Operation Residential/Commercial Generator Sets Models: 14RCA 14RCAL 20RCA 20RCAL Controller: RDC2 TP-7092 2/21a
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 factory-authorized distributors or dealers install and service the generator. Product Identification Information Product identification numbers determine service parts.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 3.2.2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3 LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued Section 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 Circuit Protection . . . . . . . . . . . . . . . . . . . . .
Notes 6 TP-7092 2/21
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 gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment.
Fuel System WARNING Hazardous Noise CAUTION Explosive fuel vapors. Can cause severe injury or death. Hazardous noise. Can cause hearing loss. Use extreme care when handling, storing, and using fuels. Never operate the generator set without a muffler or with a faulty exhaust system. 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.
Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.
Introduction This manual provides operation and maintenance instructions for residential/commercial model 14/20RCA/RCAL generator sets equipped with the RDC2 generator set/transfer switch controller. See Figure 1. Kohler strongly recommends that only factoryauthorized distributors or dealers install and service the generator. Have the generator set installed by an authorized distributor/dealer or service technician. Refer to the Installation Manual for installation instructions.
Nameplate Emission Compliance Period 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 in Section 1.9 for the nameplate location.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. Visit the Kohler Co. website at KOHLERPower.com. Look at the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. Call toll free in the US and Canada 1-800-544-2444. Outside the US and Canada, call the nearest regional office.
Notes 14 Service Assistance TP-7092 2/21
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 distributor/ dealer. 1.
Built-in battery charger RDC2 Controller Features Six-button keypad Remote two-wire start/stop capability for connection of Model RDT or other transfer switches OFF, AUTO, and RUN pushbuttons Select and arrow buttons for access to system configuration and adjustment menus LED indicators for OFF, AUTO, and RUN modes LED indicators for utility power and generator set source availability and ATS position (Model RXT transfer switch required) Diagnostic messages Displays diagnostic messages for the engine, g
1.7 OnCue Plus Generator Management System 1.8.2 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.
1.8.4 Battery Heater Kit 1.8.5 The battery heater kit contains a heating wrap to help warm the battery in cold climates. See Figure 4. The battery heater is equipped with a thermostat that turns the heater on at 16- 18 C (60- 65 F) and off at 27 C (80 F). Battery heaters are recommended for regions where the temperature regularly falls below 0 C (32 F). Note: Battery heaters are compatible with all Kohler-supplied lead-acid batteries.
1.8.6 Carburetor Heater Voltage An optional carburetor heater is recommended for improved cold starting in locations where the ambient temperature drops below 0 C (32 F). The carburetor heater prevents condensation and carburetor icing. The heater requires a continuous source of AC power. See the generator set Installation manual for more information.
1.8.8 instructions to install the heaters and connect 120VAC power. 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). See Figure 14 and Figure 15 for illustrations of the 120VAC breather tube heater and oil heater. Heater Part Number GM110893, GM110894 Voltage Note: The heaters require a continuous source of AC power.
1.8.9 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 16 for illustrations of the installed kit. Follow the instructions provided with the kit to install the boot. 1 14RESA(L) 1 GM102176 20 kW Models 1.
1.9 Service Views 1 5 2 6 3 10 9 8 4 3 7 15 13 14 11 16 12 20 21 17 22 23 24 25 26 27 7 19 18 ENCLOSURE PANELS REMOVED TO SHOW DETAIL 31 28 30 29 ADV9746 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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 detectors. Carbon monoxide can cause severe nausea, fainting, or death. Install carbon monoxide detectors on each level of any building adjacent to the generator set. Locate the detectors to adequately warn the building’s occupants of the presence of carbon monoxide. Keep the detectors operational at all times. Periodically test and replace the carbon monoxide detectors according to the manufacturer’s instructions. CAUTION 2.3.
Shutdown Switch The generator set may be equipped with a Shutdown switch. See Figure 2-2. This switch, also referred to as the Engine Shutdown switch, commands an immediate shutdown and prevents an engine start if the switch is turned to the off (open, O) position. When the shutdown switch is activated, the controller display shows Emerg Stop Shutdwn. The switch is a mechanical, rocker-style switch. Press O to prevent engine start during generator set service. Press I to allow the engine to start and run.
