Operation Residential/Commercial Generator Sets Models: 14RCA 14RCAL 20RCA 20RCAL 26RCA 26RCAL Controller: RDC2 TP-7092 7/23d
WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov Kohler strongly recommends that only factoryauthorized dealers install and service the generator. Product Identification Information Product identification numbers determine service parts.
Table of Contents Safety Precautions and Instructions ........................................................................................................................................ 7 Introduction .............................................................................................................................................................................. 13 Service Assistance..............................................................................................................
2.5.6 Faults Related to Paralleling .................................................................................................................... 39 Section 3. RDC2 Controller Operation ................................................................................................................... 41 3.1 RDC2 Generator Set/Transfer Switch Controller .................................................................................................... 41 3.2 Control and Indicators ...................
4.7 Battery .................................................................................................................................................................... 79 4.7.1 Cleaning the battery ................................................................................................................................. 80 4.7.2 Checking Electrolyte Level ....................................................................................................................... 80 4.7.
TP-7092 4/23
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. 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.
Engine Backfire/Flash Fire 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 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.
Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children.
Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hazardous voltage. Backfeed to the utility system. Can cause property damage, severe injury, or death.
Heavy Equipment WARNING Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid. Hot Parts WARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generator set until it cools. Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.
Introduction This manual provides operation and maintenance instructions for Residential/Commercial Model 14RCA/RCAL, 20RCA/RCAL, and 26RCA/L generator sets equipped with the RDC2 generator set/transfer switch controller. See Figure 1. RCAL models are shipped with a Kohler model RXT Automatic Transfer Switch (ATS). The ATS Operation/Installation Manuals are included with the transfer switch. Kohler strongly recommends that only factory authorized dealers install and service the generator.
List of Related Literature Figure 2 identifies literature available for the generator sets and related accessories covered in this manual. Only trained and qualified personnel should install or service the generator set. Generator Set Literature Literature Part No.
Nameplate The following illustration shows a typical 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 views section for the nameplate location.
Generator Set Application Kohler® Co. ensures that all Kohler® generator sets are certified to applicable standards for their intended application. It is the owner/operator’s responsibility to operate Kohler® generator sets exclusively according to the directions provided in the accompanying operation manuals. Kohler® generator sets designated as Stationary Standby, Emergency or Emergency Standby may only be operated for emergency power generation and for maintenance/testing.
Section 1. Descriptions and Service Views 1.1 Introduction The generator set specification sheets provide specific generator and engine information. Refer to the spec sheet for data not supplied in this manual. Consult the generator set service manual, engine operation manual, and engine service manual for additional specifications. Obtain copies of the latest spec sheets, manuals, diagrams, and drawings from your local dealer. 1.
1.6 Controller RCA and RCAL models are equipped with the RDC2 controller. See Figure 5. The controller provides integrated control for the generator set, Kohler® Model RXT transfer switch, programmable interface module (PIM) and load management devices. The controller’s 2-line LCD screen displays status messages and system settings that are clear and easy to read, even in direct sunlight or low light.
• Digital voltage regulation: ±0.
OnCue® Plus Generator Management System 1.7 The Kohler® OnCue® Plus Generator Management System is now included with the generator set. The OnCue® Plus System allows monitoring and control of your generator set from your home or other location with Internet access using a computer or mobile device. OnCue® Plus can be configured to send email or text message notifications in the event of a generator set fault.
Power cord for 120 volt kits Battery heater wrap Power cord Power cord for 240 volt kits Retaining strap or cable ties (included) Figure 6 1.8.3 Battery Heater (typical) Breather Tube Heater and Oil Heater Kit The breather tube heater and oil heater kit is recommended for improved cold starting in locations where the ambient temperature drops below 0°C (32°F). Note: The heaters require a continuous source of AC power. See Figure 7 and Figure 8 for the power supply voltage required.
Label Thermostat Heating element 120 VAC male connector (connect to breather tube heater) Heating probe GM101483 Figure 10 1.8.4 Oil Heater Fuel Regulator Heater (20 and 26 kW models only) An optional fuel regulator heater is recommended for models 20RCA/L and 26RCA/L for improved cold starting in locations where the ambient temperature drops below -18°C (0°F). The heater requires a continuous source of AC power.
