery voltage is checked before
exercise to verify engine starting capability. Battery For a loaded exercise with a transfer switch other than a
voltage provides a measurement of battery health. If Kohlerr Model RXT, program the exercise at the
the controller detects low battery voltage, low battery transfer switch controller. Refer to the transfer switch
or low charging battery is displayed and the exercise operation manual for instructions.
does not start.
D Coolant level check. The coolant level is checked. 2.5.4 Shutdown During Exercise
D Communication integrity tests. J1939, RBUS, The following advanced diagnostic operation applies to
Ethernet, and USB are monitored for messages RDC2 controllers with firmware versions 5.04 and
indicating that the controller and wiring are reliable. higher.
D Engine speed. Engine speed is measured at low If the generator set shuts down on a fault during an
speed and full speed. An overspeed or underspeed exercise, the controller will try to restart the engine. If the
condition will result in a fault condition and shutdown. engine starts, the generator set will run at full speed for
two minutes and then stop. The event history will show
D Generator output frequency and voltage. Advanced Diagnostic Active. The exercise schedule is
Operating the generator at full speed allows the maintained.
RDC2 controller to check the output power for correct
voltage, frequency, and stability. When the engine is If the engine does not start, the shutdown message will
running at full speed, the controller verifies that the be displayed. Correct the fault condition and reset the
voltage and frequency are within acceptable limits. A fault as described in Section 2.6.
fault message is displayed if the voltage or frequency
is out of range. 2.5.5 Power Failure During Exercise
D Oil pressure. Oil pressure is verified to ensure If the utility power is lost during an unloaded exercise,
proper lubrication of critical engine components. the ATS transfers to the emergency source, the exercise
Pressure is monitored at both low and full speeds. If is ended and the control remains in the AUTO mode.
the oil pressure is low, low oil pressure is displayed
and the generator set shuts down.

If the utility power is lost during a loaded exercise, the 10. Press Select. The controller exits the exercise
exercise is ended. The ATS remains in the emergency menu.
position and the control goes into the AUTO mode.
11. Press the Auto button and verify that the AUTO
The generator set continues to run and supply power to LED is lit. The generator set must be in automatic
the load for the duration of the utility power outage. mode for the exercise to run as scheduled.
When Utility power is restored, the ATS will re-transfer to
the utility source through normal timing sequences. 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
2.5.6 Exerciser Reset following procedure.
To reset the exerciser to run at a different day and/or
time or to change the exercise mode, follow the 2.5.8 Changing the Exercise Setting
procedure in Section 2.5.7 to change the exerciser
settings. Set the date and time on the controller before setting the
exercise schedule. Set the exerciser to automatically
run the generator set for 20 minutes every week or every
2.5.7 Setting the Exerciser at Power-up two weeks. Follow the procedure below and see the
When power is connected to the controller, you will be flowchart in Figure 2-3 to set the exercise time and date,
prompted to select the language and set the date, time, mode, and frequency.
and exercise schedule.
Procedure to Change the Exercise Setting
1. At power-up, you will be prompted to select a
language for the controller displays, Use the up 1. Press the AUTO button on the controller.
and down arrow buttons to step through the
2. Press the Select button to go to the main menu.
language options, Press the Select button when
See Figure 2-2.
the desired language is displayed.
3. Press the down arrow button to step to the Genset
2. Next, the date is displayed with the year flashing.
System menu.
Use the up or down arrow key to step to the current
year. 4. Press the Select button to enter the Genset system
menu. See Figure 2-3.
3. Press Select button to save the year and move to
the month. 5. Use the down arrow button to step to the next
Exercise menu.
4. Use the arrow and select buttons to set the month
and the day. 6. Press the Select button. The setting flashes to
show that it can be changed. For example, the hour
5. The time is displayed with the hour flashing. Use
flashes to show that the hour can be changed.
the up or down arrow key to step to the current hour
and am or pm setting. 7. Press the UP or Down arrow buttons to change the
setting.
Note: Check the am/pm setting displayed. If pm is
displayed and you need to change it to am, 8. Press the Select button to save the setting and
use the down arrow button to step down in move to the next. For example, save the hour
time until the correct hour and am are setting and move to minutes.
displayed.
9. Repeat steps 5 through 8 to change the next item
6. Press the Select button to save the hour and move on the line until the desired settings are displayed.
to minutes.
10. Press Select to save after all settings have been
7. Use the up or down arrow button to change the selected. Settings will stop flashing.
minutes.
11. If the generator set is connected to a Kohlerr Model
8. Press Select to save the time and move to the next RXT transfer switch, the exercise can be changed
screen. to a loaded exercise. Set the Exercise Mode to
loaded full speed, unloaded full speed, or unloaded
9. Next Exercise is displayed. Use the up, down, and
cycle as shown in Figure 2-3.
select buttons to set the exercise time and date. Be
sure to set a time and date in the future.

12. Set the exercise frequency (weekly or every two After a scheduled exercise run, the next exercise time
weeks). Weekly exercises are recommended. and date will be updated automatically based on the
Exercise Frequency setting.
13. Press the down arrow button to step to the Return
menu. Press the Select button to return to the main Other transfer switches: For a loaded exercise with a
menu. transfer switch other than a Kohlerr Model RXT,
program the exercise at the transfer switch controller.
14. Check that the AUTO LED is lit. The generator set Refer to the transfer switch operation manual for
must be in automatic mode for the exercise to run instructions.
as scheduled.
Status Overview ---->

Displays 1.2 h
Engine ----> ATS ---->

Metering Configuration
Generator----> Date ---->

Metering and Time
Genset ----> Network ---->

Information Information
Genset ----> PIM ---->

Run Time Status
Genset ----> Load ---->

System Control
ATS ----> Event Log---->

Status
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Figure 2-2 RDC2 Main Menu

Genset ----> System Voltage:
System 240 V
System Freq:
60 Hz
VR Voltage Adj:
240.0V
System Phase:
Single
System Battery:
12 V
Next Exercise * Next Exercise See Section 2.5.8, Changing

HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY the Exercise Setting
Exercise Mode: Exercise Mode:

Unloaded Cycle None/Unloaded Full Sp/ Un-
loaded Cycle/Loaded Full SP
Exercise Freq: Exercise Freq:

Weekly Weekly/Every Other Week
Meas. System:
English
Contrast:
50
<---- Return
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* If the exerciser has not been set, No Exercise Sch will be displayed.
Figure 2-3 Procedure to Set the Exerciser

2.6 Faults the transfer switch has been lost. Check the connection
to the ATS interface board.
Selected fault conditions are shown in Figure 2-5. Fault
conditions are classified as warnings or shutdowns. If a
fault occurs that is not listed in the table, contact an
2.6.4 Resetting the Controller after a
authorized distributor/dealer for service. Fault Shutdown
If a programmable interface module (PIM) is connected Always identify and correct the cause of a fault
to the generator set controller, additional faults can be shutdown before resetting the controller. Check the
activated by customer-supplied equipment. See fault message displayed on the controller and refer to
TT-1584, Installation Instructions for the Programmable Figure 2-5 to identify and correct the fault condition
Interface Module, for available inputs and outputs. before proceeding. Contact an authorized
distributor/dealer for service, if necessary.
2.6.1 Warnings Press the OFF button to reset the controller, or follow the
procedure below. See Figure 2-4.
The controller displays a fault message but the
generator set does not shut down on a warning. The
Procedure to Reset the Controller after a Fault
controller resets automatically after a warning condition
Shutdown
is corrected.
1. Press the Select button to go to the Overview
menu.
2.6.2 Shutdowns
Under a fault shutdown condition, the generator set 2. Press Select again. The active fault is displayed.
shuts down automatically and the controller displays a
3. Press Select. Confirm Clear Fault: NO is
fault message. The OFF LED flashes. See Figure 2-5.
displayed.
Shutdown switches (such as the low coolant level switch
4. Press the Up arrow button. Confirm Clear Fault:
or high engine temperature switch) on the generator set
YES is displayed.
will automatically reset when the problem is corrected.
However, the fault condition at the controller does not 5. Press the Select button to enter YES and clear the
clear until the controller is reset. fault.
The generator set cannot be restarted until the fault 6. Press the Select Button to return to the overview
condition is corrected and the controller is reset. See menu.
Section 2.6.4 to reset the controller after a fault
shutdown. 7. Press AUTO to put the generator set into automatic
mode.
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
Fault Message Overview ----> Fault Message Confirm Clear

1.2 h Fault: NO
Press Up
arrow button.
Confirm Clear
Fault: YES
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Figure 2-4 Clearing a Fault

Warning (W) or
Fault Shutdown (SD) Condition Check
AC Sens Lost W (1 sec.) AC Sensing Lost. In Auto mode, generator Contact an authorized
SD (3 sec.) output AC sensing is lost. Starts 10 seconds distributor/dealer for service.
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.
Accy PwrOver W Accessory Power Overload. An over current Contact an authorized
Warning fault (short circuit) on the accessory controller distributor/dealer for service.
power output.
Alt Protect SD High generator current has been detected. The Reduce the load.
Shtdwn generator set shuts down to protect the
alternator from damage caused by overheating
the windings.
ATS Com Error W Ats Communication Error. Warning is displayed Check communication wiring between
if RXT interface connection is lost. See transfer switch interface board and
Section 2.6.3. generator set.
ATS PhaseRot W ATS Phase Rotation Mismatch. Transfer switch Correct the ATS connection. Refer to
phase rotation does not match. ATS will not the ATS Installation manual, wiring
transfer. diagrams, and labels on the transfer
switch.
Aux Input SD Auxiliary Input. An optional customer-connected Check customer-supplied equipment.
input is closed. (Digital input from optional PIM.)
Batt Chg Flt W Battery charger fault. Input to PIM from an Check external battery charger.
external battery charger (not the built-in battery
charger).
Battery Voltage W Engine starting battery voltage rises above Check the battery rating and
High 125% of the battery voltage setting for more than condition.
10 seconds. Inhibited during the engine crank Check the battery charger operation.
cycle.
Clears when the battery voltage returns to an
acceptable level.
Battery Voltage W Engine starting battery voltage falls below the Check the battery rating and
Low battery voltage setting (typically 12.5 volts) for condition.
more than 90 seconds when the engine is not Check the battery charger operation.
running. Inhibited during the engine crank cycle.
Charge or replace the battery.
Clears when the battery voltage returns to an
acceptable level.
CAN comm SD Engine CAN communications fault. Check wiring to ECM.
fault Check power to ECM.
Engine Coolant SD Engine coolant temperature exceeds the Check for blocked air inlets and
Temperature maximum temperature for more than 5 seconds. exhaust outlets.
High Function becomes active after crank disconnect.
Engine Oil SD The engine ECM indicates low oil pressure for Check for leaks in the lubrication
Pressure Low more than 5 seconds. Function becomes active system.
30 seconds after crank disconnect (30 second Check the oil level and add oil if the
inhibit). level is low.
Note: The low oil pressure shutdown does not
protect against low oil level. Check the engine
oil level regularly as recommended in Section 4.
EngineSpeed SD Engine speed exceeds 115% of the normal Contact an authorized
High running speed for more than 0.3 seconds. distributor/dealer for service.
EngineSpeed SD Engine speed drops below 85% of the normal Reduce the load.
Low running speed for more than 3 seconds. Contact an authorized
distributor/dealer for service.

