Kohler Comprehensive Troubleshooting Guide for Generator Sets
Page 58

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

Corrective Action

 

 

 

The generator

Battery weak or dead.

Recharge or replace the battery.

set does not

 

 

Battery connections reversed or poor.

Check the connections.

crank.

 

 

Blown fuse(s).

Replace the fuse. Contact an authorized Kohler

 

 

 

distributor/dealer for service if fuse blows repeatedly.

 

 

 

 

Generator set is OFF.

Press the RUN button to start the engine or press AUTO

 

 

to allow remote starting.

 

 

 

The generator

Air cleaner clogged.

Clean and/or replace the air cleaner.

set cranks but

 

 

Battery weak or dead.

Recharge or replace the battery.

does not start,

 

 

Battery connection poor.

Clean and tighten the battery connections.

starts hard,

 

 

lacks power, or

Spark plug wire connection loose.

Check the spark plug wires.

operates

 

 

Low oil pressure shutdown.

Check for oil leaks. Check the oil level and add oil if

erratically.

 

necessary.

 

 

 

 

 

 

Fuel pressure insufficient.

Check the fuel supply and valves.

 

 

 

 

Engine fuse blown.

Replace the fuse. If the fuse blows again, contact an

 

 

authorized Kohler distributor/dealer.

 

 

 

 

Engine malfunction.

Contact an authorized Kohler distributor/dealer.

 

 

 

No AC output.

AC circuit breaker in the OFF position.

Place the circuit breaker in the ON position.

 

 

 

 

AC circuit breaker tripping because of overload.

Reduce the load on the generator set.

 

 

 

 

AC circuit breaker tripping because of short

Contact an authorized Kohler distributor/dealer for

 

circuit.

service.

 

 

 

 

Engine fuse blown.

Replace the fuse. Contact an authorized Kohler

 

 

distributor/dealer for service if fuse blows repeatedly.

 

 

 

Low output or

Generator set overloaded.

Reduce the load.

excessive drop

 

 

in voltage.

 

 

 

 

 

Generator set

Low oil pressure shutdown.

Check for oil leaks. Check the oil level and add oil if

stops suddenly.

 

necessary.

 

 

 

 

Out of fuel.

Check fuel supply.

 

 

 

 

Overcrank shutdown.

Reset the controller. If the overcrank fault occurs again,

 

 

contact an authorized Kohler distributor/dealer.

 

 

 

 

Blown fuse(s).

Replace the fuse. If the fuse blows again, contact an

 

 

authorized Kohler distributor/dealer.

 

 

 

 

Overspeed shutdown.

Reset the controller. If the overspeed fault occurs again,

 

 

contact an authorized Kohler distributor/dealer.

 

 

 

 

Generator set is OFF.

Press the RUN button to start the engine or press AUTO

 

 

to allow remote starting.

 

 

 

 

Remote stop command received from a remote

Check the remote switch position.

 

switch, ATS, or OnCuer.

 

 

 

 

 

Engine malfunction.

Contact an authorized Kohler distributor/dealer.

 

 

 

Fans run after

The fans continue to run for 2 minutes after the

None.

engine shuts

engine shuts down to evacuate the engine

 

down.

compartment.

 

Figure 5-1General Troubleshooting Chart

58 Section 5 Troubleshooting

TP-6810 11/13

Page 57 Page 59
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Page 57 Page 59
Contents RDC2 TP-6810 11/13bController Identification Accessory Number Accessory DescriptionProduct Identification Information Generator Set Identification NumbersTable of Contents Troubleshooting Scheduled MaintenanceAppendix a Abbreviations Accidental Starting Safety Precautions and InstructionsBattery Accidental starting Can cause severe injury or deathExhaust System Engine Backfire/Flash FireFuel System Hazardous noise Can cause hearing loss Hazardous NoiseHazardous voltage Will cause severe injury or death Hot Parts Heavy EquipmentHot coolant and steam Can cause severe injury or death Introduction NameplateList of Related Literature Literature Type Part NumberService Assistance Service Assistance TP-6810 11/13 Service Views NON-SERVICE Side260RCL Service Views Operating Area Prestart ChecklistGenerator Set Operation Keep the generator set area clear. Maintain at leastExercising the Generator Set Generator Set OperationSystem Diagnostics Automatic Operation with Model RDT or RSB Transfer SwitchesUnloaded Cycle Exercise with Complete System Diagnostics ExerciseSetting the Exerciser at Power-up Power Failure During ExerciseExerciser Reset Unloaded Full-Speed ExerciseChanging the Exercise Setting Procedure to Change the Exercise Setting2RDC2 Main Menu 3Procedure to Set the Exerciser ATS Communication Errors FaultsResetting the Controller after a Fault Shutdown Procedure to Reset the Controller after a Fault ShutdownFault Shutdown SD Condition Check 5Controller Fault Messages Setting Model RXT Transfer Switch OperationProcedure to View Event History Event LogATS Control Sequence of Operation Time DelaysATS Load Control Relay Time Delay Preferred Source FailsControls and Indicators RDC2 Controller OperationButton Function Controller Keypad LED IndicatorsButton LED OperationLCD Display Active AlertChanging Settings Controller PowerBattery Charging Procedure to Change SettingsChanging Settings on the RDC2 Controller 6Changing SettingsController Menus Main MenuOverview Menu Engine Metering MenuGenerator Metering Menu Voltage CalibrationGenerator Set Information Menu Genset Run Time MenuAdjusting the Display Contrast Voltage Regulator VR Voltage AdjustSetting the Exerciser Genset System MenuATS Status Menu 14ATS Status Menu, with CalibrationATS Configuration Menu Changing ATS Configuration SettingsDate and Time Menu Date and Time 02Dec2011 1234pm Time Format 12hr24hrNetworking Information Menus 17Networking Information MenuNetworking Status Submenu DhcpNetworking Configuration Submenu OnCue Password OnCue PasswordRbus Information Submenu 20RBUS Information SubmenuRemote Devices Submenu 21Remote Devices SubmenuProgrammable Interface Module PIM Menus Load Control Menus 23Load Control Status MenuScheduled Maintenance General MaintenanceService Schedule Every Operation DailyOil Check Oil SpecificationsLubrication System Oil AdditionsAir Cleaner Service Procedure Air CleanerReset the maintenance timer on the RDC2 Check for leaksChecking and Filling Coolant Cooling SystemExhaust System Inspection Points Cooling System Inspection Flushing and CleaningFlushing and Cleaning Procedure Draining Cooling SystemIgnition System Model Spark plug gap 38 RCL, 48RCL, and 60RCL511 Storage Procedure Scheduled Maintenance TP-6810 11/13 Introduction TroubleshootingFault Messages USB PortGenerator Set Troubleshooting Problem Possible Cause Corrective ActionController Troubleshooting 2RDC2 Troubleshooting ChartTroubleshooting TP-6810 11/13 Appendix a Abbreviations AnsiLCB 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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