1.8.5 Oil Pressure Sensor Boot Kit The oil pressure sensor boot protects the oil pressure sensor and its connection from moisture and frost buildup that can cause false low oil level faults. Install the oil pressure sensor boot in locations where the ambient temperature drops below 0°C (32°F). See Figure 14 for illustrations of the installed kit. Follow the instructions provided with the kit to install the boot. Oil pressure sensor boot 14 kW Models Figure 14 1.8.
120 VAC plug 1/8 NPT threaded fitting Heating element Power cord disconnect plug Thermostat GM57968 240 volt 3-pin plug GM88228 Figure 17 1.8.7 Carburetor Heater, 20 and 26 kW Models Emergency Stop Kit An emergency stop button is available as a loose kit. Pressing the emergency stop button causes the generator set to shut down immediately. The generator controller displays an emergency stop shutdown message after the button is pressed.
1.8.9 PowerSync Automatic Paralleling Module (APM) The PowerSync® Automatic Paralleling Module (APM) allows the use of two Model 14RCA/L or two 20RCA/L or 26RCA/L generator sets in a single-phase paralleling system to supply power to one building or site. See Figure 18. The APM provides a common connection point for paralleling generators and permits individual control of the generator connections, allowing for synchronization, redundancy, and generator management. Automatic paralleling requires: 1.
1.9 Service Views 2 1 5 6 3 10 9 15 4 8 16 7 3 14 13 21 18 22 23 12 24 25 11 26 27 17 19 28 7 32 31 20 ENCLOSURE PANELS REMOVED TO SHOW DETAIL 29 ADV9746 1. Hinged roof 17. Oil fill 2. Lock 18. AC receptacle for accessories 3. Air intake 19. Oil drain valve 4. Enclosure key, provided with generator set 20. Exhaust outlet 5. High voltage electrical in 21. Silencer 6. Optional emergency stop button location 22. USB connector (for firmware updates) 7.
2 1 5 6 3 10 8 9 3 4 13 14 10 16 15 23 24 187 26 25 12 12 13 1 2 27 28 18 21 19 20 19 19 10 31 29 22 ENCLOSURE PANELS REMOVED TO SHOW DETAIL 30 ADV9919 1. Hinged roof 17. AC receptacles for accessories (not shown) 2. Lock 18. Oil fill 3. Air intake 19. Three-pin connectors for accessories 4. Enclosure key, provided with generator set 20. Oil level switch 5. Optional emergency stop button location 21. Oil drain valve 6. High voltage electrical in 22.
TP-7092 4/23
Section 2. Generator Set Operation 2.1 Prestart Checklist 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 clean and unobstructed air inlets. Battery.
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.
Emergency Stop Switch Operation Press the red STOP button to shut down the generator set in an emergency. Using the emergency stop button bypasses the engine cooldown cycle, stopping the engine immediately. The controller emergency stop lamp lights (if equipped) and the unit shuts down. The generator set cannot be restarted until the emergency stop switch(es) is/are reset. Lockout/Tagout The emergency stop button can be locked in the STOP position.
2.3.5 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 the Faults section. Cranking 1, 2, and 3 are displayed during the crank cycle. Pressing the OFF button during the crank cycle stops the cranking. No other buttons are acknowledged during the crank cycle. 20 and 26 kW Models (RDC2.4 v 1.4.
2.3.8 Automatic Operation with Other Transfer Switches If a transfer switch other than the Model RXT (such as a Kohler Model RDT) is used, the engine start contacts from the ATS must be connected to engine start leads 3 and 4 on the generator set. The controller must be in AUTO mode to respond to remote start/stop signals from an ATS or remote switch. Press the AUTO button to put the controller into automatic mode.
2.4.2 Unloaded Cycle Exercise with Complete System Diagnostics An unloaded exercise runs the generator set without signaling the transfer switch to transfer the electrical load from the utility source to the generator set. The Unloaded Cycle exercise with diagnostics is the recommended exercise mode and is the default exercise setting. The Unloaded Cycle exercise runs the engine for 20 minutes in the cycle shown in Figure 23 and described below.
2.4.3 EcoExercise (26RCA/L only) A new 90 second EcoExercise cycle is available for the 26RCA/L model only. Its main features are: • Lowers the fuel cost. • In cold temperatures, limits condensation build- up in the crankcase. The EcoExercise Cycle runs for 60 seconds at 3600 RPM with active diagnostics, and 30 seconds at reduced speed. Monthly EcoExercise cycles are recommended for cold climates. 2.4.
