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GENERATOR SETS INFORMATION
KOHLER, Power Syst ems Operation Generator Sets 14 Utting. Model: 24RCL 30RCL 38RCLB Controller: RDC2 09001 NATIONALLY REGISTERED TP-6905 4/16b i r...,._ California -Proposition .65.....- A WARNING. Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Kohler strongly recommends that only factory -authorized distributors or dealers install and service the generator. Product Identification Information Generator Set Identification (Numbers Record the product identification numbers from the generator set nameplate(s). i Model Designation Specification Number " Serial Number Accessory Number Accessory Description i I Engine Identification Record the product identification information from the engine nameplate. Manufacturer Model Designation Serial Number Controller Identification Record the controller description from the generator set operation manual, spec sheet, or sales invoice. Controller Description Table of Contents Product Identification Information........................................................... 2 SafetyPrecautions and Instructions ...:... ..... ..........:................................. 5 Introduction............................ I ............. ................ ............. 9 Service Assistance.......................I................................................. 11 Section1 Service Views..................I...............:................................. 13 Section2 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 Staring and Stopping ...... 17 2.4.4 Engine Start lCrank 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 ..........I ............ ............................ .... 18 2.5.1 Unloaded Cy.Cycle Exercise with Complete System Diagnostics ........ 18 2.5.2 Unloaded Full -Speed Exercise .................................. 19 2.5.3 Loaded Fulli Speed Exercise (with RXT only) ...................... 19 2.5.4 Shutdown During Exercise ................................... 19 2.5.5 Power Failure During Exercise .................................. 19 2.5.6 ExerciserFIeset................................................ 19 2.5.7 Setting the Exerciser at Power -up' ..... ........................ 19 2.5.8 Changing te Exercise Setting .................................... 20 2.6 Faults ............ ........ ............................. 23 2.6.1 Warnings J.................................................... 23 2.6.2 Shutdowns .................................................... 23 2.6.3 ATS Communication Errors ...................................... 23 2.6.4 Resetting he Controller after a Fault Shutdown .................... 23 2.6.5 Event Log .................................................. 28 2.7 Model RXT Transfe 'Switch Operation ..... .... ................. .: 28 2.7.1 Source Availability ................. .... .................. 28 2.7.2 ATS Control Sequence of Operation .............................. 29 2.7.3 Time Delays ................................................... 29 2.7.4 ATS Loads Control Relay Time Delay ............................. 29 Section 3 RDC2 Controller Operation I .................................................... 31 3.1 RD02 Generator Set/Transfer Switch Controller ........................... 31 3.2 Controls and Indicators ................................................... 31 3.2.1 Controller Keypad ............................................. 32 3.2.2 LED Indicators ................................................ 32 3.2.3 LCD Display ................................................... 33 3.3 Controller Power ...................................................... 34 3.4 Battery Charging ...................................................... 34 3.5 Changing Settings ..................................................... 34 3.6 Controller Menusl...................................................... 36 3.7 Main Menu .... 36 3.8 Overview Menu .I ....................................................... 37 3.9 Engine Metering Menu ................................................. 37 3.10 Generator Meterinng Menu ............................................... 38 3.11 Generator Sotln1ormation Menu ......................................... 39 TP-6905 4/16 1 Table of Contents 3 Table of Contents, continued 3.12 Genset Run Time Menu ................................................. 39 3.13 Genset System Menu ................................................... 40 3.14 ATS Status Menu ...................................................... 41 3.15 ATS Configuration Menu ................................................ 42 3.16 Date avid Time Menu .................................................... 43 i 3.17 Networking Information Menus .......................................... 44 3.17.1 Networking Status Submenu..................................... 45 3.17.2 Networking Configuration Submenu (OnCue Plus Password) ........ 46 3.17.3 RBUS Information Submenu.................................... 47 3.17.4 Remote Devices Submenu...................................... 48 3.18 Programmable Interface Module (PIM) Menus ............................. 49 3.19 Load Control Menus ..................................... ........... 50 Section4 Scheduled Maintenance....................................................:..... 51 4.1 General Maintenance .................................................. 51 4.2 Service Schedule...................................................... 53 4.3 Lubrication System ................... .............................. 54 4.3.1 Oil Specifications .............................................. 54 4.3.2 Oil Check ..................................................... 54 4.3.3 Oii Additions .................................................. 54 _ 4.3.4 Oil and Filter Change ........................................... 54 4.4 Air Cleaner ............................................................ 56 4.5 Exhaust System ....................................................... 56 4.6 Cooling System ....................................................... 57 4.6.1 Checking and Filling Coolant .................................... 58 4.6.2 Cooling System Inspection ...................................... 58 4.6.3 Draining Cooling System ....................................... 58 4.6.4 Flushing and Cleaning........... ............. ................ 58 4.6.5 Filling Cooling System .......................................... 58 4.7 Ignition System ........................................................ 59 4.8 Battery . 62 4.8.1 Checking Electrolyte Level ...................................... 63 4.8.2 Checking Specific Gravity ............................. :......... 63 4.9 Storage Procedure..................................................... 64 Section 5 Troubleshooting................................................................. 65 5.1 Introduction.......................................................... 65 5.2 USB Port ............................................................ 65 5.3 Fault Messages ....................................................... 65 5.4 Circuit Protection...................................................... 65 5.4.1 Load Circuit Breaker ................. ................ . .... 65 5.4.2 Fuses ................................. .................:.. 65 5.4.3 Controller Internal Circuit Protection .............................. 65 5.5 Generator Set Troubleshooting : ..... .................................... 66 5.6 Controller Troubleshooting .............................................. 67 AppendixA Abbreviations ..... ......................................................... 69 4 Table of Contents TP-6905 4/16 IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily. harm and pose fife -threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read � and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS. This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice. A DANGER Danger indicates the presence of a hazard that will cause severe personalinjury, death, orsubstantial property damage. A WARNING Warning indicates the presence of a hazard that can cause severe personal injury, death, orsubstantial property damage. A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage. NOTICE Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to, act safely. The decals are shown throughout this publication to. improve operator recognition. Replace missing or damaged decals. Safety Precautions and Instructions Accidental Starting A WARNING O IVA Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (-) lead first when disconnecting the battery. Reconne � the negative (-) lead last when reconnecting the battery. Disablingl the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipmenIi connected to the set, disable toe generator set as follows: (1) Pressi the generator set . off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, equipped. (3)' Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. Battery A WARNING Sulfuric acid in batteries.. Can cause severe injury or death. Wear l protective goggles and clothing. Battery acid may cause blindness and burn skin. A WARNING Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well -ventilated area. Isolate the battery charger from explosive fumes. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after, placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the, spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks -to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded TP-6905 4/16 1 Safety Precautions and Instructions 5 metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections'while-the'°batt6ty'"i is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to j prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. , Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (-) lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery. Never connect the negative (-) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Engine Backfire/Flash Fire A WARNING if Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe Injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do' -not operate -the generator set with the air cleaner removed. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fdel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully: charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures. Exhaust System A WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must leakproof and routinely inspected. I - 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 I n or near the generator set. Never operate the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon ,monoxide poisoning symptoms include but are not limited to the following: • Light-headedness, dizziness • Physical fatigue, weakness in joints and muscles • Sleepiness, mental fatigue, inability to concentrate - 1 or speak clearly, blurred vision 0 Stomachache, vomiting, nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or (fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons -does -- not improve within minutes of breathing fresh air. Carbon monoxide detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the 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. Fuel System A WARNING 1 Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well -ventilated area away from spark -producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may -ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines. with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: 6 Safety Precautions and Instructions I TP-6905 4/16 Propane (LPG) —Adequate ventilation Hazardous Voltage/ is mandatory. Because propane is heavier than air;- install propane gas Moving (Parts detectors low in a room. Inspect the detectors per the manufacturer's A I DANGER instructions. Natural Gas —Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the Hazardous voltage. manufacturer's instructions. Will cause severe injury or death. Gas fuel leaks. Explosive fuel Disconnect all power sources before vapors can cause severe injury or opening the enclosure. death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by WARNING using asoap and watersolution with the fuel system test pressurized to 6-8 ounces per square inch (10-14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both Hazardous voltage. Moving parts.. prevent bubble formation. Asuccessful Can cau a severe injury or death. test depends on the ability of the solution to bubble. Operate t e generator set only when all guards and electrical enclosures are in place. Hazardous Noise A WARNING A CAUTION Hazardous voltage. Backfeed to the utility system can Hazardous noise. cause property damage,' severe Can. cause hearing loss. injury, or death. Never operate the generator set If the I generator set is used for without a muffler or with a faulty standbpower, install an automatic exhaust system. transfetl switch to prevent inadvertent interconnection of standby and Engine noise. Hazardous noise can normal sources of supply. cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than I A DANGER 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause I `' permanent hearing loss. Wear hearing protection when near an operating generator set. Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical A CAUTION, A Welding the generator set. Can cause severe electrical equipment damage. Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM). A WARNING Airborne particles. Can cause severe injury or blind- ness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and, heavily taping the ends of the leads. High voltage -transferred. to the load during testing may cause personal 'injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load. TP-6905 4/16 Safety Precautions and Instructions 7 Welding on the generator set. Can cause severe electrical equipment damage. Before. -welding on the generator set perform the following steps: (1) Remove the battery cables, negative (-) lead first. (2) Disconnect all' engine electronic control module (ECM) connectors. (3) Disconnect all generator set controller and voltage regulator circuit board connectors. (4) Disconnect the engine battery - charging alternator connections. (5) Attach the weld ground connection close to the weld location. Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). • Have a qualified electrician install the battery(ies). . Short . circuits. IHazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Engine oil pan heater. Hazardous voltage can cause severe injury or death. The engine oil pan heater can cause electrical shock. Disconnect power to the engine oil pan heater and allow to cool before working on the oil pan heater electrical connections. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or.death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of.power. Electrical backfeed intoa utility electrical system can ,cause severe injury or death to utility personnel working on power lines. Servicing the generator set when it Is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set ; is running. Replace guards, screens, and covers before operating the generator set. Hot Parts A WARNING o0!. h Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. A WARNING i1? rm*m 7�� Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. ,Servicing the alternatoii. 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. i Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install the heater before connecting it to power. Operating the heater before installation can cause burns and component damage. Disconnect power to the heater and allow it to cool before servicing the heater nearby parts. Notice NOTICE Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1. NOTICE Electrostatic discharge damage. Electrostatic discharge (ESD) damages electronic circuit boards. Prevent electrostatic discharge damage by wearing an approved grounding ,wrist strap when handling electronic circuit boards or integrated circuits. An approved grounding wrist strap provides a high resistance (about 1 megohm), not a direct short, to ground. 