Warning (W) or
Fault Shutdown (SD) Condition Check
Exer Not Sch W Exercise Not Scheduled. No exercise has been See Section 2.5 for instructions to set
scheduled on the RDC2 controller. the exerciser.
Generator SD Governed frequency exceeds 110% of the Contact an authorized

Frequency High system’s frequency setpoint for more than 10 distributor/dealer for service.
seconds. Function becomes active 10 seconds
after engine start (10 second inhibit).
Generator SD Governed frequency falls below 90% of the Reduce the load and restart the
Frequency Low system frequency setting for more than generator set.
10 seconds, or 1 Hz below the system frequency Contact an authorized
setting for more than 60 seconds. distributor/dealer for service.
Function becomes active 10 seconds after
engine start (10 second inhibit).
Generator SD Generator Voltage High. Output voltage Contact an authorized
VoltageL1-L2 exceeds 120% of the system nominal voltage for distributor/dealer for service.
High more than 2 seconds.
Generator SD Generator Voltage Low. Output voltage falls Reduce the load and restart the
VoltageL1-L2 below 80% of the nominal system voltage for generator set.
Low more than 10 seconds. Contact an authorized
Lo Crank Vlt W Low cranking voltage. Battery voltage falls Charge or replace the battery.
below 60% of system battery voltage for more
than 6 seconds while the starter is engaged.
Locked Rotor SD No engine rotation is sensed during cranking. Check the battery.
Shuts down 3 seconds after the fault is detected. Check for loose connections.
Contact an authorized
MainPwrOverL SD Main power overload. An over current fault on Contact an authorized
Shutdown the 70 controller power output (short circuit). distributor/dealer for service.
Not in Auto W The generator set is not in Automatic (standby) Press AUTO to place the generator
mode. Remote start and stop commands from a set in Automatic mode, when
transfer switch or remote switch will be ignored. appropriate.
Over Crank SD Three unsuccessful starting attempts. Check the fuel supply, spark plug,
and battery.
Check for loose connections.
Contact an authorized
Speed Sensor SD Engine speed sensor has failed or engine Contact an authorized
Fault stalled. distributor/dealer for service.
Total Power SD Measured load is greater than 102% of the Reduce the load.
High ShtDwn generator set power rating for more than 1
minute.
Figure 2-5 Controller Fault Messages

2.6.5 Event Log 2.7 Model RXT Transfer Switch
The event log displays up to 1000 controller faults and Operation
notices, starting with the most recent event. Events are
The RDC2 generator set/transfer switch controller
numbered 1--1000, with 1 being the most recent. Each
manages automatic transfer switch (ATS) functions
event is displayed with the date and time of the event,
when connected to a Kohlerr Model RXT transfer switch
the number of the event, a code to indicate whether the
through the ATS interface board. Refer to the Model
event was a warning ( W), shutdown (S), or
RXT Operation/Installation Manual for information
informational notice ( I), the engine hours at the time of
about the transfer switch operation.
the event, and the event description.
Procedure to View Event History 2.7.1 Source Availability

1. Press Select to enter the main menu. The Model RXT transfer switch supplies voltage
sensing data to the RDC2 controller through the ATS
2. Press the down arrow to step down to the event log. interface board. If the source voltage falls below the
undervoltage dropout setting, the source is considered
3. Press Select to display the most recent event. to have failed. See Figure 2-7.
4. Press the down arrow to step to the next event.
Item Setting
5. Use the up and down arrow buttons to view events. Accuracy ±5%
Undervoltage Dropout 90% of Pickup
6. Press the Select button to exit the event log.
Undervoltage Pickup 90% of Nominal
To stop viewing the event history before the last event, Figure 2-7 Voltage Sensing Parameters
press the select button to return to the main menu.
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
Date MO/DA/YEAR source is supplying power to the building. See
Event Log ----> time HR:MN Figure 3-1.
event number, W/S/I, engine hours
event name Note: The power system LEDs operate only if a Model
RXT transfer switch is connected. They will not
Press UP and Down arrow but- operate if a Model RDT transfer switch is used.
tons to scroll through events
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
I = Informational Notice
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Figure 2-6 Event Log

2.7.2 ATS Control Sequence of 2.7.3 Time Delays
Operation
Time delays are factory-set to the values shown in
See Figure 2-8 for time delay settings. Figure 2-8. An authorized distributor/dealer can adjust
time delays using a personal computer and Kohlerr
SiteTecht software.
Preferred Source Fails:
1. The load control contact opens. Time delays described in this section operate only when
the controller is connected to a Kohlerr Model RXT
2. The engine start time delay times out. transfer switch.
3. The generator set is signaled to start. The engine start and load transfer time delays prevent
engine start and load transfer caused by brief variations
4. The generator starts and the emergency source in the utility power source.
becomes available.
5. The normal-to-emergency time delay times out. 2.7.4 ATS Load Control Relay Time
Delay
6. The transfer switch transfers to the emergency
source. The load control time delay allows delayed starting of
large motor loads (such as air conditioners), preventing
7. The load control contact time delay times out. simultaneous starting of large motors after transfer to
the generator set. The load control time delay is fixed at
8. The load control contact closes. 5 minutes. It is not adjustable.
Normal Source Returns: The load must be connected to the load control output
on the interface board of the Model RXT transfer switch.
1. The emergency-to-normal time delay times out. See the transfer switch operation and installation
manual for connection instructions.
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 Setting Description

Engine Start 3 seconds 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.
Transfer, Emergency to Normal 2 minutes 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 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.
Figure 2-8 Time Delays

Notes

Section 3 RDC2 Controller Operation
3.1 RDC2 Generator Set/Transfer 3.2 Controls and Indicators

Switch Controller Figure 3-1 illustrates the keypad, display, and indicators
Model 48RCLB and 60RCLA generator sets are on the controller’s user interface.
equipped with the RDC2 generator set/transfer switch
controller. The RDC2 controls the following power 1
system components:
D Generator set
2
11
D Model RXT automatic transfer switch (ATS)
3
D Load management device
10
4
D Programmable interface module (PIM)
RDC2 Controller features include:
D Two-line x 16 character backlit LCD display with

adjustable contrast 5
D OFF, AUTO, and RUN generator set master control

buttons 9 8 7 6
1. 2-line LCD display
2. Up button
D Generator set status indicating LEDs (OFF, AUTO,
3. Select button
RUN) 4. Down button
5. RUN button and LED
D Up, Down, and Select buttons for navigation through 6. Generator power available LED *
menus and adjustments 7. Generator supplying power to the building LED *
8. Utility supplying power to the building LED *
9. Utility power available LED *
D Power system indicator LEDs to show utility and 10. OFF button and LED
generator source status, and to show which source 11. AUTO button and LED GM77569
(utility or generator) is supplying power to the building * These LEDs operate only if a Model RXT transfer switch is
(Model RXT automatic transfer switch is required) connected.
Figure 3-1 RDC2 User Interface
TP-7102 7/18 Section 3 RDC2 Controller Operation 29

3.2.1 Controller Keypad 3.2.2 LED Indicators
The Run, Off, and Auto buttons control the generator set LEDs above the RUN, OFF, and AUTO buttons indicate
as described in Figure 3-2. Use the Select, Up arrow, the mode of operation as shown in Figure 3-2.
and Down arrow buttons to navigate through the menus
and change settings, if necessary. See Section 2.4 for The RDC2 controller also has a set of power system
operation instructions. 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
RUN Starts the generator set. The engine start time delay is ignored.
OFF 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 Places the generator set in Automatic (standby) mode.
Down arrow
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 LED Operation

RUN Lights when the generator set has been started locally by pressing the RUN button.
Remote start and stop commands are ignored.
OFF 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.
AUTO 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 OnCuer 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
30 Section 3 RDC2 Controller Operation TP-7102 7/18

3.2.3 LCD Display The display contrast is adjustable. Navigate to the
Genset System menu and step down to the Contrast
The controller is equipped with a two-line x 16 character screen. Press the Select button, and then use the up
backlit liquid crystal diode (LCD) display with adjustable and down arrow buttons to adjust the contrast. See
contrast. When the generator is running, the controller Section 3.5, Changing Settings, and Section 3.11,
automatically scrolls through the displays shown in Generator Set System Menu.
Figure 3-4. When the system is in AUTO, the LCD
display scrolls through the status messages shown in The display backlight turns off after about a minute of no
Figure 3-5. activity. The backlight turns on when a button is pressed
or when the generator set starts.
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.
Genset Status
Controller menus display power system information, Standby
including status information for the engine, generator,
and optional RBUS accessories, exercise settings, and
event history. Some menus allow changes to the Battery
controller settings. See Sections 3.6 through 3.19 for 12.3V
menu diagrams.
Engine Runtime:
27.4 h
Active Alert
Date: 02Jan2018
Time: HR:MNpm
Genset Status
Running
Next Exercise:
Voltage: 240V 09:00p 09Jan2018
Freq: 60.0Hz
Next Maintenance:
150 h or Jan2019
Engine: 123F
Oil Pressure: 40 psi
SW Version:
Battery 1.01
12.3V
Sample data shown.

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Engine Runtime:
27.4 h
Figure 3-5 Autopaging Displays, Automatic Mode
Date: 02Jan2018
Time: HR:MNpm
Sample data shown.