2.5 Faults The RDC2 controller displays fault messages for generator set warnings and shutdowns. Selected fault messages are shown in the Resetting the Controller After a Fault Shutdown section. Contact an authorized dealer for service, if necessary. 2.5.1 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. 2.5.
Overview ---> 1.2 h Fault Message Fault Message Confirm Clear Fault: NO Press UP arrow button. Confirm Clear Fault: YES Figure 24 tp6809 Clearing a Fault on the RDC2 Controller Fault Message Warning (W) or Shutdown (SD) Condition Check AC sensing lost. In Auto mode, generator output AC sensing is lost. Detection begins10 seconds after crank disconnect. Warning: after 1 second if no output detected after crank disconnect. Shutdown: after 3 seconds if voltage was present and then lost.
Fault Message Frequency High Frequency Low Warning (W) or Shutdown (SD) Condition Check SD * Governed frequency exceeds 110% of the system’s frequency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine start (10 second inhibit). Contact an authorized dealer for service. SD * Governed frequency falls below 90% of the system frequency setting for more than 10 seconds, or 1 Hz below the system frequency setting for more than 60 seconds.
2.5.6 Faults Related to Paralleling If the PowerSync® Automatic Paralleling Module (APM) is used with two 14 kw or two 20 kW or 26 kW generator sets, additional faults and events related to the paralleling system may be displayed on the controller and/or in OnCue Plus. This section lists those faults and events. See the installation instructions provided with the APM for additional paralleling information.
Fault Text Description Possible Causes * LossOfComm2 The primary controller has lost communication with the secondary controller. (A secondary controller was detected, then communication was lost.) RBUS disconnected, secondary controller battery disconnected, updating firmware in secondary controller, or intermittent RBUS connections. LossOfField This generator has absorbed more than 25% reactive power (magnetic excitation current) for 20 seconds.
Section 3. RDC2 Controller Operation 3.1 RDC2 Generator Set/Transfer Switch Controller Model RCA and RCAL generator sets are equipped with the RDC2 generator set/transfer switch controller. The RDC2 controls the following power system components: • Model RCA or RCAL generator set • Model RXT Automatic Transfer Switch (ATS) • Load management device • Programmable Interface Module (PIM) The RDC2 controller features include: 3.
2-line LCD display Up button AUTO button and LED Select button OFF button and LED Down button RUN button and LED Utility power available LED* Building on utility power LED* Generator power available LED* Building on generator power LED* These LEDs operate only if a Model RXT automatic transfer switch is connected. Figure 30 3.2.1 GM77569 RDC2 User Interface Controller Keypad The RUN, OFF, and AUTO buttons control the generator set as described in Figure 31.
3.2.2 LED Indicators LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 32. Power System LEDs indicate the status of the utility power and the generator set, and indicate which source is supplying power to the building (based on the position of the RXT transfer switch). See Figure 32. Note: The power system LEDs operate only if a Model RXT transfer switch is connected.
Active Alert Active Alert Genset Status Running Genset Status Standby Voltage: 240V Freq: 60.0 Hz Battery Engine: 72.0F Oil Pressure: OK Engine Runtime: 24.5 h Battery Date: 02DEC2011 Time: HR:MNpm 12.3V Engine Runtime: 24.5 h Next Exercise: 09:00p 09Dec2011 Date: 02DEC2011 Time: HR:MNpm Next Maintenance: 150 h or Mar2012 Generator running Figure 33 3.3 12.3V Automatic mode Sample data shown.
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 require field adjustment under normal circumstances. Check and adjust the settings and/or output when: • The controller has been replaced. • The voltage requires adjustment for a particular application. • Troubleshooting generator set problems.
Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. Press: 2. Display: Press the down arrow button until the desired menu is displayed. See the Main Menu section. Date and Time are used for this example. Display: Press: 3. Date --> and Time Press the Select button to enter the Date and Time menu. Display: Press: 4. Overview --> 1.2 h Date 05Dec2011 To change the date and time settings, press the Select button again. The year will flash.
3.6 Setting the Exerciser Set the exerciser to automatically run the generator set for 20 minutes every week or every two weeks. 3.6.1 Setting the Exerciser at Controller Power-up When battery power is connected to the controller, you will be prompted to set the language, date and time, and then to set the 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.
