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.

TP-7102 9/21 11Section 1 Service Views
Section 1 Service Views
1. Nameplate location
2. Engine ECM and EPR (electronic fuel pressure regulator)
3. Oil check (dipstick)
4. See cooling system detail
5. Exhaust outlet
6. Enclosure locking tool (shipping location only)
7. Spark plugs
8. Block heater connection valve
9. Block heater (optional)
10. Fuel inlet (1 in. NPT)
11. Fuel solenoid valve
12. Fuel conversion lead location
13. Oil fill location (on valve cover)
14. Customer load lead access
15. Customer connection access panel
16. Line circuit breaker
17. Generator set master control buttons (on RDC2 controller)
18. RDC2 controller
19. Air cleaner
20. Cooling air inlet (remove this panel to access coolant drain)
21. Access to coolant fill
22. Fan fuses
23. Battery
24. Oil drain valve
25. Lube oil filter
26. Block heater connection valve
27. Coolant drain
28. Fans (qty. 3)
29. Radiator
30. Pressure cap (engine coolant fill)
31. Coolant overflow tube
32. Coolant overflow bottle
ADV-8954
24
16
18
19
17
29
12 10
7
20
1
25
1415
42 3
13
23
GM103966
Cooling System Detail
28
28
31
30
27
32
7
5
22
8
26
9
21
6
SERVICE SIDE
NON-SERVICE SIDE
11
Figure 1-1 Service Views, 48RCLB and 60RCLA

TP-7102 9/2112 Section 1 Service Views
1. Nameplate location
2. Engine ECM and EPR (electronic fuel pressure regulator)
3. Oil check (dipstick)
4. Fan fuses
5. See cooling system detail
6. Exhaust outlet
7. Enclosure locking tool (shipping location only)
8. Spark plugs
9. Block heater connection valve
10. Block heater (optional)
11. Fuel inlet (1 in. NPT)
12. Fuel solenoid valve
13. Fuel conversion lead location
14. Oil fill location (on valve cover)
15. Customer load lead access
16. Customer connection access panel
17. Line circuit breaker
18. Generator set master control buttons (on RDC2 controller)
19. RDC2 controller
20. Air cleaner
21. Cooling air inlet (remove this panel to access coolant drain)
22. Access to coolant fill
23. Battery
24. Oil drain valve
25. Lube oil filter
26. Block heater connection valve
27. Coolant drain
28. Fans (qty. 3)
29. Radiator
30. Pressure cap (engine coolant fill)
31. Coolant overflow tube
32. Coolant overflow bottle
ADV-9760
24
17
19
20
18
29
13 11
8
21
1
25
1516
52 3
14
23
GM116144
Cooling System Detail
28
28
31
30
27
32
8
6
4
9
26
10
22
7
SERVICE SIDE
NON-SERVICE SIDE
12
Figure 1-2 Service Views, 48RCLC and 60RCLB

TP-7102 9/21 13Section 2 Generator Set Operation
Section 2 Generator Set Operation
2.1 Operating Area
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
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.
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 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.
Keep the generator set area clear. Maintain the
required clearance on all sides of the generator set.
Verify that there are no windows, air vents, or other
openings in the building near the generator set exhaust
outlet in any direction. See the generator set dimension
drawing in the Installation Manual for required
clearance.
Keep the air intake area clean. Do not leave rags, tools,
or debris on or near the generator set.
Notice
DO NOT locate patios, decks, play areas, or
animal shelters near the generator set. Keep items
such as lawn furniture, toys, sports equipment,
and all combustible materials away from the
generator set exhaust outlet. Remind family
members, children, and visitors to use caution
near the generator set.
Generator sets connected to automatic transfer
switches start automatically during exercise
periods and power outages. Some generator set
components become hot when the generator set is
running and remain hot for a time after the
generator set shuts down.
2.2 Prestart Checklist
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.

TP-7102 9/2114 Section 2 Generator Set Operation
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
causearcsorsparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
WARNING
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 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 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.
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
DANGER
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.
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.

