Kohler 48RCLB/C Instruction Manual

Residential/Light Commercial Generator Sets
Model:
48RCLB/C
60RCLA/B
Controller:
RDC2
TP-7102 9/21d
Operation

TP 7102 9/212
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
dealers install and service
the generator.
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field- installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
Accessory Number Accessory Description

Table of Contents
TP-7102 9/21 Table of Contents 3
Safety Precautions and Instructions 5........................................................
Introduction 9..............................................................................
Service Assistance 10........................................................................
Section 1 Service Views 11...................................................................
Section 2 Generator Set Operation 13.........................................................
2.1 Operating Area 13.......................................................
2.2 Prestart Checklist 13.....................................................
2.3 Exercising the Generator Set 15...........................................
2.4 Generator Set Operation 15...............................................
2.4.1 Local Starting and Stopping 15....................................
2.4.2 Automatic Starting and Stopping 15................................
2.4.3 Remote Starting and Stopping 15..................................
2.4.4 Engine Start Crank Cycle 15......................................
2.4.5 Engine Cooldown 15.............................................
2.4.6 Automatic Operation with Model RXT Transfer Switch 16..............
2.4.7 Automatic Operation with Other Transfer Switches 16.................
2.5 Exercise 16.............................................................
2.5.1 Unloaded Cycle Exercise with Complete System Diagnostics 17.......
2.5.2 Unloaded Full-Speed Exercise 17..................................
2.5.3 Loaded Full-Speed Exercise (with RXT only) 17......................
2.5.4 Shutdown During Exercise (Advanced Diagnostic) 18.................
2.5.5 Power Failure During Exercise 18..................................
2.5.6 Exerciser Reset 18...............................................
2.5.7 Setting the Exerciser at Power-up 18...............................
2.5.8 Changing the Exercise Setting 18..................................
2.6 Faults 21...............................................................
2.6.1 Warnings 21....................................................
2.6.2 Shutdowns 21...................................................
2.6.3 ATS Communication Errors 21.....................................
2.6.4 Resetting the Controller after a Fault Shutdown 21...................
2.6.5 Status and Notice Messages 25...................................
2.6.6 Event Log 26....................................................
2.7 Model RXT Transfer Switch Operation 26...................................
2.7.1 Source Availability 26.............................................
2.7.2 ATS Control Sequence of Operation 27.............................
2.7.3 Time Delays 27..................................................
2.7.4 ATS Load Control Relay Time Delay 27.............................
Section 3 RDC2 Controller Operation 29.......................................................
3.1 RDC2 Generator Set/Transfer Switch Controller 29..........................
3.2 Controls and Indicators 29................................................
3.2.1 Controller Keypad 30.............................................
3.2.2 LED Indicators 30................................................
3.2.3 LCD Display 31..................................................
3.3 Controller Power 32......................................................
3.4 Battery Charging 32......................................................
3.5 Changing Settings 32....................................................
3.6 Controller Menus 34......................................................
3.7 Main Menu 34...........................................................
3.8 Overview Menu 35.......................................................
3.9 Engine Metering Menu 35.................................................
3.10 Generator Metering Menu 36..............................................
3.11 Generator Set Information Menu 37........................................
3.12 Genset Run Time Menu 37................................................