8 Safety Precautions and Instructions TP-6905 4/16 This manual provides operation instructions for 24RCL, 30RCL, . and 38RCLB resident! commercial generator sets equipped with the generator set/transfer switch controller. Kohler strongly recommends that only fai authorized distributors or dealers install service the generator. This generator set is approved for use in stationary applications in locations served by a reliable ytility power source. Refer to the Installation Manual for installation instructions. Information in this publication represents data available at the time of print. Kohler Co. reserves the rigpt to change this publication and the products represented without notice and without any obligation or liability whatsoever. Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual wii:h the equipment for future reference. - The equipment maintenance requirements ar important for safe and efficient operation. Inspi parts often and perform required maintenance prescribed intervals. Obtain service from an autt Kohler distributor/ dealer or service technician t equipment in top condition. Figure 1 Model 24RCL Generator Set very t the t the keep Introduction Nameplate Figure 2 shows atypical generator set nameplate. Copy the model, serial, and specification numbers from the nameplate into the spaces provided in the product information section on the inside front cover of this manual. See the service view in Section 1 for the nameplate location. KOHLER.- Power Systems Genset Model Spec Number Serial Number Material Number I�.J S.W.0,4= ' I..^J -= Vdt.9.= Pna=WA= AUM.d.l= RPM= PF= Nsdatlon�eaemy� H.= III�II�Illlllll�llllllllllul� Figure 2 Nameplate, Typical TP-6905 4/16 1 Introduction 9 List of Related Literature )I Figure 3 identifies related literature iavailable for the generator sets covered in this manual, Only trained and qualified personnel should install �, or service the generator set. Literature Type ; Part Number Specification Sheet, 24RCL G4-228 Specification Sheet, 30RCL G4-261 Specification Sheet, 38RCLB G4-262 Installation Manual, Generator Set TP-6906 Operation Manual, KG2204/KG2204T Engine TP-6901 Service Manual, Generator Set TP-6907 Service Manual, KG2204/KG2204T Engine Mechanical TP-6902 Service Manual, Engine ECM Diagnostics TP-6903 Parts Catalog, KG2204/KG2204T Engine TP-6904 Parts Catalog, 24RCL, 30RCL, 38RCLB Generator Set TP-6908 Operation Manual, OnCue® Plus Software TP-6928 Operation/installation Manual, RXT ATS TP-6807 Operation/installation Manual, RDT ATS i TP-6345 Installation Instructions, Programmable Interface Module (PIM) TT-1 584 Installation Instructions, Load Shed Kit TT-1 609 Installation Instructions, 50 Amp Power Relay Modules for Load Management TT-1 646 Figure 3 Related Literature 10 Introduction I TP-6905 4/16 Service Assistance For. professional advice on generator set power requirements and conscientious service, please contact your nearest authorized Kohler distributor` or dealer. • Consult the Yellow Pages under the hea I ing Generators —Electric. • Visit the Kohler Power Systems website at KohlerPower.com. • Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. • Call toll free in the US and Canada 1-800-544-i444. • Outside the US and Canada, call the nearest regional office. Headquarters Europe, Middle East, Africa (EMEA) Kohler Power Systems Netherlands B.V. Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone: (31) 168 331630 Fax: (31) 168 331631 Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455 China North China Regional Office, Beijing Phone: (86) 10 6518 7950 (86) 10 6518 7951 (86) 10 6518 7952 Fax: (86) 10 6518 7955 East China Regional Office, Shanghai Phone: (86) 21 6288.0500 Fax: (86) 21 6288 0550 India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) 80 3366208, (91) 80 3366231 Fax: (91) 80 3315972 Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727 Latin America Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131 TP-6905 4/16 i Service Assistance 11 12 Service Assistance TP-6905 4/16 18 1 19- 0 0 26 25 NON -SERVICE SI 1. Oil check (dipstick) 2. Oil fill location (on valve cover) 3. See cooling system detail 4. Exhaust outlet 5. Enclosure locking key (shipping location only) 6. Spark plugs (city. 4) 7. Fuel pressure regulator 8. Engine ECM 9. Fuel inlet (1 in. NPT) 10. Fuel solenoid valves (city. 2 shown) 11. Lube oil filter 12. Customer load lead access (behind panel) 13. Customer connection access panel 14. Line circuit breaker 15. Generator set master control buttons (on RDC2 cc 16. Nameplate location Figure 1-1 24RCL Service Views for Mainte TP-6905 4/16 6 3 18 Section 1 Service Views 5 27 son GM90230 24 Aov esai Cooling System Detail 17. RDC2 controller 18. Fan -fuses 19. Cooling air inlet (remove this panel to access coolant drain) 20. Access to coolant fill 21. Air -fuel mixer 22. Throttle body 23. Air cleaner 24. Battery 25. Oil drain - 26. Coolant drain 27. Fans (qty. 3) 28. Radiator 29. Pressure cap (engine coolant fill) 30. Coolant overflow tube r) 31. Temperature sensor 32. Coolant overflow bottle Section 1 Service Views 13 15 11 14 13 - 12- 17 16 1 2 •3 ,I r\��,'► J =- ��� Ltd, • �^ 1 11 10 9 8 .7 SERVICE SIDE 18 19 20 21 'PAPI I - Mid m O �fY� •=�i�q •I 28 22 i 27 23 4 32 / . ADV-6663 ' 26 25 24 Cooling'System Detail NON -SERVICE SIDE 1. Oil check (dipstick) 19. Access to coolant fill (on roof) 2. Oil fill location (on valve cover) 20. Turbocharger 3. Exhaust outlet 21. Air -fuel mixer 4. Enclosure locking key (shipping location only) 22. Air cleaner 5. Spark plugs (qty. 4) 23. Fuel pressure regulator 6. Fuel inlet (1 in. NPT) 24. Fuel solenoid valves (located behind the fuel regulator) 7. Oil cooler adapter 25. Oil drain - 8. Battery 26. Coolant drain 9. Lube oil filter 27. Fans (qty. 3) 10. Customer load lead access 28. Charge air cooler (CAC, located between fan and radiator) 11. Customer connection access panel 29. Radiator 12. Line circuit breaker 30. Pressure cap (engine coolant fill) 13. Generator set master control buttons (on RDC2 controller) 31. Coolant overflow tube 14. Nameplate location 32. Temperature sensor 15. RDC2 controller 33. Coolant overflow bottle 16. Fan fuses 34. MAP sensor 17. Cooling air inlet (remove this panel to access coolant drain) 35. Oil cooler hoses 18. See cooling system detail 36. Oil cooler (at bottom of radiator) Figure 1-2 30RCL and 38RCLB Service',Views for Maintenance 14 Section 1 Service Views TP-6905 4/16 2.1 Operating Area A WARNING' Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be leakproof and routinely inspected. Section 2 Generator Set Operation Notice Do not locate patios, decks, play areas, or animal shelters near the generator set. Keep items such as lawn furniture, toys, sports equipment, and all combustible materials away from the generator set exhaust outlet.' Remind -family members, children, and visitors, to use caution near the generator set. Generator sets connected to automatic transfer switches start automatically during exercise periods and power outages. Some generator set components become hot when the generator set is running and remain hot for a time after the generator set shuts down. Carbon monoxide symptoms. Carbon monoxidg can cause severe nausea, fainting, or death. Carbon monoxide 2.2 Prestart Checklist is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon A WARNING monoxide poisoning symptoms include but are not limited to the following: • Light-headedness, dizziness 411X" • Physical fatigue, weakness in joints and muscles • Sleepiness, mental fatigue; Accidental starting. inability to concentrate Can cause severe injury or death. or speak clearly, blurred vision • Stomachache, vomiting, nausea Disconnect the battery cables before If experiencing any of these symptoms and carbon mo oxide working .on the generator set. poisoning is possible, seek fresh air immediately and remain Remove the negative (-) lead first active. Do not sit, lie down, or fall asleep. Alert others to the when disconnecting the battery. possibility of carbon monoxide poisoning. Seek rI edical Reconnect the negative (-) lead last attention if the condition of affected persons does not improve when reconnecting the battery. within minutes of breathing fresh air. Generator set operation. Carbon monoxide can cause Disabling the generator set. Accidental starting can severe nausea, fainting, or death. Carbon monoxide is an cause severe injury or death.. Before working on the odorless, colorless, tasteless; nonirritating gas that can cause generator set or equipment connected to the set, disable the death if inhaled for even a short time. Avoid breathing exhaust generator set as follows: (1) Press the generator set off/reset fumes when working on or near the generator set.1 Never button to shut down the generator set. (2) Disconnect the operate the generator set inside a building. Never opelrate the power to the battery charger, if equipped. (3) Remove the generator set where exhaust gas could seep inside or be battery cables, negative (-) lead first. Reconnect the negative drawn into a potentially occupied building through windows, air (-) lead last when reconnecting the battery. Follow these intake vents, or other openings.. I precautions to prevent the starting of the generator set by the Carbon monoxide detectors. Carbon monoxide can remote start/stop switch. cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately Warn the building's occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors accordii g to the manufacturer's instructions. Keep the generator set area clear. Maintaii 0.9 m (3 ft.) of clearance on all sides of the c set. Verify that there are no windows, air vents openingsin the building within 1.5 m (5ft generator set exhaust outlet in any direction. at least or other of the TP-6905 4116 Section 2 Generator Set Operation 15 A WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may 'cause blindness and burn skin. A WARNING i I Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. i Locate the battery in a well -ventilated area. Isolate the battery charger from explosive fumes. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, donot disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery electrolyte is a diluted sulfuric acid., Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin,immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. A DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits: Turn off the main. circuit breakers of all . power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a .qualified electrician install the battery(ies). Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. To ensure continued satisfactory operation perform the following checks or inspections before or at each startup; as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine. Air Inlets. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set. Battery. Check for tight battery connections. Consult the battery manufacturer's instructions regarding battery care and maintenance. Coolant Level. Check the coolant level according to the cooling system maintenance information. 16 Section 2 Generator Set Operation TP-6905 4/16 Drive Belt. Check the belt condition of the water pu and battery charging alternator belt. Exhaust System. Check for exhaust ' leaks blockages. Check the silencer and piping condition check for tight exhaust system connections. Inspect the exhaust system components for cracks corrosion (exhaust manifold, exhaust. pipe, exha clamps, and silencer). • Check for corroded or broken metal parts and reph them as needed. p • Check that there are no combustible materials near the exhaust outlet. d : Check that the exhaust outlet is unobstructed. d Carbon Monoxide Detectors. Check for the installation and operation of carbon monoxide (CO) d detectors on each level of any building near the it generator set. Oil Level. Maintain the oil level at or near, not over, the e full mark on the dipstick. TP-6905 4/16 Section 2 Generator Set Operation 17 2.3 Exercising the Generator Set Operate the generator set•without load every week or every other week for 20 minutes. Perform all of the prestart checks before starting the exercise procedure. See Section 2.5 for instructions to set the automatic exerciser. 2.4 Generator Set Operation 2.4.1 Local Starting and Stopping Start: Press the RUN button to immediately start the generator set. Stop: Press the OFF button. The engine stops. i Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown. � 2.4.2 Automatic Starting and Stopping An automatic transfer switch monitors the utility power and signals the generator set to start when utility power is lost. The ATS then transfers the load to the generator set. l When utility power is restored, the transfer switch transfers the load back to utility, runs the generator set with no load to cool down the engine, and then stops the generator set engine. The electric fans continue to run for two minutes after the engine shuts down to evacuate the engine compartment. 2.4.3 Remote Starting and Stopping A remote switch connected to terminals 3 and 4 can be used to start and stop the generator set. Close the switch to start and run the generator set. Open the switch to stop the generator set. Run the generator set with no load for at least 2 minutes to ensure adequate engine cooldown. 11 2.4.4 Engine Start Crank Cycle The controller attempts to start the generator set three times (three crank cycles, 15 seconds crank and 15 seconds off). If the generator set does not start in three attempts, the system shuts down on an overcrank fault. See Section 2.6. Pressing the OFF button during the crank cycle stops the cranking. No other buttons are acknowledged during the crank cycle. 2.4.5 Engine Cooldown The engine cooldown time delay allows the engine to run after the loads have been removed. The engine cooldown time delay is setto 5 minutes. The engine stops.before the.cooldown time delay expires if the temperature drops below the cooled -down temperature level, or if the temperature rises above the high limit during the cooldown cycle. The electric fans continue to run for two minutes after the engine shuts down to evacuate the engine compartment. If a transfer switch other than the Model RXT is used, an additional engine cooldown time delay may be programmed on the transfer switch. To allow the smart engine cooldown on the RDC2 controller to operate most efficiently, set the cooldown time on the transfer switch controller to zero or the minimum time allowed. Refer to the instructions provided with the transfer switch for more information. 2.4.6 Automatic Operation with Model RXT Transfer Switch The Model RXT transfer switch connects to the RDC2 controller through the ATS interface board on the transfer. switch. Also see Section 2.7, Model RXT Transfer Switch Operation. The RDC2 controller must be in AUTO mode for automatic transfer switch operation. Automatic Start The RDC2 controller receives utility source voltage sensing data from the Model RXT transfer switch. 1.- If, the 'utility source voltage falls below an acceptable level, the controller starts the engine start time delay. 2. If the utility source is not restored before the time delay expires, the generator set starts. 3. After the Normal -to -Emergency time delay, the ATS is signaled to transfer the load to the emergency source. Automatic Stop 1. When the utility source is restored, the Emergency -to -Normal time delay starts. 2. When the Emergency -to -Normal time delay expires, the load is transferred to the utility. 3. The generator set stops. 