Automatic Stop with Engine Cooldown 1. When the utility source is restored, Emergency-to-Normal time delay starts. the 2. When the Emergency-to-Normal time delay expires, the load is transferred to the utility. 3. The generator set runs through the engine cooldown cycle and then stops. 2.3.
Engine Speed, RPM 2.4.3 3 min. 1 min. Engine Exercise The unloaded full-speed exercise runs the generator set at full speed for 20 minutes without transferring the load. To set an unloaded full-speed exercise, follow the procedure in Figure 3-8 and select Exercise Mode: Unloaded Full. 1 min. 10 min. 5 min. Full-Speed Diagnostics Cooldown Figure 2-3 Unloaded Exercise Cycle System Diagnostics During the unloaded exercise, the controller monitors the following data.
2.4.6 Power Failure During Exercise Cycle If the utility power is lost during an unloaded exercise, the ATS transfers to the emergency source, the exercise is ended and the control remains in the AUTO mode. If the utility power is lost during a loaded exercise, the exercise is ended. The ATS remains in the emergency position and the control goes into the AUTO mode. engine starts, the generator set will run at full speed for two minutes and then stop.
Fault Message Overview - - > 1.2 h Fault Message Confirm Clear Fault: NO Press Up arrow button.
Fault Message AC Sens Loss Warning (W) or Shutdown (SD) Condition W (1 sec.) SD (3 sec.) * Check AC sensing lost. In Auto mode, generator output Contact an authorized AC sensing is lost. Detection begins10 seconds distributor/dealer for service. 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. Accy PwrOver Warning W Accessory Power Overload.
Fault Message Warning (W) or Shutdown (SD) Condition Check Frequency High 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 distributor/dealer for service. Frequency Low 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 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 * ErraticSig The power metering on this controller gives a signal that is not consistent with the system configuration. Reversing the power direction does not resolve the problem. Bad wiring to the CT. The Automatic Paralleling Module has stopped communicating on RBUS. (An APM was detected on the RBUS network but is no longer communicating.) APM is unplugged. LossOfComAPM Too much tension on wires from the CT to the controller.
Notes 34 Section 2 Generator Set Operation TP-7092 2/21
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. See Figure 3-1 for controller illustrations.
3.2.1 Controller Keypad 3.2.2 LED Indicators The RUN, OFF, and AUTO buttons control the generator set as described in Figure 3-3. LEDs above the RUN, OFF, and AUTO buttons indicate the mode of operation as shown in Figure 3-4. Use the Select, Up arrow, and Down arrow buttons to navigate through the menus and change settings, if necessary. See Section 2.3 for operation instructions.
3.2.3 LCD Display The controller is equipped with a two-line x 16 character backlit digital display with adjustable contrast. When the generator is running, the controller automatically scrolls through the displays shown in Figure 3-5. When the system is in AUTO, the screens shown in Figure 3-6 are displayed. When a fault or warning condition exists, the controller will show the corresponding message. See Section 2.5 for more information about faults.
3.3 Controller Power The RDC2 controller is powered by the generator set engine starting battery and the built-in battery charger. Note: To disconnect controller power, disconnect the utility power to the generator set and disconnect the battery. If controller power is disconnected and reconnected, you will be prompted to set the language, time, date, and exerciser. The first setting will flash. Press the Up and Down arrow buttons to change the setting.
Changing Settings on the RDC2 Controller 1. Press the Select button to enter the main menu. 8. When the correct date is shown, press the Select button. The saved date is shown. Overview - - > Press: Display: 1.2 h Press: 2. Press the down arrow button until the desired menu is displayed. See Figure 3-9. Date and Time are used for this example. Date Press: Display: --> Date: Display: 05Dec2011 4. 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. See Section 3.
Genset System --> System Freq: XX.X Hz System Phase System Volt System Battery Fuel Type HOLD: Next Exercise * Next Exercise HR:MN PM MM/DD/YY HR:MN PM MM/DD/YY HOLD: Exercise Mode: Exercise Mode: Loaded Unloaded Cycle/Unloaded Full/ Loaded Full HOLD: Exercise Freq: Exercise Freq: Weekly 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.