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Figure 3-4 Autopaging Displays, Generator Running

3.3 Controller Power The following procedure explains how to change
settings. See Figure 3-6 for an example using the Date
The RDC2 controller is powered by the generator set and Time settings.
engine starting battery and the built-in battery charger.
Note: Use caution when navigating the controller
Note: To disconnect controller power, disconnect the menus and changing the settings. In some
battery and the utility power to the generator set. menus, pressing the Select button can enable
editing of the controller settings. Changing some
If controller power is disconnected and reconnected, settings to incorrect values can adversely affect
you will be prompted to set the time, date, and exerciser. generator set operation or render the unit
The first setting will flash. Press the Up and Down arrow inoperable.
buttons to change the setting. Press Select to save the
setting and move on to the next. Repeat until all settings Procedure to Change Settings
are saved and the controller returns to the main menu.
See Section 3.5 for more detailed instructions to change 1. Press the Select button to enter the main menu.
settings on the RDC2. See Section 2.5 for more detailed
instructions to set the exerciser or change the exercise 2. Press the down arrow button until the desired menu
settings. is displayed. The Date and Time menu is used for
the example in Figure 3-6.
3.4 Battery Charging 3. Press the Select button to enter the selected menu.
See Figure 3-6.
The controller includes a built-in battery charger to
maintain the engine starting battery. The RDC2 4. Press the down arrow button to step through the
controller monitors the battery voltage and provides a parameters in the selected menu.
constant 13.4 ±2% VDC voltage and maximum 2.5
amps to charge the battery. 5. To change a setting, press the Select button. The
selected setting flashes.
The installer must connect 120 VAC/60Hz utility power
provided from the building on a breaker-protected circuit 6. Press the up or down arrow buttons to increase or
for the built-in battery charger. See the Installation decrease the setting.
Manual for instructions to connect the utility power for
the battery charger. 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
3.5 Changing Settings flashes. For example, in the date menu, the year,
month, and day can be adjusted.
Some settings can be changed from the controller
keypad. The controller settings and generator set 8. Repeat steps 5 through 7 for each setting on the
output are factory-set and should not require field screen.
adjustment under normal circumstances. Check and
adjust the settings and/or output when: 9. Press the down arrow to step to the next screen.
D The controller has been replaced. 10. To exit, press the down arrow button until Return is
displayed. Press the Select button to exit the
D The voltage requires adjustment for a particular menu.
application.
11. Press the AUTO or OFF button to exit the main
D Troubleshooting generator set problems. menu.
Have controller setup and adjustment performed only by Note: If no buttons are pushed, the controller exits the
an authorized Kohler distributor/dealer or authorized menus and returns to the generator set status
representative. display after 5 minutes.

Changing Settings on the RDC2 Controller
1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select
button. The saved date is shown.
Overview ---->
Press: Display: Date:
1.2 h Press: Display:
12Jan2018
2. Press the down arrow button until the desired

menu is displayed. See Figure 3-7. Date and Time 9. Press the down arrow button to step to the next
are used for this example. menu.
Time:
Date ----> Press: Display:
Press: Display: 01:49pm
and Time
10. Repeat steps 5 and 6, using the arrow and select

3. Press the Select button to enter the Date and Time buttons to set and save the time.
menu.
Note: To change from am to pm, press the up arrow
Date: key to increase the hour until the correct hour
Press: Display: and pm is displayed.
05Jan2017
11. Repeat to set the time format to 12 hr. or 24 hr.
4. To change the date and time settings, press the 12. Press the down arrow button. Return is
Select button again. The year will flash. displayed.
<---- Return
Date: Press: Display:
Press: Display:
05Jan2017
13. Press Select to return to the Date and Time

5. Press the up or down arrow buttons to change the menu.
year.
Date ---->
Press: Display:
and Time
Date:
Press: OR Display:
05Jan2018
14. Press the Up or Down arrow buttons to step to a

different menu.
15. Press Auto to signal the controller to exit the

6. When the correct year is shown, press the Select
menus and return to the generator set status
button. The year is saved and the next setting
display.
(month) flashes.
Genset State
Date: Press: Display:
Press: Display: Standby
05Jan2018
AUTO
7. Repeat steps 5 and 6, using the arrow and select

buttons to set the month and the date.
Note: If no buttons are pressed, the controller returns
to the status display after 5 minutes.
Figure 3-6 Changing Settings

3.6 Controller Menus 3.7 Main Menu
The following sections show the RDC2 controller menus Press the Select button once to bring up the main menu.
and submenus. Use the Select button and the up and Overview is displayed. See Figure 3-7. Press the down
down arrow buttons to navigate the menus as shown in arrow button to step to the next menu, Engine Metering.
the diagrams. Use the UP and DOWN arrow buttons to step up and
down through the menus shown in Figure 3-7.
Note: Use caution when navigating the controller
menus. In some menus, pressing the Select The controller will exit the main menu after 5 minutes if
button can enable editing of the controller no buttons are pressed. To exit the main menu
settings. Changing the settings to incorrect immediately, press the controller’s OFF or AUTO
values can adversely affect generator set button.
operation or render the unit inoperable.
If a setting on the controller display is flashing, edit mode

has been enabled. Press the OFF or AUTO button to
exit the edit mode.
Status Overview ---->

Displays 1.2 h
Press the Up and Down arrow buttons Engine ----> ATS ---->
to move between menus. Metering Configuration *
Press OFF or AUTO to exit the menus.
Generator----> Date ---->

Metering and Time
Genset ----> Network ---->

Information Information
Genset ----> PIM ---->

Run Time Status [
Genset ----> Load ---->

System Control ]
ATS ----> Event Log---->

Status
* ATS Configuration appears only if a Model RXT transfer switch is connected. tp6804
[ 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

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
Overview ----> Active Alert
1.2 h (if any) from this menu.
Engine ----> Eng Speed:

Metering 1800 RPM
Genset Status
Standby
Oil Pressure:
Voltage: 240V 40 PSI
Freq: 60.0Hz
Coolant Temp:
73 F
Engine: 95F
Oil: 40 PSI
Oil Temp:
73 F
Battery
13.4V
Battery:
13.4 V
Engine Runtime:
27.4 h
<---- Return
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Date: 01Mar2018
Time: HR:MNpm
Figure 3-9 Engine Metering Menu
Next Exercise:
09:00p 09Mar2018
Next Maintenance:
150 h or Jan2019
SW Version:
1.01
<---- Return
tp6809
Figure 3-8 Overview Menu

3.10 Generator Metering Menu Voltage Calibration
The generator metering menu displays the generator The voltage calibration mode can be entered from the
voltage and frequency. See Figure 3-10. Generator Metering menu. Contact a Kohler-authorized
The Reset Calibration menu allows you to set the

voltage reading back to the original value after
calibration, if necessary. See Figure 3-10.
Generator ---->
Metering
Single-phase
Three-phase
Volts L1--L2: Volts:

240 V 240 V
Volts L2--L3: Frequency:

240 V 60.0 Hz
Volts L3--L1:
240 V
Frequency:
60.0 Hz
Reset Reset
Calibration Calib? No
Reset
<---- Return Calib? Yes
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Figure 3-10 Generator Metering Menu

3.11 Generator Set Information 3.12 Genset Run Time Menu
Menu The data shown in Figure 3-12 are displayed. No
The generator set model number and serial numbers changes are allowed from this menu.
are displayed. No changes are allowed from this menu.
The Next Maintenance menu shows the number of
Model and serial numbers are factory set and should not hours of generator set operation until maintenance is
require changes in the field, except in the event that the required. The estimated date for the next scheduled
controller is being replaced. A personal computer maintenance is also displayed. The maintenance
running Kohlerr SiteTecht software is required to enter reminder intervals are based on the engine
the generator set model number and serial numbers on manufacturer’s recommendation for changing the oil.
a replacement controller. Contact an authorized Kohler Refer to Section 4, Scheduled Maintenance, for
distributor/dealer for service. maintenance instructions.
After changing the oil and performing other

recommended maintenance, go to the Overview menu
to reset the maintenance timer. See Section 4.3.4 for
Genset ----> Genset M/N:
instructions to reset the maintenance timer.
Information 48RCL
Genset S/N: Genset ----> Eng Runtime:

######## Run Time 27.4 h
or
Eng Starts:
Controller S/N:
######## 40
<---- Return Next Maintenance:

150 h or Jan2019
tp6810
Figure 3-11 Generator Set Information Menu <---- Return
tp6810
Figure 3-12 Generator Set Run Time Menu

3.13 Genset System Menu adjust the contrast. Press the Select button to save the
contrast setting.
The genset system menu displays the system
information shown in Figure 3-13. Generator sets are
factory set and should not require changes to the system
settings in the field. Genset ----> System Voltage:
System 240 V
A Kohler-authorized distributor or dealer can adjust
these settings, if necessary. If the generator set is
reconnected to a different voltage or the system settings
require adjustment for some other reason, see Section System Freq:
3.5 for instructions to enable editing and change the 60 Hz
system settings.
Note: Use caution when navigating the controller VR Voltage Adj:

menus. In some menus, pressing the Select 240.0V
button can enable editing of the controller
settings. Changing the settings to incorrect
values can adversely affect generator set System Phase:
operation or render the unit inoperable. Single
Voltage Regulator (VR) Voltage Adjust System Battery:

12 V
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 Fuel Type
distributor or dealer for service. Refer to the generator LP
set Installation Manual for instructions to adjust the
voltage.
Next Exercise
06:30p 15Mar2018
Fuel Type
The fuel type, LP or natural gas, is shown. Do not
change the fuel type in this menu unless the Exercise Mode:
generator s fuel system has been converted by an Unloaded Cycle
authorized distributor or dealer.
Exercise Freq:
Setting the Exerciser
Weekly
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 Language:
generator set. English
After a scheduled exercise run, the Next Exercise time

and date will be updated automatically based on the Meas System:
Exercise Frequency setting. English
Language Contrast:
The language for the controller display can be set to 50
English, French, Spanish, Dutch, or German.
<---- Return
Adjusting the Display Contrast
To adjust the display contrast, use the down arrow
Note: Actual settings may vary.
button to step to the Contrast menu. Press the Select tp6804
button, and then use the up and down arrow buttons to Figure 3-13 Genset System Menu

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.
Note: If there is no Model RXT transfer

ATS ---->
switch connected to the generator set,
Status
ATS Position: Remote ATS is displayed and the other
Normal screens on this page do not appear.
Normal Status:
Not/Acceptable
Emerg. Status:
Acceptable
Single-phase Three-phase
Voltage: Voltage L1--L2:

240V 240 V
Frequency: Voltage L2--L3:

60.0 Hz 240 V
Voltage L3--L1:
240 V
Frequency:
60.0 Hz
Reset Reset
Calibration Calib? No
Reset
<---- Return Calib? Yes
tp6810
Figure 3-14 ATS Status Menu, with Calibration

3.15 ATS Configuration Menu
Note: The ATS Configuration menu appears only if a ATS ----> Normal Freq:
Model RXT transfer switch is connected. Configuration 60.0 Hz
Use the ATS Configuration submenu to check the Model
RXT transfer switch system settings and time delays,
and change the settings, if necessary. Normal Voltage:
240.0 V
Changing ATS Configuration Settings
To enable editing, press the select button. The value
Emerg. Freq:
flashes to indicate that it can be changed. Press the up
60.0 Hz
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 Emerg. Voltage:
value to be changed. Repeat the adjustment process 240.0 V
until all values are correct.
Press the down arrow until Return is displayed. Press

the select button to return to the main menu. Emerg. Engine
Start: 3 sec
Transfer From
Normal: 3 sec
Transfer From
Emerg.: 120 sec
<---- Return
tp6810
Figure 3-15 ATS Configuration Menu

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
Time Date:
02Feb2018
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

3.17 Networking Information Menus The Networking Information menu leads to submenus
for network and RBUS communication settings.
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 Kohlerr OnCuer Plus Home
Generator Management System.
Networking----> Networking---->
NS See Figure 3-18.
Information Status
Networking----> NC See Figure 3-19.