TP-7102 9/21 15Section 2 Generator Set Operation
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 obstructions that could block the
flow of cooling air. Keep the air intake area clean. Do not
leave rags, tools, or debris on or near the generator set.
Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.
Coolant Level. Check the coolant level according to the
cooling system maintenance information.
Note: Block heater damage. The block heater will fail if
the energized heater element is not immersed in
coolant. Fill the cooling system before turning on
the block heater. Run the engine until it is warm,
and refill the radiator to purge the air from the
system before energizing the block heater.
Drive Belt(s). Check the belt condition of the water
pump and battery charging alternator belt(s).
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components for cracks and
corrosion (exhaust manifold, exhaust pipe, exhaust
clamps, and silencer).
DCheck for corroded or broken metal parts and replace
them as needed.
DCheck that there are no combustible materials near
the exhaust outlet.
DCheck that the exhaust outlet is unobstructed.
Carbon Monoxide Detectors. Check for the
installation and operation of carbon monoxide (CO)
detectors on each level of any building near the
generator set.
Oil Level. Maintain the oil level at or near, not over, the
full mark on the dipstick.
2.3 Exercising the Generator Set
Operate the generator set every week or every other
week for 20 minutes. Perform all of the prestart checks
before starting the exercise procedure. See Section 2.5
for instructions to set the automatic exerciser.
2.4 Generator Set Operation
2.4.1 Local Starting and Stopping
Start: Press the RUN button to immediately start the
generator set.
Stop: Press the OFF button. The engine stops.
Run the generator set with no load for at least 2 minutes
to ensure adequate engine cooldown.
2.4.2 Automatic Starting and Stopping
An automatic transfer switch monitors the utility power
and signals the generator set to start when utility power
is lost. The ATS then transfers the load to the generator
set.
When utility power is restored, the transfer switch
transfers the load back to utility, runs the generator set
with no load to cool down the engine, and then stops the
generator set engine. The electric fans continue to run
for two minutes after the engine shuts down to evacuate
the engine compartment.
2.4.3 Remote Starting and Stopping
A remote switch connected to terminals 3 and 4 can be
used to start and stop the generator set. Close the
switch to start and run the generator set. Open the
switch to stop the generator set.
Run the generator set with no load for at least 2 minutes
to ensure adequate engine cooldown.
2.4.4 Engine Start Crank Cycle
The controller attempts to start the generator set three
times (three crank cycles, 15 seconds crank and
15 seconds off). If the generator set does not start in
three attempts, the system shuts down on an overcrank
fault. See Section 2.6.
Pressing the OFF button during the crank cycle stops
the cranking. No other buttons are acknowledged during
the crank cycle.
2.4.5 Engine Cooldown
The engine cooldown time delay allows the engine to
run after the loads have been removed.

TP-7102 9/2116 Section 2 Generator Set Operation
The engine cooldown time delay is set to 5 minutes. The
engine stops before the cooldown time delay expires if
the temperature drops below the cooled-down
temperature level, or if the temperature rises above the
high limit during the cooldown cycle.
The electric fans continue to run for two minutes after the
engine shuts down to evacuate the engine
compartment.
If a transfer switch other than the Model RXT is used, an
additional engine cooldown time delay may be
programmed on the transfer switch. To allow the smart
engine cooldown on the RDC2 controller to operate
most efficiently, set the cooldown time on the transfer
switch controller to zero or the minimum time allowed.
Refer to the instructions provided with the transfer
switch for more information.
2.4.6 Automatic Operation with Model
RXT Transfer Switch
The Model RXT transfer switch connects to the RDC2
controller through the ATS interface board on the
transfer switch. Also see Section 2.7, Model RXT
Transfer Switch Operation.
The RDC2 controller must be in AUTO mode for
automatic transfer switch operation.
Automatic Start
The RDC2 controller receives utility source voltage
sensing data from the Model RXT transfer switch.
1. If the utility source voltage falls below an
acceptable level, the controller starts the engine
start time delay.
2. If the utility source is not restored before the time
delay expires, the generator set starts.
3. After the Normal-to-Emergency time delay, the
ATS is signaled to transfer the load to the
emergency source.
Automatic Stop
1. When the utility source is restored, the
Emergency-to-Normal time delay starts.
2. When the Emergency-to-Normal time delay
expires, the load is transferred to the utility.
3. The generator set stops.
2.4.7 Automatic Operation with Other
Transfer Switches
If a Kohler Model RDT transfer switch is used, the
engine start contacts from the ATS must be connected
to engine start leads 3 and 4 on the generator set.
The RDC2 generator set controller must be in AUTO
mode to respond to remote start/stop signals from an
ATSorremoteswitch.PresstheAUTObuttononthe
RDC2 controller to put the generator set into automatic
mode.
Automatic Start
The engine start contacts on the ATS close to signal the
generator set to start, and remain closed while the
generator set is running.
Automatic Stop
The engine start contacts on the ATS open to signal the
generator set to stop.
2.5 Exercise
The RDC2 controller can be set to automatically run the
generator set at the same time and day every week or
every other week. Exercising the generator set every
week or every two weeks is required in order to keep the
engine and alternator in good operating condition.
Three exercise modes are available: unloaded cycle,
unloaded full speed, and loaded full speed. See
Sections 2.5.1 through 2.5.3 for information about the
exercise modes. A loaded exercise can be set at the
RDC2 controller only if a Model RXT transfer switch is
connected.
Note: With the RDT transfer switches, it is possible to
have two exercise settings (one unloaded
exercise set at the generator set controller, and
another exercise set at the ATS controller). If the
exercise times overlap, the ATS exercise setting
takes priority.
If a Model RDT transfer switch is used, refer to the
instructions provided with the transfer switch to set a
loaded exercise at the ATS, if desired.