18 Section 2 Generator Set Operation TP-6905 4/16 2.4.7 Automatic Operation with Other Transfer Switches If a Kohler Model RDT transfer switch is used, � engine start contacts from the ATS must be connect to engine start leads 3 and 4 on the generator set. The RDC2 generator set controller must be in AUTO mode to respond to remote start/stop signals fro i an ATS or remote switch. Press the AUTO -button on the RDC2 controller to put the generator set into automatic atic mode. Automatic Start The engine start contacts on the ATS close to signal the generator set to start, and remain closed while the generator set is running. Automatic Stop The engine start contacts on the ATS open to signal the .generator set to. stop. I 2.5 Exercise The RDC2 controller can be set to automatically rUn the generator set at the same time and day every w ek or every other week: Exercising the generator set Ievery week or everytwo weeks is required in order to.keIep the engine and alternator in good operating conditiop. Three exercise modes are available: unloaded cycle, unloaded full speed, and loaded full speed. See Sections 2.5.1 through 2.5.3 for information about the exercise modes. A loaded exercise can be se� at the RDC2 controller'only if a Model RXT transfer switch i is connected. Note: With the RDT transfer switches, it is possible to have two exercise settings (one urilloaded exercise set at the generator set controller, and another exercise set at the ATS controlle ). If the exercise times overlap, the ATS exercise setting takes priority. I - If a Model RDT. transfer switch is used, refer to the instructions provided with the transfer switch Ito set a loaded exercise at the ATS, if desired. 1 2.5.1 Unloaded Cycle Exercise Complete System Diagnc 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. The Unloaded Cycle exercise -with diagnostics is TP-6905 4/16 the recommended exercise- mode and is the factory -default exercise setting. The Unloaded Cycle exercise runs the engine for 20 minutes in the cycle shown in Figure 2-1 and described below. • Runs at reduced speed for 10 minutes to warm up and exercise the engine. Ramps up and runs at full speed for 3 minutes. Engine diagnostics are performed during this full -speed portion of the cycle, which provides the best test of engine and alternator power backup capability. Diagnostic tests at full speed can identify potential problems with the power output and alertthe operator before an emergency event. • Ramps down and runs at reduced speed for 5 minutes to cool down the engine before shutting down automatically. 3 min. a. Q a) to 1 min. 1 min. a� tm G W 10 min. 5 min. Engine Full -Speed Cooldown Exercise Diagnostics Figure 2-1 Unloaded Exercise Cycle System Diagnostics During the unloaded cycle. exercise, the controller monitors the following data. The controller display indicates an unloaded exercise run during the diagnostics, unless a fault is detected as described below. • ATS connection. The controller verifies that the Model RXT ATS interface board is connected. • Battery voltage. Battery voltage is checked before exercise to verify engine starting capability. Battery voltage provides a measurement of battery health. If the controller detects low battery voltage, low battery or low charging battery is displayed and the exercise does not start. • Coolant level check. The coolant level is checked. Section 2 Generator Set Operation 19 • Communication integrity tests. J1939, RBUS, Ethernet, and USB are monitored for messages indicating that the controller and wiring are reliable. i • Engine speed:Engine speed is measured at low speed and full speed. An overspeed or underspeed condition will result in afault condition and shutdown. • Generator output frequency and voltage. Operating the generator at full speed allows the RDC2 controller to check the output power for correct voltage, frequency, and stability. When the engine is running at full speed, the controller', verifies that. the voltage and frequency are within acceptable limits. A fault message is displayed if the voltage orfrequency is out of range. • Oil pressure. Oil pressure is verified to ensure proper lubrication of critical engine components. Pressure is monitored at both low and full speeds., If the oil pressure is low, low oil pressure is displayed and the generator set shuts down. I 2.5.2 Unloaded Full -Speed Exercise The unloaded full speed exercise runs the generator set atfull.speed for 20 minutes without transferring the load. To set an unloaded full speed exercise, follow the procedure in Figure 2-3 and select Exercise Mode: Unloaded Full. I 2.5.3 Loaded Full -Speed Exercise (with RXT only) A loaded exercise starts the generator set, ramps up to full speed, and then transfers the electrical load from the utility source to the generator set. IThe load is transferred back to the utility source before the generator set shuts down. Note: With a loaded exercise, power to the building is lost for up to 10 seconds during load transfer.. For a loaded exercise controlled by the RDC2 controller, a Model RXT transfer switch must be connected to the generator set. To set a loaded exercise, follow the procedure in Section 2.5.8 and select Exercise Type: Loaded. For a loaded exercise with atransfer switch other than a Kohler® -Model RXT, program the exercise at the transfer switch controller. Refer to the transfer switch operation manual for instructions. 2.5.4 Shutdown During Exercise The following advanceddiagnostic operation applies to RDC2 controllers with firmware versions 5.04 and higher. If the generator set shuts down on a fault during an exercise, the cont roller will try to restart the engine. If the engine starts, the generator set will run at full speed for two minutes and then stop. The event history will show Advanced Diagnostic Active. The exercise schedule is maintained. If the engine does not start, the shutdown message will be displayed. Correct the fault condition and reset the fault as described in Section 2.6. 2.5.5 Power Failure During Exercise If the utility power is lost during an unloaded exercise, the ATS transfers to the emergency source, the exercise is ended and the control remains in the AUTO mode. If the utility power is lost during a loaded exercise, the exercise is ended. The ATS remains in the emergency position and the control goes into the AUTO mode. The generator set continues to run and supply power to the load for the duration of the utility power outage. When Utility power is restored, the ATS will re -transfer to the utility source through normal timing sequences. 2.5.6 Exerciser Reset To reset the exerciser to run at a different day and/or time or to change the exercise mode, follow the procedure in Section 2.5.7 to change the exerciser settings. 2.5.7 Setting the :Exerciser at Power -up When power is connected to the controller, you will be prompted to set the date, time, and exercise schedule. 1. At power -up, the date is displayed with the year flashing. Use the up or down arrow key to step to the current year. 2. Press Select button to save the year and move to the month. 3. Use the arrow and select buttons to set the month and the day. 20 Section 2 Generator Set Operation TP-6905 4/16 4. The time is displayed with the hour flashing. the up or down arrow keyto step to the current - and am or pm setting. Note: Check the am/pm setting displayed. If pm is displayed and you need to change it to am, use the down arrow button to step down in time until the correct hour and am Tare displayed. 5. Press the Select button to save the hour and to minutes. 6. Use the up or down arrow button to chang i the minutes. 7. Press Select to save the time and move to the next screen. 8. Next Exercise is displayed. Use the up, down and select buttons to set the exercise time and date. Be sure to set a time and date in the future. 9. Press Select. The controller exits the menu. 10. Press the Auto button and verify that the LED is lit. The generator set must be in.aut, mode for the exercise to'run as scheduled. The exercise will run every 7 days at the same time, starting on the date set. To change the exerciserlto run every other week or on a different day and time, use the following procedure. 2.5.8 Changing the Exercise Set the date and time on the controller before se exercise schedule. Set the exerciser to autor run the generator setfor 20 minutes everyweek two weeks. Follow the procedure below and flowchartin Figure 2-3 to setthe exercise time a mode, and frequency. Procedure to Change the Exercise Setting 1. Press the AUTO button on the controller. 2. Press the Select button to go to the See Figure 2-2. the every :e the date, 3. Press the down arrow button to step to the Genset System menu. 4. Press the Select button to enter the Genset system menu. See Figure 2-3. 5. Use the down arrow button to step to the next Exercise menu. 6. Press the Select button. The setting flashes to showthat it can be changed. For example, the hour flashes to show that the hour can be changed. 7. 'Press the U P or Down arrow buttons to change the setting. 8. Press the Select button to save the setting and move to the next. For example, save the hour setting and move to minutes. 9. Repeat steps 5 through 8 to change the next item on the line until the desired settings are displayed. 10. Press Select to save after all settings have been selected. -Settings will stop flashing. 11. If the generator set is connected to a Kohler@ Model RXT transfer switch, the exercise can be changed to a loaded exercise. Set the Exercise Mode to loaded full speed, unloaded full speed, or unloaded cycle as shown in Figure 2-3. 12. Set the exercise frequency (weekly or every two weeks). Weekly exercises are recommended. 13. Press the down arrow button to step to the Return menu. Press the Select button to return to the main menu. 14. Check that the AUTO LED is lit. The generator set must be in automatic mode for the exercise to run as scheduled. After a scheduled exercise run, the next exercise time and date will be updated automatically based on the Exercise Frequency setting. Other transfer switches: For a loaded exercise with a transfer switch other than a Kohler® Model RXT, menu. program the exercise at the transfer switch controller. Refer to the transfer switch operation manual for instructions. TP-6905 4/16 1 Section 2 Generator Set Operation 21 --> Displays - status 1tEngine --> ATS --> Configuration i Generator--> Date --> Metering and Time enset --> Network --> formation F Information Genset _-> PIM --> Run Time Status Genset --> Load --> System , Control i ATS -=> Event Log --> Status Figure 2-2 RDC2 Main Menu tp6810 22 Section 2 Generator Set Operation TP-6905 4/16 ❑(' Genset --> System Voltage: System 240 V , System Freq: 60 Hz VR Voltage Adj: 240.OV System Phase: Single System Battery: 12V Next Exercise * I ❑0 Next Exercise See Section 2.5.8, Changing HR:MN PM MM/DD/YY I HR:MN PM MM/DD/YY the Exercise Setting i Exercise Mode: I F(D Exercise Mode: Unloaded Cycle None/Unloaded Full Sp/ Un- loaded Cycle/Loaded Full SP Exercise Freq: Exercise Freq: Weekly . Weekly/Every Other Week F Meas. System: English El Contrast: 50 <-- Return * If the exerciser has not been set, No Exercise Sch will be displayed. tpseos Figure 2-3 Procedure to Set the Exerciser TP-6905 4/16 1 Section 2 Generator Set Operation 23 2.6 Faults Selected fault conditions are shown in Figure 2-5. Fault conditions are classified as warnings or shutdowns. If a fault occurs that is not listed in the table, contact an authorized distributor/dealer for service. Note: All ECM faults are grouped under one listing in Figure 2-5. If a programmable interface module (PIM) is connected to the generator set controller, additional faults can be activated by customer -supplied equipment. See TT-1584, Installation Instructions for the Programmable Interface Module, for available inputs and outputs. 2.6.1 Warnings The controller displays a fault message but the generator set does not shut down on a warning. The controller resets automatically after a warning condition is corrected. i 2.6.2 Shutdowns Under a fault shutdown condition, thel generator set shuts down automatically and the controller displays a fault message. The OFF LED flashes. lee Figure 2-5. Shutdown switches (such as the Iowl coolant level switch or .high engine temperature switch) on the generator set will automatically reset when the problem is corrected. However, the fault condition at the controller does not clear until the controller is reset. The generator set cannot be restarted until the fault condition is corrected and the controllers is reset. See Section 2.6.4 to reset the controller 'after a fault shutdown. 2.6.3 ATS Communication Errors When a Model RXT transfer switch is used, an ATS fault indicates that the connection to the interface board on the transfer switch has been lost. Check the connection to the ATS interface board. 2.6.4 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller. Check the fault message displayed on the controller and refer to Figure 2-5 to identify and correct the fault condition before proceeding. Contact an authorized distributor/dealer for service, if necessary. Press the OFF button to reset the controller, or follow the procedure below. See Figure 2-4. Procedure to Reset the Controller after a Fault Shutdown 1. Press the Select button to go to the Overview menu. 2. Press Select again. The active fault is displayed. 3. Press Select. Confirm Clear Fault: NO is displayed. 4. Press the Up arrow button. Confirm Clear Fault: YES is displayed. 5. Press the Select button to enter YES and clear the fault. 6. Press the Select Button to return to the overview menu. 7. Press AUTO to putthe generator set into.automatic . mode. Fault Message Overview --> Fault Message Confirm Clear 1.2 h 101 Fault: NO PressUp arrow button. tton. Fol Confirm Clear Fault: YES tp6810 Figure 2-4 Clearing a Fault 24 Section 2 Generator Set Operation TP-6905 4/16 Fault (RDC2) Fault (OnCues Condition i Check Plus) AC Sens Loss AC Sensing AC Sensing Lostf In Auto mode, generator Contact an authorized Lost output AC sensing is lost. Detection begins 10 distributor/dealer for service. Warning seconds after crank disconnect. (1 sec.) Warning: after 1 second if no output detected Shutdwn after crank disconnect. (3 sec.) Shutdown: after 3 seconds if voltage was present and then lost. Accy PwrOver Accessory Accessory Power Overload. An over current Contact an authorized Warning Power Overload fault (short circuit) on the accessory controller distributor/dealer for service. power output. ATS ComError ATS ATS Communication Error. Warning is Check communication wiring between Warning Communication displayed if R i interface connection is lost. transfer switch interface board and Error See Section 2.613. generator set. ATS PhaseRot ATS Phase ATS Phase Rotation Mismatch. Transfer Correct the ATS connection. Refer to Warning Rotation switch phase rotation does not match. ATS will the ATS Installation manual, wiring Mismatch not transfer. diagrams, and labels on the transfer I switch. Aux Input Auxiliary Input Auxiliary Input. An optional Check customer -supplied equipment. Shutdwn customer -connected input is closed. (Digital input from optional PIM.) Battery CrLo Critically Low Engine startinglbattery voltage falls below 11 Check the battery rating and Warning Battery Voltage V for more than 10 seconds. Inhibited during condition. the engine crank cycle. Check the battery charger operation. Clears when the battery voltage returns to an acceptable level. Charge or replace the battery. Battery High High Battery Engine starting battery voltage rises above Check the battery rating and Warning Voltage 133% (16 V) of the battery voltage setting for condition. more than 10 seconds. Inhibited during the engine crank cycle. Check the battery charger operation. Clears when the battery voltage returns to an acceptable level. Battery Low Low Battery Engine starting battery voltage falls below the Check the battery rating and Warning Voltage battery voltage setting (typically 12.5 volts) for condition. more than 90lseconds when the engine is not Check the battery charger operation. running. Inhibited during the engine crank cycle. L Charge or replace the battery. Clears when battery voltage returns to an acceptable level. Chk DateTime Verify Date The time andl date have not been set on the Enter the date and time using the Warning Time Setting generator controller. RDC2 controller. See Figure 3-8 and I Figure 3-16. Coolant Lvl Low Low Coolant The coolant Level switch input has been Check coolant level. Shutdwn Level Shutdown activated. I Check