Status Displays Press the Up and Down arrow buttons to move between menus. Press OFF or AUTO to exit the menus. Overview - - > 1.2 h Engine - - > Metering ATS --> Configuration * Generator- - > Metering Date --> and Time Genset - - > Information Network - - > Information Genset - - > Run Time PIM Status --> Genset System --> Load Control --> ATS Status --> Event Log- - > * ATS Configuration appears only if a Model RXT transfer switch is connected.
3.9 Overview Menu Overview - - > 1.2 h 3.10 Engine Metering Menu The engine metering menu displays engine status information as shown in Figure 3-11. This menu displays status information only. No settings can be changed from this menu. Active Alert (if any) Engine - - > Metering Genset Status Standby Eng Speed: 3600 RPM Oil Pressure: Switch: OK Voltage: 240V Freq: 60.0Hz Oil Temp: 72.0 F Engine: 72F Oil Pressure: OK Battery: 12.0 V Battery 12.0V <- - Return Engine Runtime: 24.
Voltage Calibration 3.11 Generator Metering Menu The generator metering menu displays the generator voltage and frequency. See Figure 3-12. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced by qualified electrical personnel. The voltage calibration mode can be entered from the Generator Metering menu. Contact a Kohler-authorized distributor/dealerdealer for service.
3.12 Generator Set Information Menu 3.13 Genset Run Time Menu The generator set model number and serial numbers are displayed. 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.
3.14 Genset System Menu The genset system menu displays the system information shown in Figure 3-15. Generator sets are factory set and should not require changes to the system settings in the field. adjust the contrast. Press the Select button to save the contrast setting. Genset System A Kohler authorized distributor or dealer can adjust these settings, if necessary.
The ATS Status menu displays Model RXT transfer switch and source information. 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. ATS --> Status 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. ATS - - > Configuration Normal Freq: 60 Hz Normal Voltage: 240 V Changing ATS Configuration Settings To enable editing, press the select button. The value flashes to indicate that it can be changed.
3.17 Date and Time Menu Date and Time The date and time will typically be set at controller power- up. To change the date, time, or time format (12 hour or 24 hour), use the Date and Time menu. See Figure 3-18. Date: 02Dec2011 Time: 12:34pm 3.18 Networking Information Menus Use the networking menus to view and adjust communication settings for systems with remote RBUS devices such as a PIM or load shed kit, and for systems that use the Kohler OnCue Plus Generator Management System.
3.18.1 Networking Status Submenu The Networking Status submenu contains settings for OnCue . Changes to these settings are not typically required. To enable or disable DHCP and change the IP settings, go to the Networking Configuration menu. See Section 3.18.2. 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.
3.18.2 Networking Configuration Submenu (OnCue Password) reset after the OnCue Plus system has been set up, the connection will be lost. Disconnect the battery power to the controller, wait a minute, then reconnect power. The Networking Configuration menu includes settings used for communication with the Kohler OnCue Plus Generator Management System.
Networking- - > Information Networking- - > Status HOLD Networking Configuration Reset OnCue Password? No Reset OnCue Password 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 Model RXT transfer switch 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: 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. PIM Status: PIM 1 --> <- - Return A personal computer running Kohler SiteTech software is required to change the input and output settings.
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. Load - - > Control Generator Current: Generator current is displayed as a percent of the maximum generator capacity.
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.
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 System Component or Procedure Fuel See Section Procedure Visually Inspect Check Change Clean Test Flexible lines and connections X Main tank supply level Fuel piping Lubrication R Frequency Quarterly X Weekly Yearly X 4.2 Oil level X Crankcase breather hose Every 8 hours of engine operation X X Yearly or 500 hours Change oil X Yearly or 100 hours Replace filter X Yearly or 200 hours Cooling 4.5 Air ducts, louvers Exhaust Line X Yearly 4.
4.1.2 Service Schedule, 20 kW Models Procedure System Component or Procedure Fuel See Section Flexible lines and connections X Main tank supply level Fuel piping Lubrication Visually Inspect Check Change Clean Test R Frequency Quarterly X Weekly Yearly X Every 8 hours of engine operation X 4.2 Oil level Change oil X Yearly or 150 hours Replace filter X Yearly or 150 hours Crankcase breather hose Oil cooler Cooling X X X X Yearly 4.
4.2 Lubrication System 4.2.2 See the service schedules in Section 4.1 for oil change and oil filter replacement intervals. See the service views in Section 1.9 for the oil drain, oil check, oil fill, and oil filter locations. The generator set is shipped with oil. Before operating the generator set, check the engine oil in the crankcase. WARNING Accidental starting. Can cause severe injury or death. Oil Check To check the oil level, shut down the generator set and wait several minutes.