Configuration
RBUS ---->
RB See Figure 3-20.
Information
<---- Return
tp6810
Figure 3-17 Networking Information Menu

3.17.1 Networking Status Submenu If DHCP is enabled, IP parameters are not displayed. If
DHCP is disabled (i.e., if a static IP address is used), the
The Networking Status submenu contains settings for IP parameters are displayed.
OnCuer Plus. See the OnCuer Plus Software
Operation Manual for information about the appropriate To enable or disable DHCP and change the IP settings,
network settings for OnCuer Plus. go to the Networking Configuration menu. See
Section 3.17.2.
Networking----> Networking----> OnCue Status:

Information Status Connected
DHCP:
Enabled
IP Address:
0.0.0.0
Subnet Mask:
0.0.0.0
Gateway:
0.0.0.0
DNS 1:
0.0.0.0
DNS 2:
0.0.0.0
Ethernet Status:
Disconnected
OnCue Server:
0.0.0.0
<---- Return
tp7102
Figure 3-18 Network Status Submenu

3.17.2 Networking Configuration Note: Use the OnCue password shown on the
Submenu (OnCuer Plus controller display for OnCue Plus applications.
Password) For the initial OnCue Plus setup, you will be required to
The networking Configuration menu includes settings reset the OnCue password on the RDC2 controller, and
used for communication with the Kohlerr OnCuer Plus then enter it into the OnCue Plus software. To reset the
Generator Management System. password, follow the instructions in Figure 3-19.
For most applications, DHCP is enabled and the IP Note: The password is displayed for only 10 seconds.
settings cannot be changed from the controller keypad. Be sure to write down the password and serial
If DHCP is enabled, IP parameters are not displayed. number.
If DHCP is disabled (i.e., if a static IP address is A new password is generated each time the reset
required), then the IP parameters can be modified. For password procedure is performed. If the password is
applications that require static IP addresses, press and reset after the OnCue Plus system has been set up, the
hold the select button to enable editing, disable DHCP, connection will be lost. Disconnect the battery power to
and then step to the next parameters and enter the the controller, wait a minute, then reconnect power.
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.
Information Status
HOLD
Networking Reset OnCue Reset OnCue

Configuration Password Password? No
UP arrow for YES,
Down arrow for NO.
Reset OnCue
Password? Yes
Press Select to enter YES

or NO as displayed. New
password is displayed for
DHCP: approximately 10 seconds.
Enabled
S/N: 1234567
New PW: 12345
<---- Return
tp6804
Figure 3-19 Network Configuration Submenu

3.17.3 RBUS Information Submenu D Model RXT transfer switch
The RBUS Information menu contains settings for D Programmable Interface Module (PIM)
remote modules that communicate with the RDC2
controller using RBUS protocol. This includes the D Load Shed Kit or RXT combined interface/load
following optional modules: management board
Information Status
Networking---->
Configuration
RBUS ----> Modules Connected:

Information 3
<---- Return Remote ---->

Devices RD
See Figure 3-21.

Net Cycle Time:
123ms
Module Timeouts:
1234
Module Errors:
1
< ---- Return
tp6804
Figure 3-20 RBUS Information Submenu

3.17.4 Remote Devices Submenu
Check the status of remote devices communicating
through RBUS. Device types can include:
D Model RXT ATS
D Programmable interface module (PIM)
D Load 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.
RD
S/N: XXXXXXXXX S/N: XXXXXXXXX <---- Return

...
<<*DeviceType*>> <<*DeviceType*>>
Device Status:
Connected
Comm. Errors:
12345
Comm. Timeouts:
12345
ModBus ID:
12
Firmware Ver.:
1.01
Connected: Connected: Displays date/time device was connected.

MM/DD/YY 12:12 Disconnected: Displays date/time of the last successful
communication.
Return ----> tp6810
Figure 3-21 Remote Devices Submenu

3.18 Programmable Interface A personal computer running Kohlerr SiteTecht
software is required to change the input and output
Module (PIM) Menus settings. Contact an authorized distributor or dealer for
The PIM status menu displays the status of inputs and service.
outputs connected to the programmable interface
The Kohlerr OnCuer Plus Generator Management
module (PIM). This is a status display menu only. Input
System can be used to turn outputs on and off. See the
and output settings cannot be changed from the RDC2
OnCuer Plus Software Operation Manual for
controller’s user interface.
instructions.
PIM PIM 1 ----> Input 1

Status: In/Active
<---- Return Input 2

In/Active
Output 1:
In/Active
Output 2:
In/Active
Output 3:
In/Active
Output 4:
In/Active
Output 5:
In/Active
Output 6:
In/Active
<---- Return
tp6810
Figure 3-22 Programmable Interface Module (PIM) Status Menu

3.19 Load Control Menus device adds and sheds loads based on the generator
current.
The Load Control menu displays the status of the load
management inputs and outputs, and allows a test of the The test function cycles the relays in the order of their
load management output relays. This menu appears priority. For detailed information about load
only if a load management device is connected. management operation, refer to TT-1609, provided with
the load shed kit, or TP-6807, RXT Transfer Switch
Generator current is displayed as a percent of the Operation and Installation Manual.
maximum generator capacity. The load management
Load ----> Generator

Control Current: 123 %
Load ----> Test Outputs

Control 1 Push Select (blinking)
<---- Return
Input 1:
In/Active
Input 2:
In/Active
Output 1:
Add/Shed
Output 2:
Add/Shed
Output 3:
Add/Shed
Output 4:
Add/Shed
Output 5:
Add/Shed
Output 6:
Add/Shed
<---- Return
tp6810
Figure 3-23 Load Control Status Menu

Section 4 Scheduled Maintenance
4.1 General Maintenance DANGER
WARNING
Hazardous voltage. Moving parts.

Will cause severe injury or death.
Accidental starting. Operate the generator set only when

Can cause severe injury or death. all guards and electrical enclosures
are in place.
Disconnect the battery cables before
working on the generator set. Servicing the generator set when it is operating. Exposed
Remove the negative (--) lead first moving parts will cause severe injury or death. Keep
when disconnecting the battery. hands, feet, hair, clothing, and test leads away from the belts
Reconnect the negative (--) lead last and pulleys when the generator set is running. Replace
when reconnecting the battery. guards, screens, and covers before operating the generator
set.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the WARNING
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 Risk of fire.
precautions to prevent the starting of the generator set by the Can cause severe injury or death.
remote start/stop switch.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the air cleaner. A sudden backfire can cause
severe injury or death. Do not operate the generator set with
the air cleaner removed.
Servicing the fuel system. A flash fire can cause severe
Hot engine and exhaust system. injury or death. Do not smoke or permit flames or sparks near
Can cause severe injury or death. the carburetor, fuel line, fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors. Catch fuels in an
Do not work on the generator set until
approved container when removing the fuel line or carburetor.
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.
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-7102 7/18 Section 4 Scheduled Maintenance 49

The fuel system. Explosive fuel vapors can cause severe repair, or operate the generator set. Have an authorized
injury or death. Vaporized fuels are highly explosive. Use Kohler distributor/dealer perform generator set service.
extreme care when handling and storing fuels. Store fuels in a
well-ventilated area away from spark-producing equipment Engine Service. Perform generator set engine service
and out of the reach of children. Never add fuel to the tank at the intervals specified by the engine operation
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit
manual.
flames or sparks to occur near sources of spilled fuel or fuel
vapors. Keep the fuel lines and connections tight and in good Routine Maintenance. Refer to the following generator
condition. Do not replace flexible fuel lines with rigid lines. Use set service schedule, the engine service schedule, and
flexible sections to avoid fuel line breakage caused by the runtime hours shown on the RDC2 controller to
vibration. Do not operate the generator set in the presence of determine when to schedule routine maintenance.
fuel leaks, fuel accumulation, or sparks. Repair fuel systems Service generator sets that are subject to extreme
before resuming generator set operation. weather or dusty or dirty conditions more frequently.
Gas fuel leaks. Explosive fuel vapors can cause severe
injury or death. Fuel leakage can cause an explosion. Check Maintenance and Service Parts. Obtain maintenance
the LPG vapor or natural gas fuel system for leakage by using and service parts from an authorized Kohler
a soap and water solution with the fuel system test pressurized distributor/dealer.
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 4.2 Service Schedule
test depends on the ability of the solution to bubble.
Perform maintenance on each item in the service
The engine and generator set may use both American
schedule at the designated intervals for the life of the
Standard and metric hardware. Use the correct size
generator set. References are given for procedures that
tools to prevent rounding of the bolt heads and nuts.
may require additional instructions.
See the Safety Precautions and Instructions at the
beginning of this manual before attempting to service,
50 Section 4 Scheduled Maintenance TP-7102 7/18