TP-7102 9/21 17Section 2 Generator Set Operation
2.5.1 Unloaded Cycle Exercise with
Complete System Diagnostics
An unloaded cycle exercise runs the generator set
without signalling the transfer switch to transfer the
electrical load from the utility source to the generator
set. The Unloaded Cycle exercise with diagnostics is the
recommended exercise mode and is the factory-default
exercise setting.
TheUnloadedCycleexerciserunstheenginefor
20 minutes in the cycle shown in Figure 2-1 and
described below.
DRuns at reduced speed for 10 minutes to warm up
and exercise the engine.
DRamps up and runs at full speed for 3 minutes.
Engine diagnostics are performed during this
full-speed portion of the cycle, which provides the
best test of engine and alternator power backup
capability. Diagnostic tests at full speed can identify
potential problems with the power output and alert the
operator before an emergency event.
DRamps down and runs at reduced speed for
5 minutes to cool down the engine before shutting
down automatically.
Engine
Exercise
Full-Speed
Diagnostics
Cooldown
3min.
1min.
1min.
10 min. 5 min.
Figure 2-1 Unloaded Exercise Cycle
System Diagnostics
During the unloaded cycle exercise, the controller
monitors the following data. The controller display
indicates an unloaded exercise run during the
diagnostics, unless a fault is detected as described
below.
DATS connection. The controller verifies that the
Model RXT ATS interface board is connected.
DBattery voltage. Battery voltage is checked before
exercise to verify engine starting capability. Battery
voltage provides a measurement of battery health. If
the controller detects low battery voltage, low battery
or low charging battery is displayed and the exercise
does not start.
DCoolant level check. The coolant level is checked.
DCommunication integrity tests. J1939, RBUS,
Ethernet, and USB are monitored for messages
indicating that the controller and wiring are reliable.
DEngine speed. Engine speed is measured at low
speed and full speed. An overspeed or underspeed
condition will result in a fault condition and shutdown.
DGenerator output frequency and voltage.
Operating the generator at full speed allows the
RDC2 controller to check the output power for correct
voltage, frequency, and stability. When the engine is
running at full speed, the controller verifies that the
voltage and frequency are within acceptable limits. A
fault message is displayed if the voltage or frequency
is out of range.
DOil pressure. Oil pressure is verified to ensure
proper lubrication of critical engine components.
Pressure is monitored at both low and full speeds. If
the oil pressure is low, low oil pressure is displayed
and the generator set shuts down.
Note: See Section 2.5.4 for information about
Advanced Diagnostic Active in the event history.
2.5.2 Unloaded Full-Speed 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 2-3 and select Exercise Mode:
Unloaded Full.
2.5.3 Loaded Full-Speed Exercise (with
RXT only)
A loaded exercise starts the generator set, ramps up to
full speed, and then transfers the electrical load from the
utility source to the generator set. The load is transferred
back to the utility source before the generator set shuts
down.
Note: With a loaded exercise, power to the building is
lost for up to 10 seconds during load transfer.
For a loaded exercise controlled by the RDC2 controller,
a Model RXT transfer switch must be connected to the
generator set. To set a loaded exercise, follow the
procedure in Section 2.5.8 and select Exercise Type:
Loaded.