Table of Contents, continued
TP-7102 9/21Table of Contents4
3.13 Genset System Menu 38..................................................
3.14 ATS Status Menu 39.....................................................
3.15 ATS Configuration Menu 40...............................................
3.16 Date and Time Menu 41..................................................
3.17 Networking Information Menus 42..........................................
3.17.1 Networking Status Submenu 43....................................
3.17.2 Networking Configuration Submenu (OnCuerPlus Password) 44......
3.17.3 RBUS Information Submenu 45....................................
3.17.4 Remote Devices Submenu 46.....................................
3.18 Programmable Interface Module (PIM) Menus 47............................
3.19 Load Control Menus 48...................................................
Section 4 Accessories 49....................................................................
4.1 Introduction 49..........................................................
4.2 Battery Heaters 49.......................................................
4.3 Block Heaters 50........................................................
4.4 Emergency Stop Kits 50..................................................
4.5 OnCue Plus Generator Management System 51.............................
4.6 Load Management 51....................................................
4.7 Programmable Interface Module (PIM) 51...................................
Section 5 Scheduled Maintenance 53..........................................................
5.1 General Maintenance 53..................................................
5.2 Service Schedule 54.....................................................
5.3 Lubrication System 56....................................................
5.3.1 Oil Specifications 56.............................................
5.3.2 Oil Check 56....................................................
5.3.3 Oil Additions 56..................................................
5.3.4 Oil and Filter Change 56..........................................
5.4 Air Cleaner 58...........................................................
5.5 Exhaust System 59......................................................
5.6 Cooling System 60.......................................................
5.6.1 Checking and Filling Coolant 60...................................
5.6.2 Cooling System Inspection 60.....................................
5.6.3 Draining Cooling System 60.......................................
5.6.4 Flushing and Cleaning 61.........................................
5.6.5 Filling Cooling System 61.........................................
5.7 Spark Plugs 61..........................................................
5.8 Battery 64..............................................................
5.8.1 Checking Electrolyte Level 65.....................................
5.8.2 Checking Specific Gravity 65......................................
5.9 Storage Procedure 66....................................................
Section 6 Troubleshooting 67.................................................................
6.1 Introduction 67..........................................................
6.2 USB Port 67............................................................
6.3 Fault Messages 67.......................................................
6.4 Circuit Protection 67......................................................
6.4.1 Load Circuit Breaker 67...........................................
6.4.2 Fuses 67.......................................................
6.4.3 Controller Internal Circuit Protection 67.............................
6.5 Generator Set Troubleshooting 68..........................................
6.6 Controller Troubleshooting 69.............................................
Appendix A Abbreviations 71................................................................

TP-7102 9/21 5Safety Precautions and Instructions
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.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
DANGER indicates a hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a hazardous
situation which, if not avoided, could
result in death or serious injury.
CAUTION
CAUTION indicates a hazardous
situation which, if not avoided, could
resultinminorormoderateinjury.
NOTICE
NOTICE is used to address practices
not related to physical injury.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
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.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Press the generator set off/reset
button to shut down the generator set.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (- ) lead first.
Reconnect the negative (- ) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.
Battery
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
WARNING
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the case
of eye contact. Never add acid to a
battery after placing the battery in
service, as this may result in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
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. Discharge static electricity
from your body before touching
batteries by first touching a grounded

TP-7102 9/216 Safety Precautions and Instructions
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (- ) lead first when
disconnecting the battery. Reconnect
the negative (- ) lead last when
reconnecting the battery. Never
connect the negative (- ) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Risk of fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Generator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes when working
on or near the generator set. Never
operate the generator set inside a
building. Never operate the generator
set where exhaust gas could seep
inside or be drawn into a potentially
occupied building through windows, air
intake vents, or other openings.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide is an
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:
DLight-headedness, dizziness
DPhysical fatigue, weakness in
joints and muscles
DSleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
DStomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
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.
Fuel System
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
WARNING
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. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.

TP-7102 9/21 7Safety Precautions and Instructions
Explosive fuel vapors can cause
severe injury or death. Take
additional precautions when using the
following fuels:
Propane (LPG)—Adequate ventilation
is mandatory. Because propane is
heavier than air, install propane gas
detectors low in a room. Inspect the
detectors per the manufacturer’s
instructions.
Natural Gas—Adequate ventilation is
mandatory. Because natural gas rises,
install natural gas detectors high in a
room. Inspect the detectors per the
manufacturer’s instructions.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LPG vapor or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6- 8 ounces per square inch
(10- 14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. A successful
test depends on the ability of the
solution to bubble.
Hazardous Noise
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
CAUTION
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Moving Parts
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
DANGER
Hazardous voltage. Backfeed to
the utility system.
Can cause property damage,
severe injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
WARNING
Welding the generator set.
Can cause severe electrical
equipment damage.
Welding on generator set will cause
serious damage to engine electronic
controls components. Disconnect all
engine electronic control connections
before welding.
CAUTION
Grounding electrical equipment.
Hazardous voltage will cause severe
injury or death. Electrocution is
possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage will cause severe
injury or death. Disconnect the
generator set from the load by turning
off the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.
Weldingonthegeneratorset. Can
cause severe electrical equipment
damage. Before welding on the
generator set perform the following
steps: (1) Remove the battery cables,
negative (- ) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine battery-
charging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
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.Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
Engine block heater. Hazardous
voltage will 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.