Genset - - > System System Freq: XX.X Hz System Phase System Volt System Battery Fuel Type HOLD: Next Exercise * HR:MN PM MM/DD/YY Next Exercise HR:MN PM MM/DD/YY HOLD: Exercise Mode: Unloaded Cycle/Unloaded Full/ Loaded Full Exercise Mode: Loaded HOLD: Exercise Freq: Weekly Exercise Freq: Weekly/Bi-Weekly Language: Contrast: 50 <- - Return If the exerciser has not been set, No Exercise Sch will be displayed.
3.7 RDC2 Controller Menus Controller menus display power system information, including status information for the engine, generator, and optional RBUS accessories, exercise settings, and event history. Some menus allow changes to the controller settings. Status information, including the engine runtime, cannot be changed by the operator. Diagrams in the following sections show how to navigate through the menus. The diagrams show sample settings. Settings for your application may vary.
3.9 Overview Menu Overview ---> 1.2 h Active Alert (if any) Genset Status Standby Voltage: 240V Freq: 60.0 Hz Engine: 72F Oil Pressure: OK Battery: 12.0V Engine Runtime: 24.5 h Date: 02DEC2011 Time: HR:MNpm Next Exercise: 09:00p 09Dec2011 Next Maintenance: 150 h or Mar2012 SW Version: 4.07 Note: Actual settings may vary.
3.10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 38. This menu displays status information only. No settings can be changed from this menu. Engine ---> Metering Eng Speed: 3600 RPM Oil Pressure: Switch: OK Oil Temperature: 72.0 F Battery: 12.0 V <--- Return Note: Actual settings may vary.
3.11 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See the figure titled: Generator Metering Menu. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. Voltage Calibration The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized dealer for service.
3.12 Generator Set Information Menu The generator set model number and serial numbers are displayed (see Figure 40). No changes are allowed from this menu. Model and serial numbers are factory-set and should not require changes in the field, except in the event that the controller is being replaced. A personal computer running Kohler® SiteTech™ software is required to enter the generator set model number and serial numbers on a replacement controller. Contact an authorized Kohler dealer for service.
3.14 Genset System Menu The genset system menu displays the system information shown in Figure 42. Generator sets are factory-set and should not require changes to the system settings in the field. A Kohler-authorized dealer can adjust these settings, if necessary. If the generator set is reconnected to a different voltage or the system settings require adjustment for some other reason, see the Changing Settings section for instructions to enable editing and change the system settings.
Genset ---> System System Voltage: 240 V System Freq: 60 Hz VR Voltage Adj: 240.0 V System Phase: Single System Battery: 12 V Fuel Type: LP Next Exercise 06:30PM 15Dec2011 Exercise Mode: Unloaded Variable Exercise Freq: Weekly Language: English Meas System: English Contrast: 50 Note: Actual settings may vary.
3.15 ATS Status Menu ATS menus appear if a Model RXT transfer switch is connected to the generator set. If no transfer switch is connected, or another model ATS is connected to the engine start connections, Remote ATS is displayed on the ATS Status screen. The ATS Status menu displays Model RXT transfer switch and source information. The voltage shown in these menus can be calibrated. Follow the safety precautions at the beginning of this manuals.
3.16 ATS Configuration Menu Note: The ATS Configuration menu appears only if a Model RXT transfer switch is connected. Use the ATS Configuration submenu to check the Model RXT transfer switch system settings and time delays, and change the 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.
3.17 Date and Time Menu The date and time will typically be set at controller powerup. To change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 45. Date and Time Date: 02Dec2011 Time: 12:34pm Time Format: 12hr <--- Return To change the date and time, press the Select button. See the Changing Settings section for instructions. Figure 45 Date and Time Menu 3.
3.18.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue® Plus. Changes to these settings are not typically required. If DHCP is enabled, IP parameters are not displayed. If DHCP is disabled (i.e., if a static IP address is used), the IP parameters are displayed. To enable or disable DHCP and change the IP settings, go to the Networking Configuration menu. Networking- --> Information Networking- --> Status OnCue Status: Connected DHCP: Enabled IP Address: 123.456.789.
3.18.2 Networking Configuration Submenu (OnCue® Password) The networking Configuration menu includes settings used for communication with the Kohler® OnCue® Plus Generator Management System. Password Note: Use the OnCue password shown on the controller display for OnCue or 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 application.