Service Schedule Reference
Daily or Before Each Use
Check oil level and add oil if necessary. See Section 4.3
Check coolant level and add coolant if necessary. w See Section 4.6
Check for fluid leaks.
Check battery connections for tightness and signs of corrosion. See Section 4.8
Check for fuel leaks, hissing, or gas odors.
Weekly
Check main tank supply level (LPG fuel).
Check for and remove obstructions or combustible materials near exhaust outlet. See Section 4.5
Check for and remove obstructions near air intake.
Check AC electrical system for visible wear or damage.
Exercise the generator set. See Sections 2.3 and 2.5
Check for evidence of vibration, leakage, deterioration, unusual or excessive noise or temperature.
Monthly
Check battery charger operation, charge rate.
Quarterly (3 Months)
Remote control system, if equipped.
Check fuel lines and connections.
Check engine and generator for visible wear or damage.
Check interior of sound enclosure.
Every 6 Months
Check for wire abrasions where subject to motion.
Yearly
Inspect fuel piping.
Check and clean the radiator exterior.
Remove corrosion, clean and dry battery and rack. See Section 4.8
Clean and tighten battery terminals and inspect boots. See Section 4.8
Check battery electrolyte level and specific gravity. * See Section 4.8
Tighten control and power wiring connections.
Check the DEPR fuel pressure. Engine Operation Manual
Check the drive belt for cracks, splitting, or breaks. Engine Operation Manual
Yearly or 150 hours
Change engine oil and replace oil filter. See Section 4.3
Inspect crankcase breather hose. Engine Operation Manual
Check spark plugs. See Section 4.7
Check the air cleaner element. [ See Section 4.4
Yearly or 400 hours
Replace the air cleaner element. [ See Section 4.4
3 Years or 500 hours
Check engine air induction system for leaks.
Check spark plug gap and adjust if necessary. Replace spark plugs if discolored or damaged. See Section 4.7
Check spark plug wires for cuts, hardening or abrasions and replace as needed.
Check wire-cable insulation condition.
Change the engine coolant. w See Section 4.6
Measure and record resistance readings of windings with insulation tester (Meggerr, with
Generator Set Service Manual
SCR assembly or rectifier and load leads disconnected). ]
5 Years or 2000 hours
See the Engine Operation Manual for engine maintenance requirements. Engine Operation Manual
*Not necessary for maintenance-free batteries.
[Service more frequently under extremely dusty/dirty conditions.
]Have this service performed by an authorized distributor or dealer.
wLong-life coolant is recommended. When long-life coolant is used, the change interval is 5000 hours or 5 years. Do not mix coolant
types.
Meggerr is a registered trademark of Biddle Instruments.

4.3 Lubrication System 4.3.3 Oil Additions
Adding some oil between oil changes is normal. The
4.3.1 Oil Specifications amount varies with generator set usage. Open the oil fill
cap and pour in a small amount of oil using a funnel or
Kohler recommends KOHLERr Genuine Oil, 10W--40 other suitable pouring device. See Section 1, Service
or equivalent. Views, for the oil check and oil fill locations.
KOHLERr Genuine Oil is fully synthetic and engineered
specifically for gaseous-fueled (NG/LPG) engines 4.3.4 Oil and Filter Change
requiring SAE 10W--40 oil.
Note: The oil must meet the specifications for zinc, WARNING
phospohorous, and ash content shown in
Figure 4-1.
Oil Specifications
Oil Type SAE 10W-40 Accidental starting.
Zinc Content 1000--1200 ppm
Phosphorous 1000--1200 ppm Disconnect the battery cables before
working on the generator set.
Sulfated Ash Content 1% or lower Remove the negative (--) lead first
when disconnecting the battery.
Figure 4-1 Engine Oil Specifications Reconnect the negative (--) lead last
when reconnecting the battery.
4.3.2 Oil Check
Check the oil level in the crankcase every 24 hours of cause severe injury or death. Before working on the
operation or before the engine is started each day. Do generator set or equipment connected to the set, disable the
not check the oil level while operating the unit. Stop the generator set as follows: (1) Press the generator set off/reset
generator set and keep the generator set level to get an button to shut down the generator set. (2) Disconnect the
accurate reading. To check the oil level, remove the power to the battery charger, if equipped. (3) Remove the
dipstick and wipe the end clean. Reinsert the dipstick battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
and wait at least 30 seconds. Remove the dipstick and
precautions to prevent the starting of the generator set by the
check the level. Maintain the oil level between the Full remote start/stop switch.
and Add marks on the dipstick, as shown in Figure 4-2.
See Section 1, Service Views for the dipstick location. Change the oil after the first 40 hours of engine
operation. Then change the oil according to the service
Note: Do not operate the set if the oil level is below the schedule or before generator set storage. Change the
Add mark or above the Full mark on the dipstick. oil more frequently if the generator set operates under
dirty, dusty conditions. Change the oil while the engine
is still warm. See Section 1, Service Views, for oil fill, oil
check, and oil filter locations.
1
Dispose of all waste materials (engine oil, fuel, filter,
etc.) in an environmentally safe manner.
Note: Reset the maintenance timer on the RDC2

2
1. Full mark TP-5586-3 controller after changing the oil.
2. Add mark
Figure 4-2 Oil Level Check

Oil Change Procedure 4. Check for leaks.
Whenever possible, drain the oil while it is still warm. a. Press the OFF button on the RDC2 generator
set controller.
1. Drain the oil.
b. Reconnect the generator set engine starting
a. Press the OFF button on the RDC2 generator battery, negative (--) lead last.
set controller.
c. Reconnect the power for the battery charger.
b. Disconnect the power for the battery charger.
d. Start the generator set and check for leaks
c. Disconnect the generator set engine starting around the oil filter.
battery, negative (--) lead first.
e. Stop the generator set and tighten the oil filter to
d. Remove the housing side panel. stop any leaks.
e. Remove the plug from the oil drain fitting and f. Reinstall the housing side panel.
install a drain hose.
5. Stop the generator set. Check the oil level. Add
f. Open the oil drain valve on the engine. oil, as necessary, to bring the level up to the Full
mark.
g. Allow time for the engine oil to drain completely.
Note: Too high an oil level causes high oil
h. Close the oil drain valve.
consumption and engine carbonizing. Too
i. Replace the oil drain plug. low a level damages the engine.
2. Replace the oil filter. 6. Reset the maintenance timer on the RDC2.
a. Remove the oil filter by rotating it a. In the Overview menu, step down to the Next
counterclockwise with an oil filter wrench. Maintenance screen.
b. Clean the contact surface of the oil filter b. Press the Select button.
adapter.
c. Press the Up arrow button so that Reset Maint
c. Apply a light coat of clean oil to the rubber seal Timer? Yes is displayed.
of the new oil filter.
d. Press the Select button. The next maintenance
d. Install the new oil filter following the instructions interval and date will be displayed.
provided with the filter.
3. Fill with oil. See Figure 4-1 for oil selection and
Figure 4-3 for oil capacity.
Model Oil Capacity, L (qt.)

48RCLB and 60RCLA 4.7 (5.0)
Figure 4-3 Oil Capacity

4.4 Air Cleaner Air Cleaner Service Procedure
A dry-type air cleaner silences and filters the intake air.
WARNING See Figure 4-4. The air intake silencer assembly
connects to the intake manifold via a rubber hose.
working on the generator set.
Remove the negative (--) lead first
Reconnect the negative (--) lead last GM90280
when reconnecting the battery.
Disabling the generator set. Accidental starting can Figure 4-4 Air Cleaner
cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the 1. Remove the cover from the air cleaner housing.
generator set as follows: (1) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the 2. Remove the air cleaner element.
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative 3. Examine the element and housing for damage.
(--) lead last when reconnecting the battery. Follow these
Replace the element and housing if damaged.
precautions to prevent the starting of the generator set by the
remote start/stop switch.
4. Tap the element lightly against a flat surface to
dislodge loose surface dirt. Do not clean the
WARNING element in any liquid or use compressed air as
these will damage the filter element. Replace the
element and precleaner at the intervals shown in
the service schedule.
Risk of fire. 5. Wipe the cover and housing with a clean rag to
Can cause severe injury or death. remove dirt. Make sure the sealing surfaces fit
Do not smoke or permit flames or correctly.
sparks near fuels or the fuel system.
6. Replace the air cleaner cover.
Servicing the air cleaner. A sudden backfire can cause
severe injury or death. Do not operate the generator set with
the air cleaner removed.
At the interval specified in the service schedule, inspect

and clean or replace the air cleaner element. Clean the
element more frequently in dirty, dusty conditions.
Check the element for accumulated oil or dirt that could
cause poor performance. Replace the air cleaner
element if damaged. Follow the procedure described
below.

4.5 Exhaust System CAUTION
WARNING
Hazardous noise.
Can cause hearing loss.
Carbon monoxide.
Can cause severe nausea, Never operate the generator set
fainting, or death. without a muffler or with a faulty
exhaust system.
DO NOT locate the generator set
near patios, decks, play areas, or
animal shelters. WARNING
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 Hot engine and exhaust system.
operate the generator set inside a building. Never operate the Can cause severe injury or death.
generator set where exhaust gas could seep inside or be
drawn into a potentially occupied building through windows, air Do not work on the generator set until
intake vents, or other openings. it cools.
Carbon monoxide symptoms. Carbon monoxide can Servicing the exhaust system. Hot parts can cause
cause severe nausea, fainting, or death. Carbon monoxide severe injury or death. Do not touch hot engine parts. The
is a poisonous gas present in exhaust gases. Carbon engine and exhaust system components become extremely
monoxide is an odorless, colorless, tasteless, nonirritating gas hot during operation.
that can cause death if inhaled for even a short time. Carbon
monoxide poisoning symptoms include but are not limited to At the interval specified in the service schedule, inspect
the following:
the exhaust system components (exhaust manifold,
D Light-headedness, dizziness
D Physical fatigue, weakness in
exhaust outlet, exhaust line, exhaust clamps, and
joints and muscles muffler) for cracks, leaks, and corrosion.
D Sleepiness, mental fatigue,
inability to concentrate Exhaust System Inspection Points
or speak clearly, blurred vision
D Stomachache, vomiting, nausea D Check for corroded or broken metal parts and replace
If experiencing any of these symptoms and carbon monoxide them as needed.
poisoning is possible, seek fresh air immediately and remain
active. Do not sit, lie down, or fall asleep. Alert others to the D Check that the exhaust outlet is unobstructed.
possibility of carbon monoxide poisoning. Seek medical
attention if the condition of affected persons does not improve D Check the exhaust gas color. If the exhaust is blue or
within minutes of breathing fresh air.
black, contact your local authorized Kohler distributor/
Carbon monoxide detectors. Carbon monoxide can dealer.
cause severe nausea, fainting, or death. Install carbon
monoxide detectors on each level of the building. Locate the D Visually inspect for exhaust leaks (blowby). Check
detectors to adequately warn the building’s occupants of the for carbon or soot residue on exhaust components.
presence of carbon monoxide. Keep the detectors operational Carbon and soot residue indicates an exhaust leak.
at all times. Periodically test and replace the carbon monoxide Seal leaks as needed.
detectors according to the manufacturer’s instructions.
D Check that all covers and doors are undamaged, in
place, and locked.
D 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 4.6.2 Cooling System Inspection
To prevent generator shutdown or damage because of
WARNING overheating:
D Keep the cooling air inlets clean and unobstructed
D Inspect the radiator’s exterior for obstructions and

