Kohler 38RCL manual Ignition System, Model Spark plug gap 38 RCL, 48RCL, and 60RCL

Page 53

4.7 Ignition System

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.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.

5.Loosen the spark plug with a ratchet and 5/8-in. spark plug socket with a rubber insert to prevent spark plug damage.

6.Use compressed air to remove dirt from around each spark plug to prevent dirt particles from falling into the combustion chamber.

7.Remove spark plugs, one at a time, and examine. Identify a normal spark plug in good operating condition by observing a light tan or gray deposit on firing tip. See Figure 4-9 to evaluate engine condition by color/condition of a problem spark plug.

8.Clean spark plugs by wiping them with a rag. File the center electrode to keep it parallel to the side electrode.

Note: Do not sandblast, wire brush, scrape, or otherwise service spark plugs in poor condition. Obtain a new plug for best results.

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

Model

Spark plug gap

 

 

38 RCL, 48RCL, and 60RCL

0.9 mm (0.035 in.)

Figure 4-7Recommended Spark Plug Gap

 

1

 

2

 

1-514

1.

0.9 mm (0.035 in.) gap

2.

Spark plug electrodes

Figure 4-8Spark Plug Gap Inspection

Problem/Condition

Means of Identification

Possible Cause/Solution

 

 

 

Gap-bridged spark

Built-up deposits and gap between electrodes

Oil or carbon fouling. Clean and regap the spark

plug

closing.

plug.

 

 

 

Oil-fouled spark plug

Wet, black deposits on the insulator shell, bore,

Excessive oil entering combustion chamber

 

and electrodes.

through worn rings and pistons, excessive

 

 

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

 

glazed coating on the insulator tip.

spark plug.

 

 

 

Pre-ignition damaged

Melted electrodes and possibly blistered

Wrong type of fuel, incorrect timing or advance,

spark plug

insulator. Metallic deposits on insulator suggest

too hot a plug, burned valves, or engine

 

internal engine damage.

overheating. Replace the spark plug.

 

 

 

Overheated spark plug

White or light gray insulator with small black or

Engine overheating, wrong type of fuel, loose

 

gray/brown spots with bluish (burned)

spark plugs, too hot a plug, low fuel pressure or

 

appearance on electrodes.

incorrect ignition timing. Replace the spark plug.

Worn spark plug

Severely eroded or worn electrodes.

Caused by normal wear and failure to replace

 

 

spark plug at prescribed interval. Replace the

 

 

spark plug.

 

 

 