radiator hoses for leaks. Contact an authorized distributor/dealer for service. CoolTempHigh Ect Higher Coolant temperature is too high. Check coolant level. Warning Than i Check radiator and fans for Expected 1 i obstruction. Contact an authorized distributor/dealer for service and provide the fault code. TP-6905 4/16 Section 2 Generator Set Operation 25 Fault (RDC2) Fault (OnCue® Condition -Check Plus) CoolTemp Vhi Ect Higher Coolant temperature is extremely high. Check coolant level. Shutdwn Than Expected 2 Check radiator and fans for obstruction. Contact an authorized distributor/dealer for service and provide the fault code. CoolntTemp 0 Coolant Temp 0 The ECM reported a problem with the coolant Check coolant level. Shutdwn Shutdown temperature sensor reading: 0 = high Check radiator and fans for temperature. obstruction. Contact an authorized distributor/dealer for service and provide the fault code. CoolntTemp 3 Coolant Temp 3 The ECM reported a problem with the coolant Contact an authorized Shutdwn Shutdown temperature sensor reading: 3 = high voltage. distributor/dealer for service and provide the fault code. CoolntTemp 4 Coolant Temp 4 The ,ECM reported a problem with the coolant Contact an authorized Shutdwn Shutdown temperature sensor reading: 4 = low voltage. distributor/dealer for service and provide the fault code. CoolntTemp 5 Coolant Temp 5 The ECM reported a problem with the coolant Contact an authorized Shutdwn Shutdown temperature sensor reading: 5 = open circuit. distributor/dealer for service and provide the fault code. Crank Lost Crank Signal Crankshaft Position Sensor (CPS) timeout Contact an authorized Warning Lost error occurred. distributor/dealer for service and i provide the fault code. ECM warnings ECM warnings This''Igroup of faults includes a wide variety of Contact an authorized, (any warnings (any warnings faults that originate from the engine ECM distributor/dealer for service and with ECM in the with ECM in and also contain ECM in the fault name. provide the fault code. fault name) the fault name) Emerg Stop Emergency The emergency stop switch has been Contact an authorized Shutdwn Stop Shutdown activated, or there has been an open circuit in distributor/dealer for service. the wiring. Eng Speed High High Engine Engine speed exceeds 115% of the normal Contact an authorized Shutdwn - • - -• Speed running speed for more than 0.3 seconds. distributor/dealer for service. Eng Speed Low Low Engine Engine speed drops below 85% of the normal Reduce the load by turning off Shutdwn Speed running speed for more than 3 seconds. appliances. Contact an authorized distributor/dealer for service. Exer Not Sch ATS Exercise Exercise Not Scheduled. No exercise has See Section 2.5 for instructions to set Warning Not Scheduled been scheduled on the RDC2 controller. the exerciser. Frequency High High Frequency Governed frequency exceeds 110% of the Contact an authorized Shutdwn systems frequency setpoint for more than 10 distributor/dealer for service. seconds. Function becomes active 10 seconds after engine start (10 second inhibit). Frequency Low Low Frequency Governed frequency falls below 90% of the Reduce the load by turning off Shutdwn system frequency setting for more than appliances and restart the generator 10 seconds, or 1 Hz below the system set. frequency setting for more than 60 seconds. Contact an authorized Function becomes active 10 seconds after distributor/dealer for service. engine start (10 second inhibit). 26 Section 2 Generator Set Operation TP-6905 4/16 Fault (RDC2) Fault (OnCue® Condition i Check Plus) I . Genset S/N Unavailable Generator set serial number is unavailable. Contact an authorized Unaval Warning Genset Serial I distributor/dealer for service. See Number section 3.11. Ground Fault Ground Fault The digital input for Ground Fault Warning is Check customer equipment Warning Warning active (low). (PIM required.) connected to the PIM. IAT High 1 lat Higher Engine manifold air temperature is too high. Contact an authorized Warning Than distributor/dealer for service and Expected 1 provide the fault code. IAT Volt Lo [at Low The ECM reported an Engine Air Contact an authorized Warning Voltage Temperature/Manifold Absolute Pressure distributor/dealer for service and Sensor (TMAP)I error. provide the fault code. - Lo Crank Vlt Low Cranking Low cranking voltage. Battery voltage falls Charge or replace the battery. Warning Voltage below 60% of system battery voltage for more than 6 seconds iWhile the starter is engaged. Locked Rotor Locked Rotor No engine rotation is sensed during cranking. Check the battery. Shutdwn Shuts down 3 seconds after the fault is Check for loose connections. detected. Check for obstruction of alternator or engine. Contact an authorized distributor/dealer for service. MainPwrOverL Main Power Main power overload. An over current fault on Check for shorted run relay. Check Shutdwn Overload the 70 controller power output (short circuit). wiring for short circuits. I Contact an authorized distributor/dealer for service. Maint Req'd Maintenance Engine maintenance is due. Check the maintenance schedule in Warning Required the operation manual for tasks such Warning as changing the oil, spark plugs or the air filter. Not in Auto Not In Auto The generatorl set is not in Automatic Press AUTO to. place the generator Warning (standby) mode. Remote start and stop set in Automatic mode, when commands from a transfer switch or remote appropriate. switch will be ignored. Oil Pres Low Low Oilr The engine ECM indicates low oil pressure. Check for leaks in the lubrication Shutdwn Pressure Note: The low, oil pressure shutdown does not system. protect against low oil level. Check the engine Check the oil level and add oil if the oil level regularly as recommended in level is low. Section 4. I Check the oil pressure switch and wiring. Over Crank Over Crank Three unsuccessful starting attempts. Check the fuel supply, spark plug, and Shutdwn battery. Check for loose connections. Contact an authorized I distributor/dealer for service. i I i I TP-6905 4/16 Section 2 Generator Set Operation 27 Fault (RDC2) Fault (OnCue® Condition Check Plus) -- , is Priml-oopOpn Primary Loop Ignition coil 1 voltage is below normal or Check the battery voltage. Warning Open there is an open circuit. Contact an authorized distributor/dealer for service and provide the fault code. Priml-oopSht Primary Loop Ignition coil 1 voltage is abnormal. Check the battery voltage. Warning Shorted Contact an authorized distributor/dealer for service and provide the fault code. Spd Sens Fit Speed Sensor Engine speed sensor has failed or engine Contact an authorized Shutdwn Fault stalled. ECM is no longer reporting valid distributor/dealer for service. speed. Volts 1-1-1-2 High High Generator Generator Voltage High. Output voltage Contact an authorized Shutdwn Voltage Li-L2 exceeds 120% of the system nominal voltage distributor/dealer for service. for more than 2 seconds. Volts L1-L2 Low Low Generator Generator Voltage Low. Output voltage falls Reduce the load by turning off Shutdwn Voltage Li -1-2 below 80% of the nominal system voltage fdr appliances and restart the generator more than 10 seconds. set. Contact an authorized distributor/dealer for service. Volts 1-2-1-3 High High Generator Generator Voltage High. Output voltage Contact an authorized Shutdwn Voltage 1-2-1-3 exceeds 120% of the system nominal voltage distributor/dealer for service. for more than 2 seconds. Volts 1-2-0 Low Low Generator Generator Voltage Low. Output voltage falls Reduce the load by turning off Shutdwn Voltage 1-2-1-3 below 80% of the nominal system voltage for appliances and restart the generator morelthan 10 seconds. set. Contact an authorized distributor/dealer for service. Volts L3-L1 High High Generator Generator Voltage High. Output voltage Contact an authorized Shutdwn Voltage 1-3-1-1 exceeds 120% of the system nominal voltage distributor/dealer for service. for more than 2 seconds. Volts 1-3-1-1 Low Low Generator Generator Voltage Low. Output voltage falls Reduce the load by turning off Shutdwn Voltage 1-3-1-1 below,80% of the nominal system voltage for appliances and restart the generator more than 10 seconds. set. Contact an authorized distributor/dealer for service. Figure 2-5 Controller Fault Messages 28 Section 2 Generator Set Operation TP-6905 4/16 2.6.5 Event Log The -event log displays up to 1000 controller faults notices, starting With the most recent event. Event; numbered 1-1000, with 1 being the most recent. E event is displayed with the date and time of'the e� the number of the event, a code to indicate whethe event was a warning (W), shutdown (S), informational notice (1), the engine hours at the tin the event, and the event description. 2.7 Model RXT Transfer Switch and Operation... are The RDC2 generator set/transfer switch controller ach manages automatic transfer switch (ATS) functions ant, when connected to a KohlerG) Model RXT transfer the switch through the ATS interface board. Refer to the or Model RXT Operation/Installation Manual for of information about the transfer switch operation. Procedure to View Event History I 2.7.1 Source Availability 1. Press Select to enter the main menu. 2. Press the down arrow to step down to the log. 3. Press Select to display the most recent eN 4. ,Press the down arrow to step to the next E 5. Use the up and down arrow buttons to view 6. Press the Select button to exit the event I To stop viewing the event history before the last press the select button to return to the main mei Date MO/DA/YEAR Event Log --> time HR:MN event number, W/SA, engine event name Press UP. and Down arrow but- I ❑ I I 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 tp6610 Figure 2-6 Event Log The. Model, RXT transfer switch supplies voltage sensing' data to the RDC2 controller through the ATS interface board. If the source voltage falls below the undervoltage dropout setting, the source is considered to have failed. See Figure 2-7. Item Setting Accuracy ±5% Undervoltage Dropout 90% of Pickup Undervoltage Pickup 90% of Nominal Figure 2-7 Voltage Sensing Parameters The RDC2 controller also has a set of power system LEDs below the pushbuttons. The power system LEDs indicate which power sources are available and which source is supplying power to the building. See Figure 3-1. Note: The power system LEDs operate only if a Model RXT transfer_ switch is connected. They will not operate if a Model RDT transfer switch is used. TP-6905 4/1'6 1 Section 2 Generator Set Operation 29 2.7.2 ATS Control Sequence of Operation . See Figure 2-8 for time delay settings. Normal Source Fails: 1. The load control contact opens.. 2. The engine start time delay times out. 3. The generator set is signaled to start. 4. The generator starts and the emergency source becomes available. 5. The normal -to -emergency time delay times out. 6. The transfer switch transfers to the emergency source. 7. The load control contact time delay times out. i B. The load control contact closes. Normal Source Returns: 1. The emergency -to -normal time'delay times out. 2. The contactor transfers to the normal source. 3. The engine cooldown time delay times out. i 4. The generator is signaled to stop. 2.7.3 Time Delays Time- delays'are factory -set to the values shown in Figure 2-8. An authorized distributor/dealer can adjust time delays using a personal computer and Kohler@ SiteTech � software. Time delays described in this section operate only when the controller is connected to a Kohler@ Model RXT transfer switch. The engine start and load transfer time delays prevent engine start and load transfer caused by brief variations in the utility power source. 2.7.4 ATS Load Control Relay Time Delay The load control time delay allows delayed starting of large motor loads (such as air conditioners), preventing simultaneous starting of large motors after transfer to the generator set. The load control time delay is fixed at 5 minutes. It is not adjustable. The load must be connected to the load control output on the interface board of the Model RXT transfer switch. See the transfer switch operation and installation manual for connection instructions. 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 minute's 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 30 Section 2 Generator Set Operation I TP-6905 4/16 3.1 RDC2 Generator Set/Transfl Switch Controller Model 24RCL, 30RCL, and 38RCLB generator sei equipped "with the RDC2 generator set/transfer s controller. The RDC2 controls .the following p system components: • Model 24RCL, 30RCL, or 38RCLB generator s • Model RXT automatic transfer switch (ATS) • Load management device • Programmable interface module (PIM) RDC2 Controller features include: • Two-line x 16 character backlit LCD display adjustable contrast • OFF, AUTO, and RUN generator set master c buttons ion 3 RDC2 Controller Operation r 3.2 Controls -and Indicators Figure 3-1 illustrates the keypad, display, and indicators are on the controller's user interface. tvith, • Generator set status indicating LEDs (OFF, AUTO, RUN) I • Up, Down, and Select buttons for navigation through menus and adjustments • Power system indicator LEDs to show uti generator source status, and to show which (utility or generator) is supplying power to the I and ng 1 1 11 10 9, 8 7 6 2 3 4 5 1. 2-line LCD display 2. Up button 3. Select button 4. Down button 5. RUN button and LED 6. Generator power available LED 7. Generator supplying power to the building LED 8. Utility supplying power to the building LED 9. Utility power available LED 10. OFF button and LED 11. AUTO button and LED GM77569 * These LEDs operate only if a Model RXT transfer switch is connected. Figure 3-1 RDC2 User Interface TP-6905 4/16 1 Section 3 RDC2 Controller Operation 31 3.2.1 Controller Keypad The Run, Off, and Auto buttons controlfthe generator set as described in Figure 3-2. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.4 for operation instructions. 3.2.2 LED Indicators LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 3-2. The RDC2 controller also has a set of power system LEDs below the pushbuttons. The power system LEDs indicate which power sources are available and which source is supplying power to the building (based on the position of the Model RXT transfer switch). See Figure 3-1. Note: The power system LEDs operate only if a Model RXT transfer switch is connected. They will not operate if a Model RDT transfer switch is used. Button Button Function 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'ln Automatic (standby) mode. Down arrow Use to navigate through menus and change settings. This manual contains instructions to navigate the controller menus and adjust settings on the RDC2 controller. Select Up arrow Figure 3-2 Pushbutton Operation LED LED 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 afault shutdown. Attention required. Identify and correct the fault condition before resetting the controller. AUTO Lights when the generator is in automatic (standby) mode.,Generatorset will respond to engine start and stop commands from the controller (for example, exercise start and stop commands), an ATS, or OnCue@Plus, Time delays operate as described in Section 2.4. Utility Power Available * Lights when utility power is available. Building on Utility Power* Lights when the building load is connected to utility power through the RXT transfer switch. Generator Power Available * Lights when generator power is available. Building on Generator Power * Lights when the building load is connected to generator power through the RXT transfer switch. * These LEDs operate only if a Model RXT transfer switch is connected. Figure 3-3 RDC2 Controller LED Operation 32 Section 3 RDC2 Controller Operation TP-6905 4/16 3.2.3 LCD Display The controller is equipped.with atwo-line x 1.6 chat backlit liquid crystal diode (LCD) display with adju; contrast. When the generator is running, the con automatically scrolls through the displays shoe Figure 3-4. When the system is in AUTO, the display scrolls through the status messages sho Figure 3-5. When a fault or warning condition exists, the con will show the corresponding message. See Sectic for more information on fault and warning messa Controller menus display power system inform including status information for the engine, gene and optional RBUS accessories, exercise setting,, event history. Some menus allow changes ti controller settings. See Sections 3.6 through 3., menu diagrams. Active Alert Genset Status Running Voltage:240V Freq: 60.01-lz Engine: 123F Oil Pressure: 40 psi Battery 12.3V Engine Runtime: 27.4 h 1 I Date: 02DEC2014 Time: HR:MN pm Sample data Figure 3-4 Autopaging Displays, Generator I i TP-6905 4/16 I i i I The display contrast is adjustable. Navigate to the Genset System menu and step down to the Contrast or screen. Press the Select button, and then use the up .. _... le and down arrow buttons to adjust the contrast. See or Section 3.5, Changing Settings, and Section 3.11, in Generator Set System Menu. �D in The display backlightturns off after about a minute of no activity. The backlight turns on when a button is pressed or when the generator set starts. or 2.6 ator, and the lfor tp6810 Genset Status Standby Battery 12.3V Engine Runtime: 27.4 h Date: 02DEC2014 Time: HR:MN pm Next Exercise: 09:00p 09Dec2014 Next Maintenance: 150 h or Mar2015 Sample data shown. tp6810 Figure 3-5 Autopaging Displays, Automatic Mode Section 3 RDC2 Controller Operation 33 i 3.3 Controller Power. I The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect the battery and the utility power to the generator set. i If controller power is disconnected and reconnected, you will be prompted to setthe time, date, and exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting. Press Select to save the setting and move on to the next. Repeat, until all settings are saved and the controller returns to the main menu. See Section 3.5 for more detailed instructions to change settings on the RDC2. See Section 2.5 for more detailed instructions to set the exerciser or change the exercise settings. 