Hot coolant and steam. remove dirt and foreign material with a soft brush or
Can cause severe injury or death. cloth to avoid damaging the radiator fins.
Before removing the pressure cap, D Check the hoses and connections for leaks and
stop the generator set and allow it to replace any cracked, frayed, or spongy hoses.
cool. Then loosen the pressure cap
to relieve pressure.
D Check the condition and tension of the radiator water
pump belt(s).
Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To D Check the rubber seal of the radiator’s pressure cap
release pressure, cover the pressure cap with a thick and replace a cracked or deteriorated cap. Remove
cloth and then slowly turn the cap counterclockwise to dirt and other debris from the pressure cap and filler
the first stop. Remove the cap after pressure has been neck. The pressure cap raises the boiling point of the
completely released and the engine has cooled. Check coolant, enabling higher operating temperatures. If
the coolant level at the tank if the generator set has a the cap leaks, replace it with the same type of cap that
coolant recovery tank. meets or exceeds SAE J164. The acceptable
pressure cap rating is shown in Figure 4-5.
Note: Block heater damage. The block heater will fail
if the energized heater element is not immersed
in coolant. Fill the cooling system before turning Item Rating
on the block heater. Run the engine until it is Pressure cap 83--110 kPa (12--16 psi)
warm and refill the radiator to purge the air from
Figure 4-5 Pressure Cap Rating
the system before energizing the block heater.
4.6.3 Draining Cooling System

4.6.1 Checking and Filling Coolant
The radiator contains a coolant drain valve to drain the
Maintain the coolant level in the coolant overflow bottle
cooling system. When draining the coolant, remove the
between the High and Low markings. See Section 1, radiator’s pressure cap, which will allow the entire
Service Views, for the coolant overflow bottle location. system to drain and will prevent air pockets from forming
Note: Periodically check the coolant level by removing and restricting coolant passage to the block.
the radiator’s pressure cap. Do not rely solely on
1. De--energize the block heater, if equipped.
the level in the coolant overflow bottle.
2. Remove the pressure cap to allow the entire
Ethylene glycol-based long-life coolant is
system to drain and prevent air pockets from
recommended. Use a coolant mixture of 50% long-life
restricting coolant flow through the engine block.
coolant and 50% clean, softened water to inhibit
rust/corrosion and prevent freezing. Add fresh coolant 3. Open the coolant drain valve and allow the system
until the level is just below the overflow tube opening. to drain.
A coolant solution of 50% ethylene glycol-based coolant 4. If the inside of the radiator has mineral deposits or
provides freezing protection to --37C (--34F) and the used coolant contains dirt or grease, go to
overheating protection to 129C (265F). A coolant Section 4.6.4, Flushing and Cleaning. If the cooling
solution with less than 50% ethylene glycol may not system does not have mineral deposits, refill the
provide adequate freezing and overheating protection. cooling system as instructed in Section 4.6.5,
A coolant solution with more than 50% ethylene glycol Filling Cooling System.
can cause engine or component damage. Do not mix
long-life coolant and conventional coolants. Do not use
alcohol or methanol antifreeze or mix them with the
specified coolant.

4.6.4 Flushing and Cleaning 4.7 Spark Plugs
For optimum protection, drain, flush, and refill the
cooling system at the interval listed in the service WARNING
schedule.
Flushing and Cleaning Procedure

1. Flush the system with clean water.
2. Drain, clean, and flush the coolant overflow bottle. Can cause severe injury or death.
3. Refill the cooling system as instructed in working on the generator set.
Section 4.6.5. Remove the negative (--) lead first
Reconnect the negative (--) lead last
4.6.5 Filling Cooling System when reconnecting the battery.
Coolant Capacity, L (gal.)

Generator Set 20.8 (5.5) cause severe injury or death. Before working on the
Generator Set generator set or equipment connected to the set, disable the
21.4 (5.7) generator set as follows: (1) Press the generator set off/reset
with Block Heater
button to shut down the generator set. (2) Disconnect the
Figure 4-6 Coolant Capacity power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
Note: Do not add coolant to a hot engine. Adding (--) lead last when reconnecting the battery. Follow these
coolant to a hot engine can cause the cylinder precautions to prevent the starting of the generator set by the
block or cylinder head to crack. Wait until engine remote start/stop switch.
has cooled.
Service the spark plugs at the interval specified in the
1. Close the radiator’s coolant drain valve and tighten service schedule using the following procedure.
the hose clamps.
1. Press the OFF button on the RDC2 controller.
2. Fill the radiator with the recommended coolant
2. Disconnect the power to the battery charger.
mixture of 50% ethylene glycol and 50% clean,
softened water to inhibit rust/corrosion and prevent 3. Disconnect the generator set engine starting
freezing. The coolant capacity is shown in battery, negative (--) lead first.
Figure 4-6.
4. Remove spark plug wires by grasping the spark
3. Operate the engine with the radiator cap removed plug boot and turning slightly while pulling. Do not
until the thermostat opens and the upper radiator pull the wire. Pulling on the wire rather than the
hose becomes hot. boot may damage the wire or terminal.
4. Stop the engine and allow it to cool. 5. Loosen the spark plug with a ratchet and 5/8-in.
spark plug socket with a rubber insert to prevent
5. Add coolant to the radiator to just below the
spark plug damage.
overflow tube on the filler neck. See Section 1,
Service Views, for the overflow tube location. 6. Use compressed air to remove dirt from around
each spark plug to prevent dirt particles from falling
6. Replace the radiator’s pressure cap.
into the combustion chamber.
7. Maintain the coolant level in the coolant overflow
7. Remove spark plugs, one at a time, and examine.
bottle between the High and Low markings. See
Identify a normal spark plug in good operating
Section 1, Service Views, for the coolant overflow
condition by observing a light tan or gray deposit on
bottle location.
firing tip. See Figure 4-10 to evaluate engine
8. Re--energize the block heater, if equipped. condition by color/condition of a problem spark plug.
8. Clean spark plugs by wiping them with a rag. File

the center electrode to keep it parallel to the side
electrode.

Note: Do not sandblast, wire brush, scrape, or
otherwise service spark plugs in poor
condition. Obtain a new plug for best
results.
9. Check the spark plug gap before installing any

spark plug. See Figure 4-7 and Figure 4-8. Attain
a correct gap when the feeler (or wire) passes
between the spark plug electrode. It should pass
easily but with some resistance or drag; otherwise
adjust as necessary.
Spark Plug Specifications

1-511
Spark plug gap 0.76 mm (0.03 in.)
Spark plug torque 27 Nm (20 ft. lbs.) Figure 4-9 Spark Plug Gap Adjustment
Figure 4-7 Recommended Spark Plug Gap
11. Reinstall the spark plug. Do not bump the
electrode against the cylinder head. Rotate the
spark plug clockwise until you feel resistance.
1 12. Use a torque wrench to tighten each spark plug to

the torque shown in Figure 4-7. Otherwise,
hand-tighten the spark plug until you feel
resistance. Then use a ratchet wrench to final
tighten an additional 1/4 turn. Do not overtighten,
2 as doing so may strip the threads or alter the
electrode gap setting.
13. Check the spark plug wire connector in the boot for
1-514 accumulated dirt, grease, and other debris, and
1. 0.9 mm (0.035 in.) gap clean as necessary.
2. Spark plug electrodes
14. Firmly push the spark plug boot onto the spark
Figure 4-8 Spark Plug Gap Inspection plug.
10. Use a gapping tool to gently bend the side 15. Reconnect the generator set engine starting
electrode closer to or farther from the center battery, negative (--) lead last.
electrode to set the correct gap. See Figure 4-9.
Position the side electrode directly over the center 16. Reconnect the power for the battery charger.
electrode.

Problem/Condition Means of Identification Possible Cause/Solution
Gap-bridged spark Built-up deposits and gap between electrodes Oil or carbon fouling. Clean and regap the spark
plug closing. plug.
Oil-fouled spark plug Wet, black deposits on the insulator shell, bore, Excessive oil entering combustion chamber
and electrodes. through worn rings and pistons, excessive clear-
ance between valve guides and stems, or worn
or loose bearings. Replace the spark plug.
Carbon-fouled spark Black, dry, fluffy carbon deposits on insulator Incorrect spark plug, weak ignition, clogged air
plug tips, exposed shell surfaces and electrodes. 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 Caused by highly leaded fuel. Replace the
glazed coating on the insulator tip. spark plug.
Pre-ignition damaged Melted electrodes and possibly blistered insula- Wrong type of fuel, incorrect timing or advance,
spark plug tor. Metallic deposits on insulator suggest inter- too hot a plug, burned valves, or engine over-
nal engine damage. heating. Replace the spark plug.
Overheated spark plug White or light gray insulator with small black or Engine overheating, wrong type of fuel, loose
gray/brown spots with bluish (burned) appear- spark plugs, too hot a plug, low fuel pressure or
ance on electrodes. incorrect ignition timing. Replace the spark plug.
Worn spark plug Severely eroded or worn electrodes. Caused by normal wear and failure to replace
spark plug at prescribed interval. Replace the
spark plug.
Figure 4-10 Engine Evaluation Using Spark Plug Condition

4.8 Battery Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or
Consult the battery manufacturer’s instructions equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
regarding battery care and maintenance.
servicing the equipment. Use tools with insulated handles.
Remove the negative (--) lead first when disconnecting the
battery. Reconnect the negative (--) lead last when
WARNING 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

Sulfuric acid in batteries.
maintenance. Also consult the battery manufacturer’s
Can cause severe injury or death. instructions for battery maintenance.
Wear protective goggles and All generator set models use a negative ground with a
clothing. Battery acid may cause 12-volt engine electrical system. Consult the generator
blindness and burn skin. set nameplate for the engine electrical system voltage.
Consult the generator spec sheet for battery capacity
Battery electrolyte is a diluted sulfuric acid. Battery acid recommendations for replacement purposes. Wiring
can cause severe injury or death. Battery acid can cause diagrams provide battery connection information. See
blindness and burn skin. Always wear splashproof safety
Figure 4-11 for typical battery connections.
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 1 2
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
EZ-273000-J
injury or death. Battery acid is electrically conductive and
corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking 1. To positive (+) terminal on starter solenoid.
soda) to a container with 4 L (1 gal.) of water and mix the 2. To ground (--) terminal on or near starter motor.
neutralizing solution. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing Figure 4-11 12-Volt Engine Electrical System Single
solution to the spilled battery acid until all evidence of a Starter Motor, Typical Battery Connection
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area. Clean the battery and cables and tighten battery
Battery gases. Explosion can cause severe injury or terminals using the service schedule recommendations.
death. Battery gases can cause an explosion. Do not smoke To prevent corrosion, maintain tight, dry electrical
or permit flames or sparks to occur near a battery at any time, connections at the battery terminals. To remove
particularly when it is charging. Do not dispose of a battery in a corrosion from battery terminals, disconnect the cables
fire. To prevent burns and sparks that could cause an from the battery and scrub the terminals with a wire
explosion, avoid touching the battery terminals with tools or
brush. Clean the battery and cables with a solution of
other metal objects. Remove all jewelry before servicing the
equipment. Discharge static electricity from your body before baking soda and water. After cleaning, flush the battery
touching batteries by first touching a grounded metal surface and cables with clean water and wipe them with a dry,
away from the battery. To avoid sparks, do not disturb the lint-free cloth.
battery charger connections while the battery is charging.
Always turn the battery charger off before disconnecting the After reconnecting the battery cables, coat the battery
battery connections. Ventilate the compartments containing terminals with petroleum jelly, silicone grease, or other
batteries to prevent accumulation of explosive gases. nonconductive grease.