Networking---> Information Networking---> Status HOLD Networking Configuration Reset OnCue Password Reset OnCue Password? No UP arrow for YES, Down arrow for NO. RBUS - - > Information Reset OnCue Password? Yes Press Select to enter YES or NO as displayed. New password is displayed for approximately 10 seconds. S/N: 1234567 New PW: 12345 HOLD DHCP: Enabled DHCP: Disabled UP arrow to enable, Down arrow to disable. IP Address: 123.456.789.123 Subnet Mask: 123.456.789.123 Gateway: 123.456.789.
3.18.3 RBUS Information The RBUS Information menu contains settings for remote modules that communicate with the RDC2 controller using RBUS protocol.
3.18.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: • Model RXT ATS • Programmable Interface Module (PIM) • Load shed kit or combined interface/ load management board on a Model RXT transfer switch • PowerSync® Automatic Paralleling Module (APM) The serial number for the RBUS module is shown on the circuit board inside the module enclosure.
3.19 Programmable Interface Module (PIM) Status Menu The PIM status menu displays the status of inputs and outputs connected to the programmable interface module (PIM). This menu appears only if a PIM is connected. This is a status display menu only. Input and output settings cannot be changed from the RDC2 controller’s user interface. A personal computer running Kohler® SiteTech™ software is required to change the input and output settings. Contact an authorized dealer for service.
3.20 Load Control Menus The Load Control menu displays the status of the load management device inputs and outputs, and allows a test of the load control output relays. This menu appears only if a load management device (load shed kit or Model RXT transfer switch with the combined interface/ load management board) is connected. Generator current is displayed as a percent of the maximum generator capacity. The load control module adds and sheds loads based on the generator current.
3.21 Event Log The event log displays up to 1000 controller faults and notices, starting with the most recent event. Events are numbered 1-1000, with 1 being the most recent. Each event is displayed with the date and time of the event, the number of the event, a code to indicate whether the event was a warning (W), shutdown (S), or informational notice (I), the engine hours at the time of the event, and the event description. The time and date for notices (I) are not stored in the controller.
Section 4. Scheduled Maintenance 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.
4.1.1 Service Schedule, 14 kW Models Procedure System Component or Procedure Visually Inspect Check Change Clean Test Frequency Fuel Flexible lines and connections X Main tank supply level Fuel piping R Quarterly X Weekly X Yearly Lubrication Oil level Crankcase breather hose X Every 8 hours.
4.1.
4.2 Lubrication System See the service schedules section for oil change and oil filter replacement intervals. See the service views section for the oil drain, oil dipstick, oil fill, and oil filter locations. 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.
4.2.2 Low Oil Level Switch (26RCA) The low oil level switch protects the engine against internal damage if the oil pressure drops below a minimum level. The engine shuts down and a fault message is displayed on the controller if the oil level is too low. See the Faults section for instructions if the generator set shuts down on a fault. Check the oil level regularly and add oil as needed. 4.2.3 Oil Check The generator set is shipped with oil.
2. 3. f. Remove the oil drain hose from its retaining clip. Remove the cap from the oil drain hose and lower the hose into an oil collection container. g. Open the oil drain valve on the engine. h. Remove the dipstick and oil fill cap. Allow time for the engine oil to drain completely. i. Close the oil drain valve. Replace the cap on the oil drain hose. Replace the oil drain hose in its retaining clip. j. Replace the dipstick. Replace the oil filter. a. Clean the area around the oil filter. b.
Dipstick Oil fill Oil cooler located under shroud (20 and 26 kW models) Note: 20 kW model shown; 14 kW and 26 kW models are similar. Figure 56 4. 5. 4.2.6 Oil Fill Components Check for leaks. a. Check for oil leaks. b. Fix leaks and recheck the oil level. c. Reinstall the housing side panel. Reset the maintenance timer on the controller. Resetting the Maintenance Timer 1. From the Overview menu, step down to the Genset Run Time menu. 2.
4.2.7 Oil Cooler (20RCA/L and 26RCA/L only) Inspect and clean the oil cooler at the intervals indicated in the service schedule. The oil cooler must be kept free of debris. See Figure 57 for the oil cooler location. The oil cooler is located under the No. 2 cylinder shroud. Remove the top mounting screw and loosen the two side screws, then lift off the cylinder shroud. Clean the outside of the oil cooler fins with a brush or with compressed air.
4.3 Spark Plugs 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.
1-511 Figure 60 4.4 Adjusting the Spark Plug Gap Air Cleaner Service 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. 4.4.1 Air Cleaner, 14 kW Models The engine has a replaceable high-density paper air cleaner element. See Figure 61.