TP-7102 9/218 Safety Precautions and Instructions
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
Servicing the generator set when it
is operating. Exposed moving parts
will 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.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
WARNING
Hot Parts
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure. Fill system
before starting unit.
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
WARNING
Servicing the alternator. Hot parts
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. An approved grounding wrist
strap provides a high resistance (about
1 megohm), not a direct short,to
ground.

TP-7102 9/21 9Introduction
Introduction
This manual provides operation instructions for Model
48RCLB, 48RCLC, 60RCLA, and 60RCLB residential/
light commercial generator sets equipped with the
RDC2 generator set/transfer switch controller. See
Figure 1 for a typical 48 kW liquid-cooled residential
generator set.
Kohler strongly recommends that only factory-
authorized dealers or technicians install and
service the generator.
This generator set is approved for use in stationary
applications in locations served by a reliable utility
power source. Have the generator set installed by an
authorized Kohler dealer or service technician. Refer to
the Installation Manual for installation instructions.
Information in this publication represents data available
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.
The equipment maintenance requirements are very
important for safe and efficient operation. Inspect the
parts often and perform required maintenance at the
prescribed intervals. Obtain service from an authorized
Kohler dealer or service technician to keep equipment in
top condition.
Figure 1 Model 48RCLB Generator Set
Nameplate
Figure 2 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 view in Section 1 for the
nameplate location.
Service Duty
Voltage
Alt Model
Insulation
MFG Date
Amps
Phase
RPM
Battery
Fuel
kW
kVA
Hz
Genset Model
Spec Number
Serial Number
Material Number
PF
Figure 2 Nameplate, Typical

TP-7102 9/2110 Service Assistance
List of Related Literature
Figure 3 identifies related literature available for the
generator sets covered in this manual. Only trained and
qualified personnel should install or service the
generator set.
Literature Type Part Number
Specification Sheet, 48RCLB G4-276
Specification Sheet, 48RCLC G4-306
Specification Sheet, 60RCLA G4-277
Specification Sheet, 60RCLB G4-307
Installation Manual, 48RCLB, 60RCLA TP-7101
Installation Manual, 48RCLC, 60RCLB TP-7203
Operation Manual, Engine TP-7095
Parts Catalog, Engine TP-6731
Parts Catalog, Generator Set TP-6812
Accessory Literature Part Number
Installation Instructions, Block Heaters TT-1587
Installation Instructions, Load Shed Kit TT-1609
Installation Instructions, Programmable
Interface Module (PIM) TT-1584
Installation Instructions, Power Relay
Modules TT-1646
User Guide, OnCuerPlus Program TP-7006
Technical Manual, OnCuerPlus Program TP-7007
Operation/Installation Manual, RXT ATS TP-6807
Operation/Installation Manual, RXT ATS* TP-7193
Operation/Installation Manual, RDT ATS TP-6345
Operation/Installation Manual, RDT ATS* TP-7192
* ATSs built after 6/15/21
Figure 3 Related Literature
Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest authorized Kohler or dealer.
DVisit the Kohler Co. website at KOHLERPower.com.
DLook at the labels and decals on your Kohler product
or review the appropriate literature or documents
included with the product.
DCall toll free in the US and Canada 1-800-544-2444.