3.4 Battery Charging The controller includes a built-in battery charger to maintain the engine starting battery. The RDC2 controller monitors the battery voltage and provides a constant 13.5 ±0.2% VDC voltage and, maximum 2.4 amps to charge the battery. The installer must connect utility powerjprovided from the building (90-265 VAC, 50/60 ' Hz) on a breaker -protected circuit for the built-in battery charger. See the Installation Manual for instructions to connect. the utility power for the battery charger. 3.5 Changing Settings Some settings can be changed from the controller. keypad. The controller settings and generator set output are factory -set and should not i require field adjustment under normal circumstances. Check and adjustthe settings and/or output when: li • The controller has been replaced. • The voltage requires adjustment for a particular application. • Troubleshooting generator set problems. Have controller setup and adjustment performed only by an authorized Kohler distributor/dealer or authorized representative. The following procedure explains how to change settings. See. Figure 3-6 for an example using the Date and Time settings: Note: Use caution when navigating the controller menus and changing the settings. In some menus, pressing the Select button can enable editing of the controller settings. Changing some settings to incorrect values can adversely affect generator set operation or render the unit inoperable. Procedure to Change Settings 1. Press the Select button to enter the main menu. 2: Press the down arrow button until the desired menu is displayed. The Date and Time menu is used for the example in Figure 3-6. 3. Press the Select button to enterthe selected menu. See Figure 3-6. 4. Press the down arrow button to step through the parameters in the selected menu. 5. To change a setting, press the Select button. The selected setting flashes. 6. Press the up or down arrow buttons to increase or decrease the setting. 7. When the desired setting is shown, press Select. The value stops flashing. If there are additional adjustable settings on the screen, the next setting flashes. For example, in the date menu, the year, month, and day can be adjusted. 8. Repeat steps 5 through 7 for each setting on the screen. 9. Press the down arrow to step to the next screen. 10. To exit, press the down arrow button until Return is displayed. Press the Select button to exit the menu. 11. Press the AUTO or OFF button to exit the main menu. Note: If no buttons are pushed, the controller exits the menus and returns to the generator set status display after 5.minutes. 34 Section 3 RDC2 Controller Operation TP-6905 4/16 Changing S 1. Press the Select button to enter the main Overview --> Press: Fol Display: 1.2 h 2. Press the down arrow button until the dE menu is displayed. See Figure 3-7. Date and are used for this example. Date --> Press: Display: and Time 3. Press the Select button to enter the Date and menu. Date: Press: Fol Display: 05Dec2013 4. To change the date and time settings, press the Select button again. The year will flash. Date: Press: Display: 05Dec2013 5. Press the up or down arrow buttons to change the year. Date: Press: OR Display: 05Dec2014 I 6. When the correct year is shown, press the Select button. The year is saved and the next setting (month) flashes. I Date: Press: F01 Display: 05Dec2014 7. Repeat steps 5 and 6, using the arrow and select buttons to set the month and the date. j Figure 3-6 Changing Settings TP-6905 4/16 on the RDC2 Controller 8. When the correct date is shown, press the Select button. The saved date is shown. Date: Press: � Display: 03Jan2014 9. Press the down arrow button to step to the next menu. Time: Press: F371 Display: 01:49pm 10. Repeat steps 5 and 6, using the arrow and select buttons to set and save the time. Note: To change from am to pm, press the up arrow key to increase the hour until the correct hour and pm is displayed. 11. Repeat to set the time format to 12 hr. or 24 hr. 12. Press- the down arrow button. Return is displayed. <-- Return Press: Display: 13. Press Select to return to the Date and Time menu. Date --> Press: � Display: and Time 14. Press the Up or Down arrow buttons to step to a different menu. 15. Press Auto to signal the controller to exit the menus and return to the generator set status display. Genset State Press: o Display: Standby AUTO Note:, If no buttons are pressed, the controller returns to the status display after 5 minutes. Section 3 RDC2 Controller Operation 35 3.6 Controller Menus The following sections show -the RDC2 controller menus and submenus. Use the Select button and the up and down arrow buttons to navigate the menus. as shown in the diagrams. Note: Use caution when navigating the controller menus. In some menus, pressing the Select button can enable editing of the controller settings. Changing the settings to incorrect values can adversely affect, generator set operation or render the unit inoperable. If a setting on the controller display is flashing, edit mode has been enabled. Press the OFF or'AUTO button to exit the edit mode. IT Main Menu Press the Select button once to bring up the main menu. Overview is displayed. See Figure 3-7. Press the down arrow button to step to the next menu, Engine Metering. Use the UP and DOWN arrow buttons to step up and down through the menus shown in Figure 3-7. The controller will exit the main menu after 5 minutes if no buttons are pressed. To exit the main . menu immediately, press the controller's OFF - or AUTO button. i D Status Overview --> Displays 1.2 h Press the Up and Down arrow buttons Engine FATS --> to move between menus. Metering Configuration Press OFF or AUTO to exit the menus. Generator--> Date --> Metering and Time I Genset -->, Network --> Information II Information Genset --> PIM --> Run Time Status t Genset --> Load --> System Control $ ATS --> Event Log --> Status * ATS Configuration appears only if a Model RXT transfer switch is connected. tp68o4 t PIM Status appears only if a programmable interface module is connected. t Load Control appears only if a load management device is connected. Figure 3-7 RDC2 Main Menu 36 Section 3 RDC2 Controller Operation TP-6905 4/16 3.8 Overview Menu Overview --> Active Alert 1.26 (if any) Genset Status Standby Voltage: 240V Freq: 60.OHz Engine: 95F Oil: 40 PSI Battery 12.3V Engine Runtime: 27.4 h Date: 02DEC2014 Time: HR:MN pm Next Exercise: 09:OOp 09Dec2014 Next Maintenance: 150 h or Mar2015 SW Version: 4.03 <-- Return Figure 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 from this menu. O EngineSpeed: --> En � 9 Metering :' 1800 RPM E E Oil Pressure: 40 PSI [— Coolant Temp: '73 F Oil Temp: 73 F Battery: 12.3 V <-- Return tP6s10 Figure 3-9 Engine Metering Menu TP-6905 4/16 1 Section 3 RDC2 Controller Operation 37 3.10 Generator Metering IMenu Voltage Calibration The generator -metering menu displays the generator voltage and frequency. See Figure 3-10. The voltage calibration mode can be entered from the generator metering menu. I 'A DANGER Hazardous voltage. Will cause severe Injury or death. This equipment must be installed and serviced by qualified electrical personnel. The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler -authorized distributor/dealer for service. The Reset Calibration menu allows you to set the voltage reading back to the original value after calibration, if necessary. See Figure 3-10. Generator --> Metering i Three-phase Single-phase i Volts L1-L2: I Volts: 240 V 1 240 V I Volts L2-L3: Frequency: 240 V 60.0 Hz I Volts L3-Li: 240 V I Frequency: 60.0 Hz T i Reset Calibration <-- Return Figure 3-10 Generator Metering Menu Reset Calib? No n Reset Calib? Yes FnI 1p6810 38 Section 3 RDC2 Controller Operation TP-6905 4/16 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 arefactory setand 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 compureminder intervals are based on the engine Liter maintenance . is also , displayed. The maintenance " running Kohler@ SiteTech' software is required to enter the generator set model number and serial numbers on manufacturer's recommendation for changing the oil. i Refer to Section 4, Scheduled Maintenance, for a replacement controller. Contact an authorized Kohler distributor/dealer for service. I 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: :Information � 24RCL instructions to reset the maintenance timer. Genset S/N: ######## or Controller S/N: ######## <-- Return Figure 3-11 Generator Set Information Menu Genset -=> M Eng Runtime: Run Time 27.4 In Eng Starts: 40 Next Maintenance: 150 h or Mar2014 ❑0 <-- Return tP6eio Figure 3-12 Generator Set Run. Time Menu TP-6905 4/16 1 Section 3 RDC2 Controller Operation 39 3.13 Genset System Men The genset system menu displays the system information shown in Figure 3-13. Generator sets are factory set and should not require ichanges to the system settings in the field. I A Kohler authorized distributor or dealer can adjust these settings, if necessary. If the generator'.set is reconnected to a different voltage orthe system settings require adjustment for some other reason, see Section 3.5 for instructions to enable editing and change -the system settings. Note: Use caution when navigating the controller menus. In some menus, pressing the Select button can enable editing of; the controller settings. Changing the settings to incorrect values can adversely affect 1 generator set operation or render the unit inoperable. I Voltage Regulator (VR) Voltage Adjust I The generator set voltage is factory set and typically does not require adjustment in the Feld. If voltage, adjustment is required, contact a Kohler authorized distributor or dealer for service. Refer to the generator set Installation Manual for instructions to adjust the voltage. Fuel Type The fuel, type, LP or natural gas, is shown. Do not change the fuel type in this menu unless the generator's fuel system has been converted by 'an authorized distributor or dealer. Setting the Exerciser Use the Genset System menus to set the generator set exerciser. Refer to Section 2.5 for instructions to set the exerciser and for more information about exercising the generator set. After a scheduled exercise run, the Next Exercise time and date will be updated automatically' based on the Exercise Frequency setting. I Language Controllers with firmware versions 6.1 or higher can be set for the following languages: English, French, Spanish, Dutch, or German. Adjusting the Display Contrast To adjust the display contrast, use the down arrow button to step to the Contrast menu. Press the Select button, and then use the up and down arrow buttons to adjust the contrast. Press the Select button to save the contrast setting_ ❑0' Genset --> System Voltage: System 240 V a a System Freq: 60 Hz VR Voltage Adj: 240.OV System Phase: Single System Battery: 12V Fuel Type LP Next Exercise 06:30p 15Dec2015 Exercise Mode: Unloaded Variable T_ Exercise Freq: Weekly Language: English Meas System: English Contrast: 50 ❑O <-- Return Note: Actual settings may vary. tp6e04 Figure 3-13 Genset System Menu 40 Section 3 RDC2 Controller Operation TP-6905 4/16 3.14 ATS Status Menu I 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 tol 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. ATS --> '-- Status I ATS Position: Norman �I Reset Figure 3-14 ATS Status Menu, with Calibratio I I I I TP-6905 4/16 Status: Note: If there is no Model RXT transfer switch connected to the generator set, Remote ATS is displayed and the other screens on this page do not appear. Three-phase Voltage L1-L2: 240V 240 V Voltage L2-L3: 60.0 Hz 240 V Voltage 1-3-1-1: 240 V Frequency: 60.0 Hz Reset Calib? No Reset. Calib? Yes Section 3 RDC2 Controller Operation 41 i I 3.15 ATS Configuration Menu Note: The ATS Configuration menu appears only if,a Model RXT transfer switch is connected. Usethe ATS Configuration submenuto checkthe Model RXT transfer switch system settings and time delays, and change the settings, if necessary.) Changing ATS Configuration Settings To enable editing, press the select button. The value flashes to indicate that it can be changed. Press the up and down arrow buttons to change the value. Press the Select button to save the value shown' Use the up and down arrow buttons to move to the next value to be changed. Repeat the adjustment process until all values are correct. Press the down arrow until Return is displayed. Press the select button to return to the main menu. i ATS--> Normal Freq:• Configuration 60.0 Hz Normal Voltage: 240.0 V Emerg. Freq: 60.0 Hz Emerg. Voltage: 240.0 V Emerg. Engine Start: 3 sec Transfer From Normal: 3 sec I Transfer From Emerg.: 120 sec <-- Return tp6810 Figure 3-15 ATS Configuration Menu 42 Section 3 RDC2 Controller Operation TP-6905 4/16 3.16 Date and Time Menu The -date and time will typically be set at controlfdF- power-up. To change the date, time, or time fo lmat (12 hour or 24 hour), use the Date and Time menu. See Figure 3-16. Date and a Time Date: 02Dec2014 Time: 12:34pm Time Format: 12hr124hr <-- Return To change the date and time, press the Select button See Figure 3-6 for instructions. Figure 3-16. Date and Time Menu TP-6905 4/16 i Section 3 RDC2 Controller Operation 43 _ I 3.17 Networking Information Menus Use the networking menus to- view and adjust communication settings for systems with remote RBUS devices such as a PIM or load management device, and for systems that use the Kohler@ OnCue@ Plus Home Generator Management System. RBUS is a proprietary RS-485 communication protocol. The Networking Information menu leads to submenus for network and RBUS communication settings. Networking--> Networking--> Information Status NS See Figure 3-18. II Networkinng--> NC See Figure 3-19. yl RBUS --> Infnrmatirin 7-PR. See Figure 3-20. Figure 3-17 Networking Information Menu I 44 Section 3 RDC2 Controller Operation tp6810 TP-6905 4/16 i ' I 3.17.1 Networking Status Submenu I 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.. OnCueo Plus. See the OnCue Plus Software Operation Manual for information about the appropriate To enable or disable DHCP and change the IP settings, network settings for OnCue Plus. go to the Networking Configuration menu. See Section 3.17.2. Networking--> Networking--> OnCue Status: Information Status Connected 0 DHCR Enabled IP Address: Subnet Mask: ###.