4.2.4 Oil Change Procedure Note: Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner. Drain the oil while it is still warm. 1. Drain the oil. a. Press the OFF button on the generator set controller. b. Disconnect the utility power to the generator set. c. Disconnect the generator set engine starting battery, negative (- ) lead first. d. Remove the end panels from the enclosure by lifting the panels up and out.
d. Reconnect the generator set engine starting battery, negative (- ) lead last. e. Reconnect the utility power to the generator set. f. Press the RUN button on the generator set controller. The generator set will start. g. Run the generator set for a minute to allow the oil pressure to reach operating range. h. Stop the generator set, wait 1 minute, and then recheck the oil level. Add oil to bring the level up to the F mark on the dipstick. 4.2.
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.
Air Cleaner Service 4.4 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. WARNING 1. Press the OFF button on the generator set controller. Risk of fire. Can cause severe injury or death. 2. Disconnect the utility power to the generator set. Do not smoke or permit flames or sparks near fuels or the fuel system. 3.
4.4.2 Air Cleaner Service Air Cleaner, 20 kW Models The engine is equipped with a replaceable, high density paper air cleaner element. See Figure 4-9. 1 Replace the paper element at the intervals indicated in the service schedule. See Section 4.1.2 for the service schedule. See Figure 4-9 for the air cleaner components. 1. Loosen the two cover retaining knobs and remove the cover. 2 2. Remove the paper element. 3 3.
4.5 Cooling System 4.7 Battery The engine fan draws cooling air through the openings in the sides and end near the battery. The alternator fan draws cooling air through openings on the side walls of the enclosure. The cooling air mixes with the engine exhaust and is discharged at the exhaust outlet. See the service view in Section 1.9 for air intake and exhaust locations. To prevent generator set damage caused by overheating, keep the housing cooling inlets and outlets clean and unobstructed at all times.
Refer to this section for general battery information and maintenance. Also consult the battery manufacturer’s instructions for battery maintenance. All generator set models use a negative ground with a 12-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator spec sheet for battery size and capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information.
Temperature °C °F Correction 71.1 160 + .032 65.6 150 + .030 + .028 EXAMPLE NO. 1— + .026 60.0 140 54.4 130 + .024 Temperature below 80°F (26.7°C) + .022 Hydrometer Reading 1.250 + .020 + .018 48.9 120 + .016 + .014 43.3 110 + .012 Acid Temperature 20°F (- 6.7°C) Subtract .024 Specific Gravity Corrected Specific Gravity is 1.226 1.250 - .024 = 1.226 + .010 37.8 100 + .008 + .006 32.2 90 + .004 + .002 26.7 80 21.1 70 15.6 60 10 50 EXAMPLE NO.
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. While the engine is still warm, drain the engine lubrication oil from the engine crankcase. 4.
Notes 72 Section 4 Scheduled Maintenance TP-7092 2/21
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 distributor/dealer.
5.6 Thermostat WARNING Procedure to Reset the Thermostat 1. Disconnect the utility power to the generator by opening (turning OFF) the corresponding circuit breaker at the building’s distribution panel. 2. Open the enclosure roof and secure it with the roof stay on the left side of the enclosure. 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.
5.7 Troubleshooting Figure 5-3 contains generator set troubleshooting, diagnostic, and repair information. Check for loose connections before replacing parts. Troubleshooting Table 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.
Troubleshooting Table Problem Generator set stops suddenly. Possible Cause Low oil pressure shutdown. Corrective Action Check for oil leaks. Check the oil level and add oil if necessary. No fuel. Check fuel valves and fuel supply. Model 20RCA/20RCAL only: Check enclosure thermostat and reset if tripped. See Section 5.6. Check and clear air inlets and exhaust outlets. Overcrank shutdown. Reset the controller. If the overcrank fault occurs again, contact an authorized distributor/dealer.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV Ah AHWT AISI ALOP alt. Al ANSI AO APDC API approx. APU AQMD AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CAN CARB CAT5 CB CC cc CCA ccw. CEC cert.
kg/cm2 kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
TP-7092 2/21a 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.
