Kohler 38RCL, 48RCL, 60RCL Heavy Equipment, Hot Parts, Notice

TP-6810 11/138 SafetyPrecautions and Instructions

Engine block heater. Hazardous

voltage can cause severe injury or

death. The engine block heater can

cause electrical shock. Remove the

engine block heater plug from the

electrical outlet before working on the

block heater electrical connections.

Electrical backfeed to the utility.

Hazardous backfeed voltage can

causesevere injury or death. Install

a transfer switch in standby power

installations to prevent the connection

ofstandby and other sources of pow er.

Electrical backfeed into a utility

electrical system can cause severe

injury or death to utility personnel

working on power lines.

Airborne particles.

Can cause severe injury or blind-

ness.

Wearprotective goggles and clothing

when using power tools, hand tools,

orcompressed air.

WARNING

Servicing the generator set when it

isoperating. Exposedmovingparts

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.

Heavy Equipment

Unbalanced weight.

Improper lifting can cause severe

injury or death and equipment

damage.

Do not use lifting eyes.

Liftthe generator set using lifting bars

inserted through the lifting holes on

theskid.

WARNING

Hot Parts

Hotcoolant and steam.

Cancause severe injury or death.

Before removing the pressure cap,

stop the generator set and allow it to

cool. Thenloosen the pressure cap

torelieve pressure.

WARNING

Hotengine and exhaust system.

Cancause severe injury or death.

Donot work on the generator set until

it cools.

WARNING

Servicing the alternator. Hotparts

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.

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.

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. Anapproved grounding wrist

strapprovides a high resistanc e (about

1 megohm), not a direct short,to

ground.

Contents

Main WARNING California Proposition 65 Product Identification Information Generator Set Identification Numbers Controller Identification Table of Contents Table of Contents, continued Safety Precautions and Instructions DANGER WARNING CAUTION Accidental Starting Engine Backfire/Flash Fire Exhaust System Fuel System Hazardous Noise CAUTION Hazardous Voltage/ Moving Parts DANGER Heavy Equipment Hot Parts Notice Introduction Nameplate List of Related Literature Figure 3 Related Literature Service Assistance Page Section 1 Service Views Cooling System Detail Figure 1-1 38/48RCL Service Views for Maintenance (38RCL shown) Cooling System Detail Figure 1-2 60RCL Service Views Section 2 Generator Set Operation 2.1 Operating Area 2.2 Prestart Checklist 2.3 Exercising the Generator Set 2.4 Generator Set Operation 2.4.1 Local Starting and Stopping 2.4.2 Automatic Starting and Stopping 2.4.3 Remote Starting and Stopping 2.5 Exercise 2.5.1 Unloaded Cycle Exercise with Complete System Diagnostics 2.5.2 Unloaded Full-Speed Exercise 2.5.3 Loaded Full-Speed Exercise (with RXT only) 2.5.4 Shutdown During Exercise 2.5.5 Power Failure During Exercise 2.5.6 Exerciser Reset 2.5.8 Changing the Exercise Setting Figure 2-2 RDC2 Main Menu See Section 2.5.8, Changing the Exercise Setting 2.6 Faults 2.6.1 Warnings 2.6.2 Shutdowns 2.6.3 ATS Communication Errors 2.6.4 Resetting the Controller after a Fault Shutdown Page Figure 2-5 Controller Fault Messages 2.6.5 Event Log 2.7 Model RXT Transfer Switch Operation 2.7.1 Source Availability 2.7.2 ATSControl Sequence of Operation 2.7.3 Time Delays 2.7.4 ATSLoad Control Relay Time Delay Section 3 RDC2 Controller Operation 3.1 RDC2 Generator Set/Transfer Switch Controller 3.2 Controls and Indicators 3.2.1 Controller Keypad 3.2.2 LED Indicators 3.2.3 LCD Display 3.3 Controller Power 3.4 Battery Charging 3.5 Changing Settings Page 3.6 Controller Menus 3.7 Main Menu 3.8 Overview Menu Figure 3-8 Overview Menu 3.9 Engine Metering Menu Figure 3-9 Engine Metering Menu 3.10 Generator Metering Menu DANGER 3.11 Generator Set Information Menu 3.12 Genset Run Time Menu 3.13 Genset System Menu 3.14 ATS Status Menu 3.15 ATS Configuration Menu 3.16 Date and Time Menu 3.17 Networking Information Menus 3.17.1 Networking Status Submenu 3.17.2 Networking Configuration Submenu (OnCue Password) 3.17.3 RBUS Information Submenu 3.17.4 Remote Devices Submenu Check the status of remote devices communicating through RBUS. Device types can include: Figure 3-21 Remote Devices Submenu 3.18 Programmable Interface Module (PIM) Menus 3.19 Load Control Menus Section 4 Scheduled Maintenance 4.1 General Maintenance 4.2 Service Schedule 4.3 Lubrication System 4.3.1 Oil Specifications 4.3.2 Oil Check 4.3.3 Oil Additions 4.3.4 Oil and Filter Change 4.4 Air Cleaner 4.5 Exhaust System 4.6 Cooling System 4.6.1 Checking and Filling Coolant 4.6.2 Cooling System Inspection 4.6.3 Draining Cooling System 4.6.4 Flushing and Cleaning 4.6.5 Filling Cooling System 4.7 Ignition System 4.8 Battery 4.9 Storage Procedure Page Section 5 Troubleshooting 5.1 Introduction 5.2 USB Port 5.3 Fault Messages 5.4 Circuit Protection 5.5 Generator Set Troubleshooting Figure 5-1 General Troubleshooting Chart 5.6 Controller Troubleshooting Figure 5-2 contains basic troubleshooting information for the RDC2 controller. Figure 5-2 RDC2 TroubleshootingChart Page Appendix A Abbreviations The following list contains abbreviations that may appear in this publication.