###.###.###' Gateway: ###.###.###.### DNS 1: ###.###.###.### DNS 2: Ethernet Status: Disconnected OnCue Server: ###.###.###.### 7—F,---Return Figure 3-18 Network Status Submenu tp6804 TP-6905 4/16 Section 3 RDC2 Controller Operation 45 3.17.2 . Networking Configuration Submenu (OnCue Plus Password). The networking Configuration menu includes settings used for communication with the Kohler@ OnCue® Plus Generator Management System. For most applications, DHCP is enabled and the IP settings cannot be changed from the controller keypad. If DHCP is enabled, IP parameters are not displayed. i If DHCP is disabled (i.e., if. a static IP address .is required), then the IP parameters can be modified. For applications that require static IP addresses, press and hold the select button to enable editing, disable DHCP, and then step to the next parameters and enter the information. If an error occurs while setting a parameter, an error message is displayed and then the controller exits the edit mode. Previous settings are preserved. Note: Use the OnCue password shown on the controller display for OnCue Plus applications. For the initial OnCue Plus setup, you will be required to reset the OnCue password on the RDC2 controller, and then enter it into the OnCue Plus software. To reset the password, follow the instructions in Figure 3-19. Note: The password is displayed for only 10 seconds. Be sure to write down the password and serial number. A new password is generated each time the reset password procedure is performed. If the password is reset after the OnCue Plus system has been set up, the connection will be lost. Disconnect the battery power to the controller, wait a minute, then reconnect power. Networking--> Networking--> Information Status ❑HOLD U Networking Reset OnCue Reset OnCue Configuration Password � Password? No t arrow for YES, Down for NO. Do ❑ arrow 1 Reset OnCue Password? Yes Press Select to enter YES or NO as displayed. New 70 password is displayed for DHCP: I approximately 10 seconds. Enabled New PW: ##### F<-- Return tp6604 Figure 3-19 Network Configuration Submenu 46 Section 3 RDC2 Controller Operation TP-6905 4/16 3.17.3 RBUS Information Submenu The— RBILIS'.°Information menu contains settings I for remote modules that communicate, with the RDC2 controller using RBUS protocol. This includes Ithe following optional modules: 0 Networking--> Networking—> Information Status Networking--> Configuration • Model RXT transfer switch • Programmable Interface.Module (PIM) • Load Shed Kit or RXT combined interface/load management board O RBUS --> Information Modules Connected: 3 ❑^ Remote --> Devices <-- Return Net Cycle Time: 123ms Module Timeouts: #### Module Errors: #### < -- Return Figure 3-20 RBUS Information Submenu RD See Figure 3-21. tP66a4 TP-6905 4/16 1 Section 3 RDC2, Controller Operation 47 3.17A Remote Devices Submenu I Check the status"of remote devides communicating through RBUS. Device types can include: • Model RXT ATS { • Programmable interface module (PIM) I • Load Shed Kit or RXT combined interface/load management board I The serial numbers for the PIM and load shed kit are printed on the circuit boards inside the'I enclosures. 091 S/N:######### «*DeviceType*>> Device Status: Connected Comm. Errors: ❑� Comm. Timeouts: ModBus ID: aFirmware Ver.: ### Connected: MM/DD/YY 12:12 Return --> Figure 3-21 Remote Devices Submenu 48 Section 3 RDC2 Controller Operation «*DeviceType*» 0 4__� Connected: Displays date/time device was connected. Disconnected: Displays date/time of the last successful com- munication. tP6810 I TP-.6905 4/16 3.18 Programmable Interface -..- Module-(PIM). Menus The PIM status menu displays the status of inputs outputs connected to the programmable inter module (PIM). This is a status display menu only. I and output settings cannot be changed from the R controller's user interface. A personal computer running Kohler® SiteTech' software is required to change the input and output settings'. Coritact'an-'authorized distributor or dealer for service. The Kohler@ OnCue@ Plus Management System_ can be used to turn outputs on and off. See the OnCue Plus Software Operation Manual for instructions. 0I i PIM PIM 1 --> I Input 1 Status: In/Active <-- Return Input 2 FIUApoutitv 1: e 2: e Output 3: In/Active Output 4: In/Active Output 5: In/Active Output 6: 1 n/Active <--Return Figure 3-22 Programmable Interface Module (PIM) Status Menu 0 tp6e10 TP-6905 4/16 j Section 3 RDC2 Controller Operation 49 3.19 Load Control Menus The Load Control menu displays the status of the load management inputs and outputs, and allows a test of the load management output relays. This menu appears only if a load management device is connected. i Generator current is displayed as a percent of the maximum generator capacity. The load management device adds and sheds loads based on the generator current. The test function cycles the relays in the order of their . priority. For detailed information about load management operation, refer to TT-1609, provided with the load shed kit, or TP-6807, RXT Transfer Switch Operation and Installation Manual. F 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 I Output 2: Add/Shed Output 3: Add/Shed Output 4: Add/Shed i Output ti: Add/Shed Output 6: Add/Shed <-- Return tP66i 0 Figure 3-23 Load Control Status Menu, 50 Section 3 RDC2 Controller Operation TP-6905 4/16 4.1 General Maintenance A WARNING • Accidental starting. Canr cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (-) lead first when disconnecting the. battery. Reconnect the negative (-) lead last when reconnecting the battery. Disabling the generator set. Accidental startinc cause severe injury or death. Before working o generator set or equipment connected to the set, disab generator set as follows: (1) Move the generator set n switch to the OFF position. (2) Disconnect the power battery charger. (3) Remove the battery cables, negati lead first. Reconnect the negative (-) lead last reconnecting the battery. Follow these precautions to pr starting of the generator set by an automatic transfer s remote start/stop switch, or engine start command fi remote computer. A WARNING �mrv��fx� Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can severe Injury or death. Do not touch hot engine parl engine and exhaust system components become exl hot during operation. Servicing the alternator. Hot parts can cause injury or death. Avoid touching the alternator field or armature. When shorted, the alternator field and armature become hot enough to cause severe burns. can the the the (-) a The Section 4 Scheduled Maintenance Servicing the engine heater. Hot parts can cause minor personal injury or property damage. Install.the heater before connecting it to power. Operating the heater before installation can cause burns and component -damage. Disconnect power to the heater and allow it to, cool before servicing the heater or nearby parts. A DANGER Hazardous voltage. -Will cause severe injury or death. Disconnect all power sources before opening the enclosure. A WARNING Hazardous voltage. Moving parts. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and,test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set. A WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. TP-6905 4/16 1 Section 4 Scheduled Maintenance 51 Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or.permitflamesorsparks near the carburetor, fuel line, fuel filter, fuel pump; or other potential sources of spilled fuels or fuel vapors. }Catch fuels in an approved container when removing the fuel line or carburetor. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are -highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well -ventilated area away from spark -producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with'hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage,caused by Vibration. Do not operate the generator set',in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation. Gas fuel leaks. Explosive fuel vapors can cause severe Injury or death. Fuel leakage can cause an explosion. Check the LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6-8 ounces per square inch (10-14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt'heads and nuts: - See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the generator set. Have an authorized Kohler distributor/dealer perform generator set service. Engine Service. Perform generator set engine service at the intervals specified by' the engine operation manual. . Generator Set Service. Perform generator set service at the intervals specified by the generator set operation manual. Routine Maintenance. Referto the following generator set service schedule, the engine service schedule, and the runtime hours shown on the RDC2 controller to determine when to schedule routine maintenance. Service generator sets that are subject to extreme weather or dusty or dirty conditions more frequently. Maintenance and Service Parts. Obtain maintenance and service. parts from an authorized Kohler distributor/dealer. 52 Section 4 Scheduled Maintenance I TP-6905 4/16 4.2 Service Schedule System Component or Procedure See Section Procedure Frequency Visually Inspect Check Change Clean Test General Maintenance Fluid leaks X Daily Engine oil level X Daily Coolant level 4.6.1 I X Daily Obstructions or combustible materials near exhaust outlet X Weekly Leaks, hissing, and gas odor I X Weekly Bolts and nuts for tightness X Quarterly or 20 hours Engine oil and filter t 4.3 X Yearly or 120 hours Inspect wiring for cuts, abrasions, or corrosion X 5 Years Belts and belt tension Engine O/M X Yearly or 120 hours Inspect vacuum lines and fittings X 5 Years Air Intake System Air cleaner element t 4.4 Quarterly or 20 hr. 3 years or 400 hr. Hours shown Air induction for leaks X 3 Years or 500 hours Intake manifold for vacuum leaks X 3 Years or 500 hours Cooling System Clamps and hoses, tightness and leaks 4.6.2 X X R Daily Radiator exterior I X X Yearly or 120 hours Engine coolant § 4.6.2 X 3 Years or 500 hours Hoses, condition 4.6.2 I X X R 3 Years or 500 hours Electrical System Battery charge 4.8 X Yearly or 120 hours Battery fluid level I X Yearly or 120 hours Battery for cracks and corrosion X Yearly or 120 hours Clean battery cables t I X Yearly or 120 hours Exhaust System 4.5 Exhaust manifold for leaks X R 5 Years or 2000 hours. Exhaust piping for leaks I X 5 Years or 2000 hours Check HEGO (oxygen) sensor connections and wires Engine O/M X 5 Years or 2000 hours Fuel System Fuel lines and connections X Quarterly Fuel regulator pressure I X Yearly or 120 hours Fuel shutoff valve operation X 5 Years or 2000 hours Ignition System Spark plug wires for cuts, abrasions, or hardening 4.7 X R 3 Years or 500 hours Secondary ignition coil wires X R 3 Years or 500 hours Spark plugs 4.7 X 3 Years or 500 hours Generator Brushes and collector ring D D Yearly or 300 hours * Not necessary for maintenance -free batteries. X Action # Service more frequently under extremely dusty/dirty conditions. D Authorized distributor/dealer only § Long -life coolant is recommended. When long -life coolant is used, the R Replace as necessary change interval is 5000 hours or 5 years. Do not mix coolant types. TP-6905 4/16. 1 Section 4 Scheduled Maintenance 53 4.3 Lubrication System 4.3.1 Oil Specifications Use oil.that displays the American Petroleum Institute (API) Starburst certification mark FOR GASOLINE ENGINES on the container. Do not use straight -weight oils recommended for industrial or stationary engines. CC or CD classification oils, even when labeled Heavy Duty or For Natural Gas Engines are not acceptable. Multi -viscosity synthetic oils are recomm_ ended. For Pest performance in colder environments (such as the United States and Canada), use Society of Automotive Engineers (SAE) 5W-30, API service class SJ or higher. In extremely hot environments where temperatures are never or rarely below 0°C (32°17), use a synthetic oil with a viscosity designation of 10W-30, API iservice class SJ or higher. 4.3.2 Oil Check Check the oil level in the crankcase every 24 hours of operation or before the engine is started each day. Do not check the oil level while operating the unit. Stop the generator set and keep the generator set level to get an accurate reading. To check the oil level, remove the dipstick and wipe the end clean. Reinsert the dipstick and wait at least 30 seconds. Remove the dipstick and check the level. Maintain the oil level between the Full and Add marks on the dipstick, as shown in Figure 4-1 ;See Section 1, Service Views for the dipstick location. i Note: Do not operate the set if the oil level is below the Add mark or above the Full mark] on the dipstick. \ 2 1. Full mark TPs586.9 2. Add mark Figure 4-1 Oil Level Check 4.3.3 Oil Additions Adding some oil between oil changes is normal. The amount varies with generator set usage.,Open the oil fill cap and pour in a small amount of oil using a funnel or other suitable pouring device. See Section 1, Service Views, for the oil check and oil fill locations. 4.3.4 Oil and Filter Change A WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (-) lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start(stop switch. A WARNING J&.0 Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the fuel system. A flash fire can cause severe injuryordeath. Do not smoke orpermit.flamesorsparks near the carburetor, fuel line, fuel filter,.fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Change the oil yearly, after every 120 hours of use, or before generator set storage. Change the oil more frequently if the generator set operates under dirty, dusty conditions. Change the oil while the engine is still warm. See Section 1, Service Views, for oil fill, oil check, and oil filter locations. Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner. Note: Reset the maintenance timer on the RDC2 controller after changing the oil. 54 Section 4 Scheduled Maintenance I TP-6905 4/16 Oil Change Procedure Whenever possible, drain the oil while it is still -warm. 1. Drain the oil. a. Press the OFF button on the RDC2 set controller. b. Disconnect the power for the battery c. Disconnect the generator set engine battery, negative (-) lead first. d. Remove the housing side panel. e. Remove the plug from the oil drain fitting install a drain hose., f. Open the oil drain valve on the engine. g. Allow time for the engine oil to drain com h. Close the oil drain valve. i. Replace the oil drain plug. 4. Check for leaks. a: Press the OFF button on -the RDC2 generator set controller. b. Reconnect the generator set engine starting battery, negative (-) lead last. c. Reconnect the power for the battery charger. d. Start the generator set and check for leaks around the oil filter. e. Stop the generator set and tighten the oil filter to stop any leaks. and f. Reinstall the housing side panel. 5. Stop the generator set. Check the oil level. Add oil, as necessary, to bring the level up to the Full mark. 2. Replace the oil filter. a. Remove the oil filter by rotating it counterclockwise with an oil filter wrench! b. Clean any surfaces that the oil filter c. Apply alight coat of clean oil to the gasket new oil filter. d. Lightly thread the new oil filter by hand L feel resistance. Then, tighten the fi additional 3/4 turn with an oil filter [Torque = 25 Nm (18.4 ft. Ibs.)]. 3. Fill with oil. Use 5W-30 for oil selectii Figure 4-2 for oil capacity. Model Oil Capacity, L (qt ) 24RCL, 30RCL, and 38RCLB 4.2 (4.4) I Figure 4-2 Oil Capacity you an and Note: Too high an oil level causes high oil consumption and engine carbonizing. Too low a level damages the engine. 