Figure 4-9Engine Evaluation Using Spark Plug Condition

TP-6810 11/13

Section 4 Scheduled Maintenance 53

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Contents TP-6810 11/13b RDC2Product Identification Information Accessory Number Accessory DescriptionController Identification Generator Set Identification NumbersTable of Contents Appendix a Abbreviations Scheduled MaintenanceTroubleshooting Battery Safety Precautions and InstructionsAccidental Starting Accidental starting Can cause severe injury or deathFuel System Engine Backfire/Flash FireExhaust System Hazardous voltage Will cause severe injury or death Hazardous NoiseHazardous noise Can cause hearing loss Hot coolant and steam Can cause severe injury or death Heavy EquipmentHot Parts Nameplate IntroductionLiterature Type Part Number List of Related LiteratureService Assistance Service Assistance TP-6810 11/13 NON-SERVICE Side Service Views260RCL Service Views Generator Set Operation Prestart ChecklistOperating Area Keep the generator set area clear. Maintain at leastGenerator Set Operation Exercising the Generator SetUnloaded Cycle Exercise with Complete System Diagnostics Automatic Operation with Model RDT or RSB Transfer SwitchesSystem Diagnostics ExerciseExerciser Reset Power Failure During ExerciseSetting the Exerciser at Power-up Unloaded Full-Speed ExerciseProcedure to Change the Exercise Setting Changing the Exercise Setting2RDC2 Main Menu 3Procedure to Set the Exerciser Resetting the Controller after a Fault Shutdown FaultsATS Communication Errors Procedure to Reset the Controller after a Fault ShutdownFault Shutdown SD Condition Check 5Controller Fault Messages Procedure to View Event History Model RXT Transfer Switch OperationSetting Event LogATS Load Control Relay Time Delay Time DelaysATS Control Sequence of Operation Preferred Source FailsRDC2 Controller Operation Controls and IndicatorsButton Controller Keypad LED IndicatorsButton Function LED OperationActive Alert LCD DisplayBattery Charging Controller PowerChanging Settings Procedure to Change Settings6Changing Settings Changing Settings on the RDC2 ControllerMain Menu Controller MenusEngine Metering Menu Overview MenuVoltage Calibration Generator Metering MenuGenset Run Time Menu Generator Set Information MenuSetting the Exerciser Voltage Regulator VR Voltage AdjustAdjusting the Display Contrast Genset System Menu14ATS Status Menu, with Calibration ATS Status MenuChanging ATS Configuration Settings ATS Configuration MenuDate and Time 02Dec2011 1234pm Time Format 12hr24hr Date and Time Menu17Networking Information Menu Networking Information MenusDhcp Networking Status SubmenuOnCue Password Networking Configuration Submenu OnCue Password20RBUS Information Submenu Rbus Information Submenu21Remote Devices Submenu Remote Devices SubmenuProgrammable Interface Module PIM Menus 23Load Control Status Menu Load Control MenusGeneral Maintenance Scheduled MaintenanceEvery Operation Daily Service ScheduleLubrication System Oil SpecificationsOil Check Oil AdditionsReset the maintenance timer on the RDC2 Air CleanerAir Cleaner Service Procedure Check for leaksExhaust System Inspection Points Cooling SystemChecking and Filling Coolant Flushing and Cleaning Procedure Flushing and CleaningCooling System Inspection Draining Cooling SystemModel Spark plug gap 38 RCL, 48RCL, and 60RCL Ignition System511 Storage Procedure Scheduled Maintenance TP-6810 11/13 Fault Messages TroubleshootingIntroduction USB PortProblem Possible Cause Corrective Action Generator Set Troubleshooting2RDC2 Troubleshooting Chart Controller TroubleshootingTroubleshooting TP-6810 11/13 Ansi Appendix a AbbreviationsLCB Page 2012, 2013 by Kohler Co. All rights reserved

38RCL, 48RCL, 60RCL specifications

The Kohler RCL series of generators, particularly the 60RCL, 48RCL, and 38RCL models, represents a premium choice for those seeking reliable power solutions for residential and light commercial applications. Each model is tailored to meet diverse power needs, ensuring uninterrupted electricity supply during outages.

The 60RCL is engineered for maximum performance, offering 60 kW of power. This model is ideal for larger homes or small businesses that require dependable backup power. Its powerful Kohler engine is designed to deliver a quiet, smooth performance, while the advanced sound-dampening features keep noise levels to a minimum. The 48RCL offers a slightly lower output at 48 kW, making it suitable for medium-sized homes. Its compact design allows for flexible installation options, whether it’s outdoors or in a utility area, while still providing robust power during critical times.

The 38RCL, while the smallest of the series with 38 kW output, is perfect for homes that need a reliable backup generator without the bulk. Its streamlined design does not compromise on performance, making it an excellent choice for energy-efficient homes. All models in the RCL series come equipped with Kohler's Command Pro commercial-grade engine, ensuring longevity and reliability even in the harshest conditions.

A standout feature of the RCL series is the integrated KOHLER® 2.4-inch color display, which allows users to monitor generator performance in real-time. This user-friendly interface provides vital information such as operational status, run time, and maintenance notifications. Additionally, the series is designed with automatic transfer switches that allow for seamless switching between utility and generator power.

Moreover, these generators incorporate advanced control systems with remote monitoring capabilities, enabling users to check the status of their power supply from a smartphone or tablet. Designed with efficiency in mind, the RCL series boasts a fuel-efficient operation that supports both natural gas and propane, catering to diverse energy preferences.

In summary, the Kohler 60RCL, 48RCL, and 38RCL generators combine high performance, advanced technology, and user-friendly features. They are reliable solutions for anyone looking to safeguard their power needs, ensuring peace of mind when it matters most.
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