TP-7102 9/2118 Section 2 Generator Set Operation
For a loaded exercise with a transfer switch other than a
KohlerrModel RXT, program the exercise at the
transfer switch controller. Refer to the transfer switch
operation manual for instructions.
2.5.4 Shutdown During Exercise
(Advanced Diagnostic)
The following advanced diagnostic operation applies to
RDC2 controllers with firmware versions 5.04 and
higher.
If the generator set shuts down on a fault during an
exercise, the controller will try to restart the engine. If the
engine starts, the generator set will run at full speed for
two minutes and then stop. The event history will show
Advanced Diagnostic Active. The exercise schedule is
maintained.
If the engine does not start, the shutdown message will
be displayed. Correct the fault condition and reset the
fault as described in Section 2.6.
2.5.5 Power Failure During Exercise
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.
The generator set continues to run and supply power to
the load for the duration of the utility power outage.
When Utility power is restored, the ATS will re-transfer to
the utility source through normal timing sequences.
2.5.6 Exerciser Reset
To reset the exerciser to run at a different day and/or
time or to change the exercise mode, follow the
procedure in Section 2.5.7 to change the exerciser
settings.
2.5.7 Setting the Exerciser at Power-up
When power is connected to the controller, you will be
prompted to select the language and set the date, time,
and exercise schedule.
1. At power-up, you will be prompted to select a
language for the controller displays, Use the up
and down arrow buttons to step through the
language options, Press the Select button when
the desired language is displayed.
2. Next, the date is displayed with the year flashing.
Usetheupordownarrowkeytosteptothecurrent
year.
3. Press Select button to save the year and move to
the month.
4. Use the arrow and select buttons to set the month
and the day.
5. The time is displayed with the hour flashing. Use
theupordownarrowkeytosteptothecurrenthour
and am or pm setting.
Note: Check the am/pm setting displayed. If pm is
displayed and you need to change it to am,
usethedownarrowbuttontostepdownin
time until the correct hour and am are
displayed.
6. Press the Select button to save the hour and move
to minutes.
7. Use the up or down arrow button to change the
minutes.
8. Press Select to save the time and move to the next
screen.
9. Next Exercise is displayed. Use the up, down, and
select buttons to set the exercise time and date. Be
suretosetatimeanddateinthefuture.
10. Press Select. The controller exits the exercise
menu.
11. Press the Auto button and verify that the AUTO
LED is lit. The generator set must be in automatic
mode for the exercise to run as scheduled.
The exercise will run every 7 days at the same time,
starting on the date set. To change the exerciser to run
every other week or on a different day and time, use the
following procedure.
2.5.8 Changing the Exercise Setting
Set the date and time on the controller before setting the
exercise schedule. Set the exerciser to automatically
run the generator set for 20 minutes every week or every
two weeks. Follow the procedure below and see the
flowchart in Figure 2-3 to set the exercise time and date,
mode, and frequency.
Procedure to Change the Exercise Setting
1. Press the AUTO button on the controller.

TP-7102 9/21 19Section 2 Generator Set Operation
2. Press the Select button to go to the main menu.
See Figure 2-2.
3. Press the down arrow button to step to the Genset
System menu.
4. Press the Select button to enter the Genset system
menu. See Figure 2-3.
5. Use the down arrow button to step to the next
Exercise menu.
6. Press the Select button. The setting flashes to
show that it can be changed. For example, the hour
flashes to show that the hour can be changed.
7. Press the UP or Down arrow buttons to change the
setting.
8. Press the Select button to save the setting and
move to the next. For example, save the hour
setting and move to minutes.
9. Repeat steps 5 through 8 to change the next item
on the line until the desired settings are displayed.
10. Press Select to save after all settings have been
selected. Settings will stop flashing.
11. If the generator set is connected to a KohlerrModel
RXT transfer switch, the exercise can be changed
to a loaded exercise. Set the Exercise Mode to
loaded full speed, unloaded full speed, or unloaded
cycle as shown in Figure 2-3.
12. Set the exercise frequency (weekly or every two
weeks). Weekly exercises are recommended.
13. Press the down arrow button to step to the Return
menu. Press the Select button to return to the main
menu.
14. Check that the AUTO LED is lit. The generator set
must be in automatic mode for the exercise to run
as scheduled.
After a scheduled exercise run, the next exercise time
and date will be updated automatically based on the
Exercise Frequency setting.
Other transfer switches: For a loaded exercise with a
transfer switch other than a KohlerrModel RXT,
program the exercise at the transfer switch controller.
Refer to the transfer switch operation manual for
instructions.
Overview - - >
1.2 h
Engine - - >
Metering
tp6810
Generator- - >
Metering
Genset - - >
Information
Genset - - >
Run Time
Date - - >
and Time
ATS - - >
Configuration
Genset - - >
System
Event Log- - >
Load - - >
Control
PIM - - >
Status
Network - - >
Information
Status
Displays
ATS - - >
Status
Figure 2-2 RDC2 Main Menu

TP-7102 9/2120 Section 2 Generator Set Operation
tp6809
Genset - - >
System
Next Exercise
HR:MN PM MM/DD/YY
Exercise Freq:
Weekly/Every Other Week
Meas. System:
English
<- - Return
Next Exercise *
HR:MN PM MM/DD/YY
Exercise Freq:
Weekly
Exercise Mode:
Unloaded Cycle
Exercise Mode:
None/Unloaded Full Sp/ Un-
loaded Cycle/Loaded Full SP
Contrast:
50
System Freq:
60 Hz
System Voltage:
240 V
VR Voltage Adj:
240.0V
System Phase:
Single
System Battery:
12 V
See Section 2.5.8, Changing
the Exercise Setting
* If the exerciser has not been set, No Exercise Sch will be displayed.
Figure 2-3 Procedure to Set the Exerciser