Air Cleaner Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. Replace the paper element more often under extremely dusty or dirty conditions. 1. Press the OFF button on the generator set controller. 2. Disconnect the utility power to the generator set. 3. Disconnect the generator set engine starting battery, negative (–) lead first. 4. Loosen the cover retaining knob and remove the cover. 5.
Air Cleaner Service Use the following procedure to replace the paper element at the intervals specified in the service schedule. See Service Schedule, 20 and 26 kW Models. See Figure 62 for the air cleaner components. 1. Loosen the two cover retaining knobs and remove the cover. 2. Remove the paper element. 3. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element.
4.7 Battery WARNING Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case.
4.7.1 Cleaning the battery 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.
Correction Example No. 1 Temperature below 26.7°C (80°F) Hydrometer Reading 1.250 Acid Temperature - 6.7°C (20°F) Subtract .024 Specific Gravity Corrected Specific Gravity is 1.226 1.250 - .024 = 1.226 Example No. 2 Temperature above 26.7°C (80°F) Hydrometer Reading 1.235 Acid Temperature 37.8°C (100°F) Add .008 Specific Gravity Corrected Specific Gravity is 1.243 1.235 + .008 = 1.243 The temperature correction amounts to about .004 (4 points) of specific gravity for each 5.
4.8 Storage Procedure Perform the following storage procedure before removing the generator set from service for three months or longer. Follow the engine manufacturer’s recommendations for storage, if available. Note: Run the generator set monthly whenever possible. 4.8.1 Lubricating System 1. Operate the generator set until it reaches operating temperature, or about 15 minutes. 2. Stop the generator set. 3.
Section 5. Troubleshooting 5.1 Introduction Use the troubleshooting charts in this section to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery, loose connections, or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, and recommended corrective actions. If the procedures in this manual do not explain how to correct the problem, contact an authorized Kohler dealer.
USB port on RDC2 controller Mini-breaker location (access through engine compartment) ADV-8928 Figure 67 5.5 USB Port and Mini-Breaker Locations Stop Switches The generator set may be equipped with an optional emergency stop switch or an engine shutdown switch. Verify that it is safe to start the generator set and apply power to the load before deactivating these switches. See the Remote Emergency Stop Switch section. 5.6 Thermostat WARNING Accidental starting. Can cause severe injury or death.
The generator sets include a resettable thermostat. See Figure 68 for the thermostat location in the air intake area, near the fuel system. The thermostat detects excess heat inside the enclosure. If the thermostat trips, the generator will shut down and the controller will display a fault (underspeed, underfrequency, or undervoltage). Check for blocked air inlets and exhaust outlets. Then follow these steps to reset the thermostat. Procedure to Reset the Thermostat 1.
5.7 Troubleshooting Figure 69 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Problem Possible Cause Corrective Action Controller display backlight is off. Backlight turns off after about 1 minute with no activity. Backlight will turn on when a button is pressed or the generator set starts. Controller display is off. Low or no battery voltage. Check connections. Check generator set battery.
Appendix A. Abbreviations A, amp ampere blk. htr. block heater DAC digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure dB decibel AC alternating current bps bits per second dB(A) decibel (A weighted) A/D analog to digital br. Brass DC direct current ADC advanced digital control; analog to digital converter BTDC before top dead center DCR direct current resistance adj.
FHM flat head machine (screw) in. inch Lpm liters per minute fl. oz. fluid ounce in. H2O inches of water LOP low oil pressure flex. flexible in. Hg inches of mercury LP liquefied petroleum freq. frequency in. Lb. inch pounds LPG liquefied petroleum gas FS full scale Inc. incorporated LS left side ft. foot, feet ind. Industrial Lwa sound power level, A weighted ft. lb. foot pounds (torque) int. internal LWL low water level ft./min. feet per minute int./ext.
N, norm. normal (power source) PMG permanent magnet generator SCR silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) NA not available, not applicable pot potentiometer, potential s, sec. second nat. gas natural gas ppm parts per million SI Systeme international d’unites, International System of Units NBS National Bureau of Standards PROM programmable read-only memory SI/EO side in/end out NC normally closed psi pounds per square inch sil.
UHF ultrahigh frequency UIF user interface UL Underwriter’s Laboratories, Inc. UNC unified coarse thread (was NC) UNF unified fine thread (was NF) univ.
TP-7092 7/23d Original Instructions (English) © 2018 Kohler Co. All rights reserved. KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.