4.8.1 Checking Electrolyte Level Temperature
Correction
C F
Check the electrolyte level of batteries with filler caps 71.1 160 + .032
monthly. Remove filler caps and verify that electrolyte + .030
level reaches bottom of filler holes. Refill as necessary 65.6 150 + .028
EXAMPLE NO. 1—
with distilled water. DO NOT add fresh electrolyte. + .026
Temperature below 80F (26.7C)
Tighten all filler caps. If water is added during freezing 60.0 140 + .024
temperatures, run the generator set for 20--30 minutes + .022 Hydrometer Reading 1.250
to mix the electrolyte and water to prevent battery 54.4 130 + .020
Acid Temperature 20F (--6.7C)
damage from freezing. + .018
48.9 120 + .016

Subtract .024 Specific Gravity
Corrected Specific Gravity is 1.226
4.8.2 Checking Specific Gravity + .014
43.3 110 + .012 1.250 -- .024 = 1.226

Use a battery hydrometer to check the specific gravity of
+ .010
the electrolyte in each battery cell. While holding the
37.8 100 + .008
hydrometer vertically, read the number on the glass bulb
+ .006 EXAMPLE NO. 2—
at the top of the electrolyte level or the number adjacent
32.2 90 + .004
to the pointer. If the hydrometer used does not have a Temperature above 80F (26.7C)
+ .002
correction table, use the correction factors in Hydrometer Reading 1.235
26.7 80 0
Figure 4-14. Determine specific gravity and electrolyte
-- .002 Acid Temperature 100F (37.8C)
temperature of battery cells. Locate temperature in
21.1 70 -- .004
Figure 4-14 and adjust the specific gravity by the Add .008 Specific Gravity
--. 006
amount shown. Corrected Specific Gravity is
15.6 60 -- .008
1.243
The battery is fully charged if the specific gravity is 1.260 -- .010
1.235 + .008 = 1.243
at an electrolyte temperature of 80F (26.7C). The 10 50 -- .012
difference between specific gravities of each cell should -- .014
not exceed 0.01. Charge the battery if the specific 4.4 40 -- .016
gravity is below 1.215 at an electrolyte temperature of -- .018
80F (26.7C). See Figure 4-12. -- 1.1 30 -- .020
-- .022
Specific Gravity, Battery -- 6.7 20 -- .024
Corrected to 80F (26.7C) Condition -- .026
Below 1.215 Needs charging -- 12.2 10 -- .028
1.260 Fully charged

Figure 4-12 Specific Gravity Interpretation
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 The temperature correction amounts to about .004 (4 points) of
manufacturer’s instructions. Figure 4-13 interprets specific gravity for each 10F (5.5C) change in temperature.
typical test results. 1-787
Battery Figure 4-14 Specific Gravity Temperature Correction

Number of Floating Beads Condition
5 Overcharged
4 Fully charged
3 Good charge
1 or 2 Low charge
0 Dead battery
Figure 4-13 Bead-Type Test Interpretation

4.9 Storage Procedure 5. Keep spark plugs in their holes or seal spark plug
holes with suitable threaded metal plugs.
WARNING 6. Clean the exterior of the generator set and spread a
light film of oil or silicon spray over any exposed
surfaces that may be subject to rust or corrosion.
7. Seal the air inlet, exhaust pipe, and fuel tank cap
Hot engine and exhaust system. with tape.
8. Disconnect and remove the battery. Place the
Do not work on the generator set until
it cools.
battery in a warm, dry location for the storage
period. Recharge the battery once a month to
maintain a full charge.
DANGER
9. Select a well-ventilated (not humid or dusty)
location to store the generator.
10. Cover the entire unit with a dust cover.
Hazardous voltage. Moving parts. Note: Run the generator set once a month
Will cause severe injury or death. whenever possible.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Follow the procedure below when storing your

generator set for a long period (3 months or more).
1. Start and run the generator set 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.
4. Check the engine coolant protection; see

Section 4.6.
Note: Use antifreeze capable of withstanding the

lowest possible temperatures.

Section 5 Troubleshooting
5.1 Introduction Identify and correct the cause of the fault condition.
Then reset the controller after a fault shutdown. See
Use the troubleshooting charts in this section to Section 2.6.4.
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 5.4 Circuit Protection
charts include a list of common problems, possible
causes of the problem, and recommended corrective If the generator set circuit breaker trips or the fuses blow
actions. repeatedly, contact an authorized Kohler distributor/
dealer for service.
If the procedures in this manual do not explain how to
correct the problem, contact an authorized Kohler
distributor/dealer. Maintain a record of repairs and 5.4.1 Load Circuit Breaker
adjustments performed on the equipment. Use the
record to help describe the problem and repairs or The load circuit breaker interrupts the generator output
adjustments made to equipment. in the event of a fault in the wiring between the generator
and the load. If the circuit breaker trips, reduce the load
and switch the breaker back to the ON position. Refer to
5.2 USB Port the service views in Section 1 for the location of the
circuit breaker.
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).
5.4.2 Fuses
Some controller settings can be adjusted using a laptop Three 30 amp fan fuses are located in the fan fuse and
computer with Kohlerr SiteTecht software. SiteTech relay box. See Section 1, Service Views, for location.
software is available to Kohler authorized distributors
Always identify and correct the cause of a blown fuse
and dealers. See TP-6701, SiteTecht Software
before restarting the generator set. Refer to Figure 5-1,
Operation Manual, for more information.
Troubleshooting Chart, for conditions that may indicate
a blown fuse. Obtain replacement parts and service
5.3 Fault Messages from an authorized Kohler distributor/dealer.
The RDC2 controller displays fault messages to aid in 5.4.3 Controller Internal Circuit
troubleshooting. Fault messages, descriptions, and Protection
recommended checks are listed in Figure 2-5.
The controller is equipped with internal circuit
protection. Press OFF to reset.
TP-7102 7/18 Section 5 Troubleshooting 63

5.5 Generator Set Troubleshooting
Figure 5-1 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections
before replacing parts.
Note: Read all safety precautions at the beginning of this publication before performing any work on the generator set.
Problem Possible Cause Corrective Action

The generator Battery weak or dead. Recharge or replace the battery.
set does not Battery connections reversed or poor. Check the connections.
crank.
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 Air cleaner clogged. Clean and/or replace the air cleaner element.
set cranks but Battery weak or dead. Recharge or replace the battery.
does not start,
starts hard, Battery connection poor. Clean and tighten the battery connections.
lacks power, or Spark plug wire connection loose. Check the spark plug wires.
operates Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if
erratically. 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 by unplugging
non-essential appliances.
AC circuit breaker tripping because of short Contact an authorized Kohler distributor/dealer for
circuit. service.
Low output or Generator set overloaded. Reduce the load by unplugging non-essential
excessive drop appliances.
in voltage.
Generator set Low oil pressure shutdown. Check for oil leaks. Check the oil level and add oil if
stops suddenly. 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 engine or press AUTO
to allow remote starting.
Remote stop command received from a remote Check the remote switch position.
switch, ATS, or OnCuer.
Engine malfunction. Contact an authorized Kohler distributor/dealer.
Fans run after The fans continue to run for 2 minutes after the None.
engine shuts engine shuts down to evacuate the engine
down. compartment.
Figure 5-1 General Troubleshooting Chart
64 Section 5 Troubleshooting TP-7102 7/18

5.6 Controller Troubleshooting
Figure 5-2 contains basic troubleshooting information for the RDC2 controller.
Problem Possible Cause Corrective Action

Controller LCD Low or no battery voltage. Check connections.
display is off. Check generator set battery. See Figure 5-1.
Controller display Backlight turns off after about 1 minute with no Backlight will turn on when a button is pressed or
backlight is off. activity. the generator set starts.
Loss of Bad connections. Check wiring and connections. Verify that cable
communication to size and length of run comply with the instructions in
accessory modules the Installation manual.
Low or no battery voltage. Check battery connections.
Check generator set battery. See Figure 5-1.
Load management Bad connections. Check wiring and connections. Verify that cable
relays do not size and length of run comply with the instructions in
operate. the Installation manual.
Low or no battery voltage. Check battery connections.
Check generator set battery. See Figure 5-1.
Date is flashing. Controller power was disconnected and then Check battery connections. See Figure 5-1.
reconnected. 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.
Figure 5-2 RDC2 Troubleshooting Chart
TP-7102 7/18 Section 5 Troubleshooting 65