6. Reset the maintenance timer on the RDC2. a. In the Overview menu, step down to the Genset Run Time menu. b. Press the Select button and then step down to the Next Maintenance screen. c. Press the Select button. d. Press the Up arrow button so that Reset Maint Timer? Yes is displayed: -- - TP-6905 4/16 1 Section 4 Scheduled Maintenance 55 4.4 Air Cleaner A WARNING o X Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generators set. Remove the negative (-) lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery: i Disabling the generator set. Accidental starting can cause severe injury,or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button ,to shut down the generator set. (2) Disconnect the power to the battery charger, if equipped 1. (3) Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. A WARNING )/ . I Risk of fire. Can cause severe injury or Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. At the interval specified in the service schedule (Section 4.2), inspect and clean or replace the air cleaner element. Clean the element more frequently in dirty, dusty conditions. Check the elementfor accumulated oil or dirt that could cause poor performance. Replace a damaged air cleaner element. Follow the procedure described below. Air Cleaner Service Procedure A dry -type air cleaner silences and filters the intake air. The air intake silencer assembly connects to the intake manifold via a rubber hose. Refer to Figure 4-3 during this procedure. Figure 4-3 Air Cleaners 1. Release the retaining clips to open the cover and then remove the air cleaner element. 2. Tap the element lightly against a flat surface to dislodge loose surface dirt. Do not clean the element in any liquid or use compressed air as these will damage the filter element. Replace the element and precleaner at the intervals shown in the service schedule. 3. Examine the element and housing for damage. Replace the element and housing if damaged. 4. Wipe the cover and housing with a clean rag to remove dirt. Make sure the sealing surfaces fit correctly. 5. Replace the air cleaner cover. 4.5 Exhaust System A WARNING Carbon monoxide. Can cause severe nausea, fainting, or death. The exhaust system must be', leakproof and routinely inspected. Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate .the generator set inside a building. Never operate the generator set where exhaust gas could seep inside or be drawn into a potentially occupied building through windows, air intake vents, or other openings. 56 Section 4 Scheduled Maintenance TP-6905 4/16 Carbon monoxide symptoms. Carbon monoxide cause severe nausea, fainting, or death. Carbon monc . is a- poisonous --gas -present- in- exhaust gases.. Ca monoxide is an odorless, colorless, tasteless, nonirritatinc that can cause death if inhaled for even a short time. Ca monoxide poisoning symptoms include but are not limits the following: • Light-headedness, dizziness . • Physical fatigue, weakness in joints and muscles • Sleepiness, mental fatigue; inability to concentrate or speak clearly, blurred vision • Stomachache, vomiting,. nausea, If experiencing any of these symptoms and carbon monc poisoning is possible, seek fresh air immediately and re active. Do not sit, lie down, or fall asleep. Alert others t( possibility of carbon monoxide poisoning. Seek me attention if the condition of affected persons does not IQ within minutes of breathing fresh air. Carbon monoxide detectors. Carbon monoxide cause severe nausea, fainting, or death. Install a monoxide detectors on each level of the building. Loca detectors to adequately warn the building's occupants presence of carbon monoxide. Keep the detectors opera at all times. Periodically test and replace the carbon mon detectors according to the manufacturer's instructions. A CAUTION Hazardous noise. Can cause hearing loss. Never- .operate the generator set without a muffler or with a faulty exhaust system. A WARNING Hot engine, and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can severe injury or death. Do not touch hot engine pai engine and exhaust system components become e) hot during operation. At the interval specified in the service schedule, the exhaust system components (exhaust rr exhaust outlet, exhaust line, exhaust claml muffler) for cracks, leaks, and corrosion. gas to the can the the The and Exhaust System Inspection Points : • Check for corroded orIbroken metal.parts and. replace them as needed. • Check that the exhaust outlet is unobstructed. • Check the exhaust gas color. If the exhaust is blue or black, contact your local authorized Kohler distributor/ dealer. • Visually inspect for exhaust leaks (blowby). Check for carbon or. soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed. • Check that all covers and doors are undamaged, in place, and locked. • Check for the installation and operation of carbon monoxide (CO) detectors on each level of any building near the generator set. 4.6 Cooling System A WARNING ifilpry� Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank. TP-6905 4/16 1 Section 4 Scheduled Maintenance 57 4.6.1 Checking and Filling Coolant -Maintain the coolant level in the coolant overflow bottle between the Hot and Cold markings. See Section 1, Service Views, for the coolant overflow bottle location. Note: Periodically check the coolant level by removing the radiator's pressure.cap. Do not rely solely on the level in the coolant overflow, bottle. Ethylene glycol -based long -life coolant is recommended. Use a coolant mikture;of 50% long -life coolant and 50% clean, softened water to inhibit rust/corrosion and prevent freezing. Add fresh coolant until the level is just below the overflow tube opening. A coolant solution of 50% ethylene glycol -based coolant provides freezing protection to -37°C (-34°F) and overheating protection to 1490C (3000F). A coolant solution with less than 50% ethylene; glycol may not provide adequate freezing and overheating protection. A coolant solution with more than 50%1 ethylene glycol can cause engine or component. damage. Do not mix long -life coolant and conventional coolants. Do not mix different types and/or colors of long i life coolants. 4.6.2 Cooling System Inspection To prevent generator shutdown or damage because of overheating: • Keep the cooling air inlets clean and unobstructed • Inspect the radiator's exterior for obstructions and remove dirt and foreign material with a soft brush or cloth to avoid damaging the radiator fins. I • Check the hoses and connections for leaks replace any cracked, frayed, or spongy hoses. • Check the condition and tension of the drive belt. and • Check the rubber seal of the radiators pressure cap and replace a cracked or deteriorated cap. Remove dirt and other debris from the pressure cap and filler neck. The pressure cap raises the boiling point of the coolant, enabling higher operating temperatures. If the cap leaks, replace it with the same rating type of cap. Find the pressure cap rating in Figure 4-4. Item Rating Pressure cap 97 kPa (14 psi) Figure 4-4 Pressure Cap Rating 4.6.3 Draining Cooling System The radiator contaihs a coolant drain valve to drain the cooling system. When draining the coolant, remove the radiator's pressure cap, which will allow the entire system to drain and will prevent air pockets from forming and restricting coolant passage to the block. Remove the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow through the engine block. 2. Open the coolant drain valve and allow the system to drain. 3. If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease, go to Section 4.6.4, Flushing and Cleaning. If the cooling system does not have mineral deposits, refill the cooling system as instructed in Section 4.6.5, Filling Cooling System. 4.6.4 Flushing and Cleaning For optimum protection, drain, flush, and refill the cooling system at the interval listed in the service schedule. Flushing and Cleaning Procedure 1. Flush the system with clean water. 2. Drain, clean, and flush the coolant overflow bottle. 3. Refill the cooling system as instructed in Section 4.6.5. 4.6.5 Filling Cooling System Model Coolant Capacity, L (gal.) Engine Engine with Block Heater 24RCL, 30RCL, 38RCLB 13.2 (3.5) 13.7 (3.6) Figure 4-5 Coolant Capacity (approximate) Note: Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until engine has cooled. Note: It is very important to purge air from the cooling system by following this entire procedure. 1. Close the radiator's coolant drain valve and tighten the hose clamps. 2. Fill the radiator with the recommended coolant mixture of 50% ethylene glycol and 50% clean, 58 Section 4 Scheduled Maintenance TP-6905 4/16 softened water to inhibit rust/corrosion and freezing. The coolant capacity is sh Figure 4=5. 3. Operate the engine with the radiator cap r until the thermostat opens and the upper hose becomes hot. 4. Stop the engine and allow it to cool. nt Disabling the generator set. Accidental starting can in cause severe injury or death. Before working on the -generator set or equipment connected to the set, disable the generator set as follows:. (1) Press the generator set off/reset :d button to shut down the generator set. (2) Disconnect the or power to the battery charger, if equipped. .(3) Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by the remote start/stop switch. 5. Add coolant to the radiator to just below) the overflow tube on the filler neck. See Section 1, Service Views, for the overflow tube location.) 6. Replace the radiator's pressure cap. . 7. Maintain the coolant level in the coolant ove bottle between the Hot and Cold markings. Section 1, Service Views, for the coolant ove bottle location. 4.7 Ignition System A WARNING Airborne particles. Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. A WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (-) lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery. Service the spark plugs at the interval specified in the service schedule using the following procedure. 1. Press the OFF button on the RDC2 controller. 2. Disconnect the power to the battery charger. 3. Disconnect the. generator set engine starting battery, negative (-) lead first. 4. Use a cloth to wipe dirt and oil away from the area around each of the four spark plug wires. 5. Remove spark plug wires by grasping the spark plug boot and turning slightly while pulling. Do not pull the wire. Pulling on the wire rather than the boot may damage the wire or terminal. 6. -Wipe the interior of the spark plug tubes. 7. Loosen the spark plug with a ratchet and 13/16-in. spark plug socket with a rubber insert to prevent spark plug damage. 8. Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber. 9. Remove spark plugs, one -at a time; and examine. Identify a normal spark plug in good operating condition by observing a light tan or gray deposit on firing tip. See Figure 4-10 to evaluate engine condition by color/condition of a problem spark plug. 10. Check that the spark plug washer is in good condition. 11. Clean spark plugs by wiping them with a rag. Note: Do not sandblast, wire brush, scrape, or otherwise service spark plugs in poor condition. Obtain a new plug for best results. TP-6905 4/16 1 Section 4 Scheduled Maintenance 59 12. Check the spark plug gap before installing any Note: Ensure that the spark plug tubes are seated spark plug. See Figure 4-6 and Figure 4-7. Attain a before installing the spark plugs. Ifthe tubes were correct gap when the feeler (or wire) passes removed, reinstall -them ' before installing the between the spark plug electrodes. It should pass spark plugs. easily but with some resistance or drag; otherwise adjust as necessary. 14. Reinstall the spark plug. Do not bump the electrode against the cylinder head. Rotate the spark plug Model Spark ,Plug Gap clockwise until you feel resistance. 24RCL 0.9-1.0 mm (0.036-0.040 in.) 30RCL and 38RCLB 0.7-0.8. mm (0.028-0.030 in.) Figure 4-6 Spark Plug Gap Figure 4-7 Spark Plug Gap Inspection 13. Use a gapping tool to gently !bend the side electrode closer to or farther from the center electrode to set the correct gap. See Figure 4-8. Position the side electrode directly over the center electrode. Figure 4-8 Spark Plug Gap Adjustment 15. Use a torque wrench to tighten each spark plug to the torque shown in Figure 4-9. Model Spark Plug Torque 24RCL 18 Nm (13.3 ft. lbs.) 30RCL and 38RCLB 25 Nm (18.4 ft. lbs.) Figure 4-9 Spark Plug Torque 1.6. Use a ratchet wrench to tighten an additional 1/4 turn. Do not overtighten, as doing so may strip the threads or alter the electrode gap setting. 17. Check the spark plug wire connector in the boot for accumulated dirt, grease, and other debris, and clean as necessary. 18. Firmly push the spark plug boot onto the spark plug. 19. Reconnect the generator set engine starting battery, negative (-) lead last. 20. Reconnect the power for the battery charger. 60 Section 4 Scheduled Maintenance TP-6905 4/16 Problem/Condition Means of Identification I Possible .Cause/Solution Gap -bridged spark Built-up deposits and gap between Oil or carbon fouling. Clean and regap the spark plug electrodes closing. plug. Oil -fouled spark plug Wet, black deposits on the insulator shell, Excessive oil entering combustion chamber through bore, and electrodes. worn rings and pistons, excessive clearance 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 spark glazed coating on the insulator tip. plug. Pre-ignition damaged Melted electrodes and possibly blistered Wrong type of fuel, incorrect timing or advance, too spark plug insulator. Metallic deposits onl insulator hot a plug, burned valves, or engine overheating. suggest internal engine damage. Replace the spark plug. Overheated spark plug White or light gray insulator with small black Engine overheating, wrong type of fuel, loose spark or gray/brown spots with bluish (burned) plugs, too hot a plug, low fuel pressure or incorrect appearance on electrodes. I 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 TP-6905 4/16 1 Section 4 Scheduled Maintenance 61 4.8 Battery Consult the battery manufacturer's instructions' regarding battery care and maintenance. A WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may bause blindness and burn skin. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can .cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the ;skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area. Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that! could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equip'iiehfdamage: - Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (-) lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting .the battery. Never connect the negative (-) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together. Refer to this section for general battery information and maintenance. Also consult the battery manufacturer's instructions for battery maintenance. All generator set models use a negative ground with a 12-volt engine electrical system. Consult the generator set nameplate for the engine* electrical system voltage. Consult the generator spec sheet for battery capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information. See Figure 4-11 for typical battery connections. /1 i2 EZ-273000J 1. To positive (+) terminal on starter solenoid. 2. To ground (-) terminal on or near starter motor. Figure 4-11 12-Volt Engine Electrical System Single Starter Motor, Typical Battery - Connection Clean the battery and cables and tighten battery terminals using the service schedule recommendations. To prevent corrosion, maintain tight, dry electrical connections at the battery terminals. To remove corrosion from battery terminals, disconnect the cables from the battery and scrub the terminals with a wire brush. Clean the battery and cables with a solution of baking soda and water. After cleaning, flush the battery and cables with clean water and wipe them with a dry, lint -free cloth. After reconnecting the battery cables, coat the battery terminals with petroleum jelly, silicone grease, or other nonconductive grease. 