Kohler Comprehensive Generator Troubleshooting Guide
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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 distributor/dealer. Maintain a record of repairs and adjustments performed on the equipment. Use the record to help describe the problem and repairs or adjustments made to equipment.

5.2 USB Port

A USB port is located on the front of the controller. Use a USB cable with a mini-B connector to connect the controller to your personal computer (laptop).

Some controller settings can be adjusted using a laptop computer with Kohlerr SiteTecht software. SiteTech software is available to Kohler authorized distributors and dealers. See TP-6701, SiteTecht Software Operation Manual, for more information.

5.3 Fault Messages

The RDC2 controller displays fault messages to aid in troubleshooting. Fault messages, descriptions, and recommended checks are listed in Figure 2-5.

Identify and correct the cause of the fault condition. Then reset the controller after a fault shutdown. See Section 2.6.4.

5.4 Circuit Protection

If the generator set circuit breaker trips or the fuses blow repeatedly, contact an authorized Kohler distributor/ dealer for service.

5.4.1Load Circuit Breaker

The load circuit breaker interrupts the generator output in the event of a fault in the wiring between the generator and the load. If the circuit breaker trips, reduce the load and switch the breaker back to the ON position. Refer to the service views in Section 1 for the location of the circuit breaker.

5.4.2Fuses

Always identify and correct the cause of a blown fuse before restarting the generator set. Refer to Figure 5-1, Troubleshooting Chart, for conditions that may indicate a blown fuse. Obtain replacement parts and service from an authorized Kohler distributor/dealer.

Fan Fuses. Three 30 amp fan fuses are located in the fan fuse and relay box. See Section 1, Service Views, for location.

5.4.3Controller Internal Circuit Protection

The controller is equipped with internal circuit protection. Press OFF to reset.

TP-6905 6/14

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Contents TP-6905 6/14 RDC2Product Identification Information Accessory Number Accessory DescriptionController Identification Generator Set Identification NumbersTable of Contents Troubleshooting Scheduled MaintenanceAppendix a Abbreviations Battery Safety Precautions and InstructionsAccidental Starting 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 Airborne particles Can cause severe injury or blind- nessHot coolant and steam Can cause severe injury or death Hot PartsNameplate IntroductionLiterature Type Part Number List of Related LiteratureService Assistance Service Assistance TP-6905 6/14 Cooling System Detail Service ViewsService Views TP-6905 6/14 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 ATS Communication Errors FaultsResetting the Controller after a Fault Shutdown Procedure to Reset the Controller after a Fault ShutdownATS Fault RDC2 Fault OnCuer Condition Check PlusECM Air filter 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 Normal 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 MenuScreens on this page do not appear ATS Status MenuChanging ATS Configuration Settings ATS Configuration MenuDate and Time 02Dec2014 1234pm Time Format 12hr24hr Date and Time Menu17Networking Information Menu Networking Information MenusDhcp Networking Status SubmenuOnCue Plus Password Networking Configuration Submenu OnCue Plus Password20RBUS Information Submenu Rbus Information Submenu21Remote Devices Submenu Remote Devices SubmenuProgrammable Interface Module PIM Menus 23Load Control Status Menu Load Control MenusGeneral Maintenance Scheduled MaintenanceScheduled Maintenance TP-6905 6/14 Service Schedule Lubrication System Oil SpecificationsOil Check Oil AdditionsReplace the oil filter Reset the maintenance timer on the RDC2Stop the generator set. Check the oil level. Add Check for leaksAir Cleaner Service Procedure Air CleanerChecking and Filling Coolant Cooling SystemExhaust System Inspection Points Flushing and Cleaning Procedure Flushing and CleaningCooling System Inspection Draining Cooling SystemModel Spark plug gap Ignition System511 Battery Storage Procedure Fault Messages TroubleshootingIntroduction USB PortProblem Possible Cause Corrective Action Generator Set Troubleshooting2RDC2 Troubleshooting Chart Controller TroubleshootingTroubleshooting TP-6905 6/14 Ansi Appendix a AbbreviationsLCB Page By Kohler Co. All rights reserved

24RCL specifications

The Kohler 24RCL is a powerful, compact generator designed to provide reliable backup power for residential applications. Equipped with a robust 24 kW output, this generator is engineered for both efficiency and durability, making it an excellent choice for homeowners looking to safeguard their property against outages.

One of the standout features of the Kohler 24RCL is its quiet operation. With a noise level significantly lower than that of traditional generators, it allows homeowners to maintain their comfort without the disruptive sounds often associated with backup power systems. This is particularly important in residential neighborhoods where maintaining peace and quiet is essential.

The generator is powered by a liquid-cooled Kohler engine, which ensures consistent performance and longevity. Liquid-cooled engines are known for their ability to provide better thermal management, thereby extending the life of the engine while also improving efficiency. Moreover, the Kohler 24RCL utilizes a proven design that enables quick starts and reliable operation, even in the most challenging conditions.

Another key technology in the 24RCL is its integrated transfer switch, which automatically detects power outages and switches the home’s electrical supply to the generator. This seamless transition ensures that there is no disruption in power, making it an ideal solution for critical loads such as refrigerators, medical equipment, and security systems. The generator’s advanced control system allows for easy monitoring and maintenance, providing users with peace of mind whenever they rely on their backup power.

The Kohler 24RCL boasts a weather-resistant enclosure, designed to withstand the elements and provide protection against rain, snow, and harsh winds. This rugged construction also contributes to the longevity of the unit, ensuring that it can perform reliably year after year.

Sustainability is another driving factor in the design of the Kohler 24RCL. The generator features efficient fuel consumption, which not only helps to reduce operating costs but also minimizes the environmental impact. With many homeowners increasingly focused on eco-friendly solutions, the 24RCL fits seamlessly into a sustainable lifestyle.

Overall, the Kohler 24RCL is a powerful, efficient, and quiet backup generator that combines advanced technology with rugged reliability. Its features make it a standout choice for homeowners seeking a dependable power solution that prioritizes convenience, safety, and sustainability. Whether facing severe weather or unexpected outages, the Kohler 24RCL ensures that homes remain powered and protected.
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