Notes
66 Section 5 Troubleshooting TP-7102 7/18

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute exh. exhaust
ABDC after bottom dead center CG center of gravity ext. external
AC alternating current CID cubic inch displacement F Fahrenheit, female
A/D analog to digital CL centerline FHM flat head machine (screw)
ADC advanced digital control; cm centimeter fl. oz. fluid ounce
analog to digital converter CMOS complementary metal oxide flex. flexible
adj. adjust, adjustment substrate (semiconductor) freq. frequency
ADV advertising dimensional com communications (port) FS full scale
drawing coml commercial ft. foot, feet
Ah amp-hour Coml/Rec Commercial/Recreational ft. lb. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued ftp file transfer protocol
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride g gram
Institute crit. critical ga. gauge (meters, wire size)
ALOP anticipatory low oil pressure CSA Canadian Standards gal. gallon
alt. alternator Association gen. generator
Al aluminum CT current transformer genset generator set
ANSI American National Standards Cu copper
Institute (formerly American GFI ground fault interrupter
cUL Canadian Underwriter’s
Standards Association, ASA) Laboratories GND, ground
AO anticipatory only CUL Canadian Underwriter’s gov. governor
APDC Air Pollution Control District Laboratories gph gallons per hour
API American Petroleum Institute cu. in. cubic inch gpm gallons per minute
approx. approximate, approximately cw. clockwise gr. grade, gross
APU Auxiliary Power Unit CWC city water-cooled GRD equipment ground
AQMD Air Quality Management District cyl. cylinder gr. wt. gross weight
AR as required, as requested D/A digital to analog HxWxD height by width by depth
AS as supplied, as stated, as DAC digital to analog converter HC hex cap
suggested dB decibel HCHT high cylinder head temperature
ASE American Society of Engineers dB(A) decibel (A weighted) HD heavy duty
ASME American Society of DC direct current HET high exhaust temp., high
Mechanical Engineers engine temp.
DCR direct current resistance
assy. assembly hex hexagon
deg.,  degree
ASTM American Society for Testing Hg mercury (element)
Materials dept. department
dia. diameter HH hex head
ATDC after top dead center HHC hex head cap
ATS automatic transfer switch DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung HP horsepower
auto. automatic hr. hour
e. V. (also Deutsche Industrie
aux. auxiliary Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E2PROM, EEPROM IBC International Building Code
BC battery charger, battery electrically-erasable IC integrated circuit
charging programmable read-only ID inside diameter, identification
BCA battery charging alternator memory IEC International Electrotechnical
BCI Battery Council International E, emer. emergency (power source) Commission
BDC before dead center ECM electronic control module, IEEE Institute of Electrical and
BHP brake horsepower engine control module Electronics Engineers
blk. black (paint color), block EDI electronic data interchange IMS improved motor starting
(engine) EFR emergency frequency relay in. inch
blk. htr. block heater e.g. for example (exempli gratia) in. H2O inches of water
BMEP brake mean effective pressure EG electronic governor in. Hg inches of mercury
bps bits per second EGSA Electrical Generating Systems in. lb. inch pounds
br. brass Association Inc. incorporated
BTDC before top dead center EIA Electronic Industries ind. industrial
Btu British thermal unit Association int. internal
Btu/min. British thermal units per minute EI/EO end inlet/end outlet int./ext. internal/external
C Celsius, centigrade EMI electromagnetic interference I/O input/output
cal. calorie emiss. emission IP internet protocol
CAN controller area network eng. engine ISO International Organization for
CARB California Air Resources Board EPA Environmental Protection Standardization
CAT5 Category 5 (network cable) Agency J joule
CB circuit breaker EPS emergency power system JIS Japanese Industry Standard
CC crank cycle ER emergency relay k kilo (1000)
cc cubic centimeter ES engineering special, K kelvin
CCA cold cranking amps engineered special kA kiloampere
ccw. counterclockwise ESD electrostatic discharge KB kilobyte (210 bytes)
CEC Canadian Electrical Code est. estimated KBus Kohler communication protocol
cert. certificate, certification, certified E-Stop emergency stop kg kilogram
cfh cubic feet per hour etc. et cetera (and so forth)
TP-7102 7/18 Appendix 67

kg/cm2 kilograms per square NC normally closed RTU remote terminal unit
centimeter NEC National Electrical Code RTV room temperature vulcanization
kgm kilogram-meter NEMA National Electrical RW read/write
kg/m3 kilograms per cubic meter Manufacturers Association SAE Society of Automotive
kHz kilohertz NFPA National Fire Protection Engineers
kJ kilojoule Association scfm standard cubic feet per minute
km kilometer Nm newton meter SCR silicon controlled rectifier
kOhm, k kilo-ohm NO normally open s, sec. second
kPa kilopascal no., nos. number, numbers SI Systeme international d’unites,
kph kilometers per hour NPS National Pipe, Straight International System of Units
kV kilovolt NPSC National Pipe, Straight-coupling SI/EO side in/end out
kVA kilovolt ampere NPT National Standard taper pipe sil. silencer
kVAR kilovolt ampere reactive thread per general use SMTP simple mail transfer protocol
kW kilowatt NPTF National Pipe, Taper-Fine SN serial number
kWh kilowatt-hour NR not required, normal relay SNMP simple network management
kWm kilowatt mechanical ns nanosecond protocol
kWth kilowatt-thermal OC overcrank SPDT single-pole, double-throw
L liter OD outside diameter SPST single-pole, single-throw
LAN local area network OEM original equipment spec specification
L x W x H length by width by height manufacturer specs specification(s)
lb. pound, pounds OF overfrequency sq. square
lbm/ft3 pounds mass per cubic feet opt. option, optional sq. cm square centimeter
LCB line circuit breaker OS oversize, overspeed sq. in. square inch
LCD liquid crystal display OSHA Occupational Safety and Health SMS short message service
Administration SS stainless steel
LED light emitting diode
OV overvoltage std. standard
Lph liters per hour
oz. ounce stl. steel
Lpm liters per minute
p., pp. page, pages tach. tachometer
LOP low oil pressure
PC personal computer TB terminal block
LP liquefied petroleum
PCB printed circuit board TCP transmission control protocol
LPG liquefied petroleum gas
pF picofarad TD time delay
LS left side
PF power factor TDC top dead center
Lwa sound power level, A weighted
ph.,  phase TDEC time delay engine cooldown
LWL low water level
PHC Phillipsr head Crimptiter TDEN time delay emergency to
LWT low water temperature (screw)
m meter, milli (1/1000) normal
PHH Phillipsr hex head (screw) TDES time delay engine start
M mega (106 when used with SI PHM pan head machine (screw)
units), male TDNE time delay normal to
PLC programmable logic control emergency
m3 cubic meter
PMG permanent magnet generator TDOE time delay off to emergency
m3/hr. cubic meters per hour
pot potentiometer, potential TDON time delay off to normal
m3/min. cubic meters per minute
ppm parts per million temp. temperature
mA milliampere
PROM programmable read-only term. terminal
man. manual memory
max. maximum THD total harmonic distortion
psi pounds per square inch TIF telephone influence factor
MB megabyte (220 bytes) psig pounds per square inch gauge
MCCB molded-case circuit breaker tol. tolerance
pt. pint turbo. turbocharger
MCM one thousand circular mils PTC positive temperature coefficient
meggar megohmmeter typ. typical (same in multiple
PTO power takeoff locations)
MHz megahertz PVC polyvinyl chloride UF underfrequency
mi. mile qt. quart, quarts UHF ultrahigh frequency
mil one one-thousandth of an inch qty. quantity UIF user interface
min. minimum, minute R replacement (emergency) UL Underwriter’s Laboratories, Inc.
misc. miscellaneous power source UNC unified coarse thread (was NC)
MJ megajoule rad. radiator, radius UNF unified fine thread (was NF)
mJ millijoule RAM random access memory univ. universal
mm millimeter RBUS RS-485 proprietary URL uniform resource locator
mOhm, mmilliohm communications (web address)
MOhm, Mmegohm RDO relay driver output US undersize, underspeed
MOV metal oxide varistor ref. reference UV ultraviolet, undervoltage
MPa megapascal rem. remote V volt
mpg miles per gallon Res/Coml Residential/Commercial VAC volts alternating current
mph miles per hour RFI radio frequency interference VAR voltampere reactive
MS military standard RH round head VDC volts direct current
ms millisecond RHM round head machine (screw) VFD vacuum fluorescent display
m/sec. meters per second rly. relay VGA video graphics adapter
mtg. mounting rms root mean square VHF very high frequency
MTU Motoren-und Turbinen-Union rnd. round W watt
MW megawatt RO read only WCR withstand and closing rating
mW milliwatt ROM read only memory w/ with
F microfarad rot. rotate, rotating WO write only
N, norm. normal (power source) rpm revolutions per minute w/o without
NA not available, not applicable RS right side wt. weight
nat. gas natural gas RTDs Resistance Temperature xfmr transformer
NBS National Bureau of Standards Detectors
68 Appendix TP-7102 7/18

Notes
TP-7102 7/18 69
Notes
70 TP-7102 7/18
KOHLER CO., Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
TP-7102 7/18b For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
E 2018 by Kohler Co. All rights reserved. KOHLERPower.com

Manual Generador Kohler

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Manual Generador Kohler

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Operation

Residential/Light Commercial Generator Sets

Kohler strongly recommends

Product Identification Information

Generator Set Identification Numbers

2 TP 7102 7/18

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TP-7102 7/18 Table of Contents 3

3.12 Genset Run Time Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4 Table of Contents TP-7102 7/18

IMPORTANT SAFETY INSTRUCTIONS.

TP-7102 7/18 Safety Precautions and Instructions 5

6 Safety Precautions and Instructions TP-7102 7/18

TP-7102 7/18 Safety Precautions and Instructions 7

8 Safety Precautions and Instructions TP-7102 7/18

This manual provides operation instructions for Model Nameplate

Information in this publication represents data available Genset Model

whatsoever. Service Duty Amps kW

Voltage Phase kVA

and safety precautions to ensure proper equipment Insulation Battery Hz

MFG Date Fuel

The equipment maintenance requirements are very

Figure 1 Model 48RCLB Generator Set

TP-7102 7/18 Introduction 9

Literature Type Part Number

10 Introduction TP-7102 7/18

For professional advice on generator set power Asia Pacific

D Look at the labels and decals on your Kohler product

TP-7102 7/18 Service Assistance 11

12 Service Assistance TP-7102 7/18

Figure 1-1 Service Views

TP-7102 7/18 Section 1 Service Views 13

14 Section 1 Service Views TP-7102 7/18

2.1 Operating Area WARNING

Carbon monoxide. Remind family members, children, and visitors to use

Keep the generator set area clear. Maintain at least

TP-7102 7/18 Section 2 Generator Set Operation 15

Hazardous voltage. Moving parts.

16 Section 2 Generator Set Operation TP-7102 7/18

TP-7102 7/18 Section 2 Generator Set Operation 17

Automatic Stop If a Model RDT transfer switch is used, refer to the

D Ramps down and runs at reduced speed for

18 Section 2 Generator Set Operation TP-7102 7/18

1 min. To set an unloaded full speed exercise, follow the

TP-7102 7/18 Section 2 Generator Set Operation 19

20 Section 2 Generator Set Operation TP-7102 7/18

Status Overview ---->

Engine ----> ATS ---->

Generator----> Date ---->

Genset ----> Network ---->

Genset ----> PIM ---->

Genset ----> Load ---->

ATS ----> Event Log---->

Figure 2-2 RDC2 Main Menu

TP-7102 7/18 Section 2 Generator Set Operation 21

Next Exercise * Next Exercise See Section 2.5.8, Changing

Exercise Mode: Exercise Mode:

Exercise Freq: Exercise Freq:

Figure 2-3 Procedure to Set the Exerciser