62 Section 4 Scheduled Maintenance TP-6905 4/16 4.8.1 Checking Electrolyte Level Check the electrolyte level of batteries with.filler monthly. Remove filler caps and verify that elect level reaches bottom of filler holes. Refill as nece with distilled water. DO NOT add fresh electr Tighten all filler caps. If -water is added during fre temperatures, run the generator set for 20-30 mi to mix the electrolyte and water to prevent bi damage from freezing. 4.8.2 Checking Specific,Gravity Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell. While holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer. If the hydrometer used does not halve a correction table, use the correction factors in Figure 4-14. Determine specific gravity and electrolyte temperature of battery cells. Locate temperature in Figure 4-14 and adjust the specific gravity by the amount shown. The battery is fully charged ifthe specific gravity is 1.260 at an electrolyte temperature of 80OF (26.70C). The difference between specific gravities of each cells ould not exceed f 0.01. Charge the battery if the specific gravity is below 1.215 at an electrolyte temperature of 80°F (26.70C). See Figure 4-12. Specific Gravity, Battery Corrected to 80°F (26.7°C) Condition Below 1.215 Needs charging 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. performer) with the battery hydrometer described previously. Usie the manufacturer's instructions. Figure 4-13 interprets typical test results. Number of Floating Beads Battery Condition 5 Overcharged 4 Fully charged 3 Good charge 1 or 2 Low charge 0 Dead battery Figure 4-13 Bead -Type Test Interpretation Temperate .0 71.1 1 65.6 1. 60.0 1 54.4 1 46.9 1' 43.3 1 37.8 1 32.2 26.7 21.1 15.6 10 4.4 -1.1 - 6.7 -12.2 ,rrection 132 130 128 EXAMPLE NO.1- 126 rt4 Temperature below 80°F (26.7°C) 122 Hydrometer Reading 1.260 120 Acid Temperature 20°F (-6.7°C) 118 116 Subtract .024 Specific Gravity 114 Corrected Specific Gravity is 1.226 112 1.250 - .024 =1.226 110 - 108 106 EXAMPLE NO.2— . Temperature above 80°F (26.7°C) 162 Hydrometer Reading 1.235 102 Acid Temperature 100°F (37.8°C) ioa Add .008 Specific Gravity 06 Corrected Specific Gravity Is 108 1.243 110 112 1.235 + .008 =1.243 114 116 118 120 122 124 126 128 The temperature correction amounts to about.004 (4 points) of specific gravity for each 10°F (5.5°C) change in temperature: 1-787 Figure 4-14 Specific Gravity Temperature Correction TP-6905 4/16 1 Section 4 Scheduled Maintenance 63 4.9 Storage Procedure A DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all,power sources before opening the enclosure. Connecting the battery and the battery charger. Hazardous voltage can cause severe lnnjury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). in ' Follow the procedure below whestoring your generator set for a long period (3 months or more). 1. Start and run- the generator set I�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. I 4. Check the engine coolant protection; see Section 4.6. Note: Use antifreeze capable of withstanding the lowest possible temperatures. 5. Keep spark plugs in their holes or seal spark plug holes with suitable threaded metal plugs. 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. with tape.. 8. Disconnect and remove the battery. Place the battery in.a warm, dry location for the storage period. Recharge the battery once a month to maintain a full charge. 9. Select a well -ventilated (not humid or dusty) location to store the generator. 10. Cover the entire unit with a dust cover. Note: Run the generator set once a month whenever possible. 64 Section 4 Scheduled Maintenance i TP-6905 4/16 Section 5 Troubleshooting 5.1 Introduction I 5.4 Circuit Protection Use the troubleshooting charts in this section to � diagnose and correct common problems. First check for If the generator set circuit breaker trips or the fuses blow repeatedly, contact an authorized_ Kohler distributor/ simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. IThe dealer for service. charts include a list of common problems, possible causes of the problem, and recommended corrective 5.4.1 Load Circuit Breaker actions. The load circuit breaker interrupts the generator output If the procedures in this manual do not explain how to' in the event of afault in the wiring between the generator correct .the problem, contact an authorized Kohler and the load. If the circuit breaker trips, reduce the load distributor/dealer. Maintain a record of repairs) and and switch the breaker back to the ON position. Refer to adjustments performed on the equipment. Use the the service views in Section 1 for the location of the record to help describe the problem and repairs or circuit breaker. adjustments made to equipment. 5.4.2 Fuses 5.2 USB Port Always identify and correct the cause of a blown fuse A USB port is located on the front of the controller.. se a before restarting the generator set. Refer to Figure 5-1, USB cable with a mini-B connector to connect the Troubleshooting Chart, for conditions that may indicate controller to your personal computer (laptop). a blown fuse. Obtain replacement parts and service from an authorized Kohler distributor/dealer. Some controller settings can be adjusted using a laptop computer with. Kohler@ SiteTech'°" software. SiteTech Fan Fuses. Three 30 amp fan fuses are located in the software is available to Kohler authorized distributors fan fuse and relay box. See Section 1, Service Views, for and dealers. See TP-6701, SiteTech -. So are location. Operation Manual, for more information. 5.4.3, -Controller Internal Circuit 5.3 Fault Messages Protection The controller is equipped with internal circuit The RDC2 controller displays fault messages to aid in protection. Press OFF to reset. troubleshooting. Fault messages, descriptions, and recommended checks are listed in Figure 2-5. Identify and correct the cause of the fault Then reset the controller after a fault shuts Section 2.6.4. dition. r See TP-6905 4/16 1 Section 5 Troubleshooting 65 5.5 Generator Set Troubleshooting Figure 5-1 contains generator set troubleshooting, diagnostic,' and repair information: Check for loose connections before replacing parts. Problem Possible Cause The generator set does not crank. Battery weak or dead. Battery connections reversed or poor. Blown fuse(s). Generator set is OFF. The generator set cranks but does not start, starts hard, lacks power, or operates erratically. No AC output. Low output or excessive drop in voltage. Generator set stops suddenly. Fans run after engine shuts down. Air cleaner clogged. Battery weak or dead. Battery connection poor.' Spark plug wire connection loose. Low oil pressure shutdown-. Fuel pressure insufficient. Engine malfunction. AC circuit breaker in the OFF position. AC circuit breaker tripping because of overload AC circuit breaker tripping because of short circuit. Generator set overloaded. Low oil pressure shutdown. Out of fuel. Overcrank shutdown. Blown fuse(s). Overspeed shutdown. Generator set is OFF. I Remote stop command received from a remote switch, ATS, or OnCue® Plus. Engine malfunction. The fans continue to run for 2 minutes after the engine shuts down to evacuate the engine Figure 5-1 General Troubleshooting Chart Corrective'Action Recharge or replace the battery. Check the connections. Replace the fuse. Contact an authorized Kohler distributor/dealer for service if fuse blows repeatedly. Press the RUN button. to start the engine or press AUTO to allow remote starting. Clean and/or replace the air cleaner. Recharge or replace the battery. Clean and tighten the battery connections. Check the spark plug wires. ' Check for oil leaks. Check the oil level and add oil if necessary. Check the fuel supply and valves. Contact an authorized Kohler distributor/dealer. Place the circuit breaker in the ON position. Reduce the load on the generator set. Contact an authorized Kohler distributor/dealer for service. Reduce the load. Check for oil leaks. Check the oil level and add oil if necessary. Check fuel supply. Reset the controller. If the overcrank fault occurs again, contact an authorized Kohler distributor/dealer. Replace the fuse. If the fuse blows again, contact an authorized Kohler distributor/dealer. Reset the controller. If the overspeed fault occurs again, contact an authorized Kohler distributor/dealer. Press the RUN button to start the engine or press AUTO to allow remote starting. Check the remote switch position. Contact an authorized Kohler distributor/dealer. None. 66 Section 5 Troubleshooting TP-6905 4/16 i 5.6 Controller Troubleshooting Figure'5=2 contains basic troubleshooting information -for th--RDC2 controller. Problem Possible Cause Corrective Action Controller LCD Low or no battery voltage. Check connections. display is off. I 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. I the generator set starts. Loss of Bad connections. Check wiring and connections. Verify that cable size communication to and length of run comply with the instructions in the accessory modules Installation manual. Low or no battery voltage. I Check battery connections. Check generator set battery. See Figure 5-1. Load management Bad connections. Check wiring and connections. Verify that cable size relays do not and length of run comply with the instructions in the operate. Installation manual. Low or no battery voltage. I 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 I I TP-6905 4/16 Section 5 Troubleshooting 67 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere CG center of gravity ext. external ABDC after bottom dead center CID cubic inch displacement F Fahrenheit, female AC alternating current. CL centerline FHM flat head machine (screw) AID analog to digital cm centimeter fl. oz. fluid ounce ADC advanced digital control; CMOS complementary metal oxide flex. flexible analog to digital converter substrate (semiconductor) freq. frequency adj. adjust, adjustment com communications (port) FS full scale ADV advertising dimensional coral commercial ft, foot, feet drawing Coml/Rec Commercial/Recreational ft. lb. foot pounds (torque) Ah amp -hour conn. co' nection ft./min. feet per minute AHWT anticipatory high water cont. co. tinued ftp file transfer protocol temperature CPVC chlorinated polyvinyl chloride g gram AISI American Iron and Steel crit. critical ga. gauge (meters, wire size) Institute CSA Canadian Standards gal. gallon ALOP anticipatory low oil pressure Association gen. generator alt. alternator CT current transformer genset generator set Al aluminum Cu copper GFI ground fault interrupter ANSI American National Standards Institute (formerly American cUL Canadian Underwriter's Laboratories GND,O- ground Standards Association, ASA) CUL Canadian Underwriter's gov. governor AO anticipatory only Laboratories gph gallons per hour APDC Air Pollution Control District cu. in. cubic inch gpm gallons per minute API American Petroleum Institute cw. clockwise gr. grade, gross approx. approximate, approximately CWC city water-cooled GRD equipment ground APU Auxiliary Power Unit cyl. cylinder gr. wt. gross weight AQMD Air Quality Management District D/A digital to analog H x W x D height by width by depth AR as required, as requested DAC digital to analog converter HC hex cap AS as supplied, as stated, as dB decibel HCHT high cylinder head temperature suggested dB(A) decibel (A weighted) HD heavy duty ASE American Society of Engineers DC direct current HET high exhaust temp., high ASME American Society of DCR direct current resistance engine temp. Mechanical Engineers deg., ° de g ree hex hexagon assy. - assembly t. department Hg mercury (element) ASTM American Societyfor Testingdepp dia. diameter HH hex head Materials DI/EO dual inlet/end outlet HHC hex head cap ATDC after top dead center DIN Deutsches� Institut fur Normung HP horsepower ATS automatic transfer switch e.1 V. (also Deutsche Industrie hr. hour auto. automatic Normenausschuss) HS heat shrink au auxiliary DIP dual inline package hsg- housing avg. average DPDT double -pole, double -throw HVAC heating, ventilation, and air AVR automatic voltage regulator DPST double -pole, single -throw conditioning AWG American Wire Gauge DS d!.sconnect switch HWT high water temperature AWM appliance wiring material DVR digital voltage regulator Hz hertz (cycles per second) bat. battery EEPROM, EEPROM IBC International Building Code BBDC before bottom dead center electrically -erasable IC integrated circuit BC battery charger, battery piogrammable read-only ID. inside diameter, identification charging memory IEC International Electrotechnical BCA battery charging alternator E, emer. emergency (power source) Commission BCI Battery Council International ECM electronic control module, IEEE Institute of Electrical and BDC before dead center engine control module Electronics Engineers BHP brake horsepower EDI electronic data interchange IMS improved motor starting blk. black (paint color), block EFR emergency frequency relay in. inch (engine) 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 F ssociation 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/extemal 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. E-Stop estimated emergency stop KBus Kohler communication protocol cert. certificate, certification, certified etc. et cetera (and so forth) kg kilogram cfh cubic feet per hour exh. exhaust cfm cubic feet per minute TP-6905 4/16 1 Appendix 69 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.._...:-.._.react/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, kQ 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 overtrequency sq. square Ibm/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 LED light emitting diode Administration SS stainless steel Lph liters per hour OV overvoltage std. standard Lpm liters per minute oz. ounce so. steel LOP LP low oil pressure liquefied petroleum p•, pp• PC page, pages personal -computer tach. TB tachometer terminal block LPG liquefied petroleum gas PCB I printed circuit board TCP transmission control protocol LS left side pF picofarad TO time delay Lwa sound power level, A weighted I PF power factor TDC top dead center LWL low water level ph., 0 phase TDEC time delay engine cooldown LWT low water temperature PHC Phillips® head Crimptite® TDEN time delay emergency to m M meter, milli 1/1000 s ( ) mega (10 when used with SI PHH (screw) Phillips® hex head (screw) TDES normal time delayengine start units), male A PHM pan head machine (screw) TONE time delanormal to Y m3 cubic meter PLC programmable logic control emergency m3/hr. cubic meters per hour PMG permanent magnet generator TDOE time delay off to emergency m3/min. cubic meters per minute I pot potentiometer, potential TDON time delay off to normal mA milliampere ppm parts per million temp. temperature man. manual I PROM 1 programmable read-only term. terminal max. MB maximum megabyte (220 bytes) 1 psi memory pounds per square Inch THD TIF total harmonic distortion telephone influence factor p MCCB molded -case circuit breaker psig pounds per square inch gauge tol. tolerance MCM - one thousand circular mils pt. PTC pint positive temperature coefficient_ turbo. typ... turbocharger (same in multiple meggar megohmmeter- PTO power takeoff ..typical locations) MHz megahertz 'PVC polyvinyl chloride U.F undertrequency mi. mil mile one one -thousandth of an inch iqt. quart, quarts UHF ultrahigh frequency min. minimum, minute qty. !R quantity replacement (emergency) UIF UL user interface Underwriter's Laboratories, Inc. min. MJ miscellaneous megajoule power source UNC unified coarse thread (was NC) mJ millijoule Irad. 'RAM radiator, radius random access memory UNF unified fine thread (was NF) mm mOhm, m0milliohm millimeter RBUS RS-465 proprietary univ. URL universal uniform resource locator communications (web address) MOhm, Mgmegohm 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 mill watt ROM read only memory w/ with µF 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 cot, weight net. gas natural gas RTDs Resistance Temperature xfmr transformer NBS National Bureau of.Standards Detectors 70 Appendix I TP-6905 4/16 KOHLER. Power Systems KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: TP-6905 4/16b Call 1-800-544-2444 or visit © 2014, 2015, 2016 by Kohler Co. All rights reserved. KO H LERPower.com